Ideal Boilers Classic FF 340 LF Installation And Servicing Manual Download

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Classic FF 340 - 360 LF

Installation & Servicing

FAULT FINDING

T FINDING FA

T FINDING

Check all connections to PCB.

If no fault found, replace PCB

Reset the overheat 'stat. Set control

'stat to maximum. Allow the boiler

to reach temperature - if the

overheat 'stat trips again, measure

flow temperature.

If above 90°C replace control 'stat.

If below 90°C replace overheat 'stat.

START

Is the mains on neon '

3' illuminated?

YES

Is there a live supply on EITHER

terminal of overheat 'stat?

Is the ignition electrode sparking?

YES

Check mains supply and fuses.

Check programmer and system

thermostats are all ON.

Check that boiler plug and socket

are OK and fully connected.

Check that the boiler thermostat is

set at maximum and the mains on/off

switch is ON. Is the fan turning ?

Replace the sensor

Check connections and leads to

pressure switch. If no fault found

change pressure switch.

Check all connections to PCB.

If no fault found change PCB.

Check pressure switch

sensing pipes for

blockages, bad connections

and reversed connection.

Is pressure difference at

switch greater than

0.9 mbar?

Change

fan

YES

Change

pressure switch

Is the boiler casing

correctly fitted?

Does the pilot light ?

YES

Does the spark

stop after the

pilot is lit?

Is there a gas

supply to the

boiler?

Is the pilot

injector blocked?

YES

Replace

gas valve

Is there a supply on terminals

of main gas valve?

YES

Is there a supply on the fan

connector at PCB ('Molex'

marked 'FAN'?).

YES

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

voltage at pilot

gas valve?

Is there a live supply on the red

lead to the pressure switch?

Is there a regular spark from

tube 'SG1' on the PCB?

Can the overheat 'stat

be reset when the

system is cold ?

YES

Replace fuse BUT, before

attempting to start boiler, check for

short between live and neutral,

also between live and earth, on all

items plugged into PCB

Check all connections to PCB.

If no error found, replace PCB.

Remove the sensor

(NTC) from the PCB.

Is the fan turning ?

YES

Has the fuse blown on PCB ?

Is there a live supply on the

violet lead to pressure switch?

Is there a supply at the fan?

Replace the overheat thermostat

Does main burner

cross-light from pilot?

Is the main burner

injector clear?

Replace main gas

solenoid valve

Check gap at ignition electrode.

Check electrode and lead are

undamaged and not close to

earthed metalwork.

YES

Change

fan

YES

Rectify bad
connection

YES

Check PCB by substitution

Is there a live supply on

BOTH terminals of limit stat?

YES

Change limit thermostat

Is there a live supply on BOTH

terminals of overheat 'stat?

YES

Summary of Contents for Classic FF 340 LF

Page 1: ......

Page 2: ... 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 3 65 0 8 Dry Weight kg lb 40 9 90 3 46 6 102 8 46 6 102 8 Maximum installation weight kg lb 31 4 69 3 37 4 82 5 37 4 82 5 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 Flue duct length max m ft 4 5 ...

Page 3: ... FF LF Data Badge on top of the controls support B G Certified P I No 87AP107 94 Destination Countries GB IE Appliance type C12 Natural Gas only BENCHMARK LOG BOOK DETAILS Boiler Page Make and model 3 Appliance serial no on data badge 11 SEDBUK No 2 Controls Time and temperature control to heating 24 25 Time and temperature control to hot water 24 25 Heating zone valves 24 25 TRV s 7 Auto bypass 7...

Page 4: ...lation 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 installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless...

Page 5: ...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 back pa...

Page 6: ...ified 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 suppliers ask for TF...

Page 7: ... boiler operating temperature should be 82 o C 180 o F WATER TREATMENT These boilers incorporate a cast iron heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Caradon Ideal Limited INVALID Caradon Ideal Limited recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems Caradon Ide...

Page 8: ...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 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 mus...

Page 9: ...m 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 valves of any sort b The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 o C 230 o F c The charge pressure must not be less than the static water head above the vessel The pressur...

Page 10: ...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 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 ci...

Page 11: ...F 340 LF 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: ...olyurethane foam seal 400 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 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 ...

Page 13: ...licable the extension flue box es 9 PACKAGING AND CASING REMOVAL FLUE KITS Pack B supplied as standard Pack D optional extension kit for side flue or rear flue outlet Refer to Frame 34 Flue Extension Ducts 1 A maximum of 5 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 ...

Page 14: ...he silicon rubber tube from the rear of the collector hood 4 Slacken the two M5 nuts on the front tie rods releasing the tie rods from the combustion chamber 5 Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood fan assembly 6 Remove the three M4 screws from the inside retaining the fan to the collector hood Keep the fan safe at one side and discard the o...

Page 15: ...selected position 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 du...

Page 16: ...ure 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 18 WALL MOUNTING PLATE 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 If downward routing ...

Page 17: ...of the 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 20 CONNECTING THE FLUE TO THE BOILER This plate allows neat concealment and...

Page 18: ...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 prov...

Page 19: ...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 27 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 20: ...f pipes 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...

Page 21: ...e 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 accuratel...

Page 22: ... 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 one 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screw provided to fix the air duct in position 6 Repeat steps 1 5 if a second flue extension is required Flue length Accessories Product No 2...

Page 23: ...den Refer to Frame 44 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 th...

Page 24: ... 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 41 PICTORIAL WIRING 42 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 g yellow green LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w...

Page 25: ...m 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 disturbance to other wiring of the programmer Designation of the terminals will vary but the programme...

Page 26: ...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 7 Switch the electricity supply ON and check that all external controls are calling for heat 46 INITIAL LIGHTING 8 Set the boiler thermostat knob D to position 6 and the boiler Mains On Off switch to ON The fan will ...

Page 27: ...813 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 11 As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Caradon Ideal Services scheme details o...

Page 28: ...e the M5 pozi situated at the 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 th...

Page 29: ...nector 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 r...

Page 30: ...mostat and reassemble in reverse order 6 Check the operation of the boiler 56 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 accordance wi...

Page 31: ... Pull 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 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...

Page 32: ...ng 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 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 ...

Page 33: ... 11 Check the operation of the boiler 1 Refer to Frame 57 2 Remove the burner and air box assembly Refer to Frame 52 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 62 8 Reassemble in reverse order 9 Check...

Page 34: ...ng posts 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 75 for fuse location 1 Refer to Frame 57 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 a...

Page 35: ...11 Fit the new heat exchanger assembly complete 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 70 HEAT EXCHANGER REPLACEMENT Not...

Page 36: ...r 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 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 su...

Page 37: ...h 1 171454 26 Thermostat knob 1 30 E83 665 Fan assembly 1 171461 35 Boiler casing assembly complete with sightglass assy insulation M5 x 16 dogpoint pozi pan hd 1 171471 37 Controls casing door with Lighting Instructions 1 171475 39 E85 313 Casing seal pack complete with screws 1 171479 45 E83 682 Overheat thermostat 1 171950 59 Limit thermostat 1 173353 The following are parts commonly required d...

Page 38: ...38 Classic FF 340 360 LF Installation Servicing LIST OF PARTS 74 BOILER CASING ASSEMBLY cla 6113 45 59 23 12 18 19 30 24 39 9 17 26 15 14 13 13 A 73 SHORT PARTS LIST ...

Page 39: ...at potentiometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 75 CONTROL BOX Exploded View LEGEND 10 Burner manifold 11 Air box and pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 17 Gas control valve 42 Gas service cock 76 BURNER ASSEMBLY Exploded View ...

Page 40: ...cation 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 pro...

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