Ideal Boilers Classic LXFF 230 Installation And Servicing Manual Download Page 9 | Manualshive

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Classic

FF

-

Installation & Servicing

9

INSTALLATION

5

BOILER ASSEMBLY - Exploded view

Classic FF 230 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.

INST

ALLA

TION

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Summary of Contents for Classic LXFF 230

Page 1: ......

Page 2: ... 3 14 5 5 8 Seasonal Efficiency SEDBUK 76 2 75 8 76 2 76 7 77 1 76 0 76 4 Boiler Size FF 230 FF 240 FF 250 FF 260 FF 270 FF 280 FF 2 100 Gas supply connection in BSP Rc 1 2 1 2 1 2 BSP Female Flow connection 22mm 28mm copper copper FEMALE Return connection 22mm 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 Bo...

Page 3: ...ombustion chamber I2H An appliance designed for use on 2nd Family gas Group H only Data Badge on top of the controls support Destination Countries GB and IE Natural Gas only Appliance type C12 C32 Models G C Appliance No Classic FF 230 41 387 01 Classic FF 240 41 387 02 Classic FF 250 41 387 03 Classic FF 260 41 387 04 Classic FF 270 41 387 05 Classic FF 280 41 387 06 Classic FF 2 100 41 349 71 Cl...

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

Page 5: ...s 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 it ...

Page 6: ...imum 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 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 ...

Page 7: ...sed for direct hot water 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 fo...

Page 8: ...tic 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 Plumb...

Page 9: ...sic FF 230 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 INSTALLATION ...

Page 10: ...te 1 off z Terminal grille assy 1 off z Polyurethane foam seal 400 lg 1 off z No 8 x 8 lg Pozi pan hd screws 3 off 6 UNPACKING Pack A Contents z The complete boiler z Installation Servicing Instructions z User s Instructions z Hardware Pack listed below z Wall mounting template z Wall mounting plate z Side outlet terminal mounting plate z Flue extension tube 1 off z Boiler sealing ring 1 off Hardw...

Page 11: ...ck D optional extension kit for side flue or rear flue outlet Refer to Flue Extension Ducts 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 bracke...

Page 12: ...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 cutting operation masonry falling outside of the building does not ca...

Page 13: ...oiler 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 15 WALL MOUNTING PLATE 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 If downward routing of pipes ...

Page 14: ...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 17 CONNECTING THE FLUE TO THE BOILER 18 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal Its use...

Page 15: ...he 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 provided for the wall mounting plate 3 Drill 4 holes with a 7mm ...

Page 16: ...re 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 24 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 of the flu...

Page 17: ...en 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 2 For downward r...

Page 18: ... 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 cut and the ou...

Page 19: ...er Extension tube Not for FF 2 100 model 33 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 th...

Page 20: ...st thermostat must be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 41 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 w...

Page 21: ...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 38 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 39 MID POSITION VALV...

Page 22: ...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 23: ...turns only Remove the pod 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 43 INITIAL LIGHTING 7 Press the overheat thermostat...

Page 24: ...e of regular servicing by a CORGI registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 46 HANDING OVER 45 GENERAL CHECKS Make the following checks for correct operation 1 Set the boiler thermostat knob to position 6...

Page 25: ...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 the bottom of the casing Swi...

Page 26: ...onnector 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...

Page 27: ...and re assemble in reverse order 6 Check the operation of the boiler 53 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 58 and ensuring that there is an inlet pressure of 20 mbar available the pilot does not light then contact Caradon Plumbing Limited Relight in accordance with ...

Page 28: ...side retaining clips and remove the switch 12 Re assemble in reverse order 57 THERMOSTAT CONTROL THERMISTOR SENSOR LEAD and ON OFF SWITCH REPLACEMENT 58 PILOT BURNER REPLACEMENT 1 Refer to Frame 54 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 clea...

Page 29: ...heck the operation of the boiler 1 Refer to Frame 54 2 Remove the burner and air box assembly Refer to Frame 49 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 58 8 Reassemble in reverse order 9 Check the ...

Page 30: ...ts and withdraw from the control box 6 Fit the new PCB and re assemble 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 70 for fuse location 1 Refer to Frame 54 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 31: ...e with water pipes and hang it on the key hole slots and screws Retighten the screws 12 Replace the 2 rubber sealing grommets 13 Re assemble 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 66 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 5 Boiler assembly Exploded v...

Page 32: ...h Is the boiler casing 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 ...

Page 33: ... off switch 1 111973 23 386 149 Automatic ignition printed circuit board PACTROL PCB 25 B 1 079716 24 385 861 Pressure switch HONEYWELL YAMATAKE C6065 F 1373 2 1 155412 26 308 283 Thermostat knob 1 079601 30 E02 661 Fan assembly SIFAN No WFFB 0221 039 FF 230 280 1 151586 SIFAN No WFFB 0226 028 FF 2 100 1 35 E04 503 Boiler casing assembly complete with sightglass assy insulation M5 x 16 dogpoint po...

Page 34: ... and pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 69 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 70 CONTROL BOX Exploded View ...

Page 35: ...Classic FF Installation Servicing 35 71 BOILER CASING ASSEMBLY 72 SHORT PARTS LIST SHORT LIST OF PARTS ...

Page 36: ...l HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 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 provisions of BS 6332 and BS 5258 The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers...

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