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8

 Classic FF - 

Propane Installation & Servicing

GENERAL

The system should be vented directly off the boiler flow pipe,
as close to the boiler as possible. The cold feed entry should
be inverted and MUST be positioned between the pump and
the vent, and not more than 150mm (6") away from the vent
connection.

There should be a minimum height - 450mm (18") of open
vent above cistern water level. If this is impossible refer below.

The vertical distance between the highest point of the system
and the feed/expansion cistern water level MUST not be less
than 450mm (18").

The pump MUST be fitted on the flow side of the boiler.

A suitable pump is a domestic 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 Ideal Limited.

Note.
A cold water feed must be available back to the boiler, when
all automatic valves are in the closed position (Refer BS.
6798) and when close coupled the feed must not be in a
vertical leg.

Minimum Requirements

3

OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED.

System 
return

Connections 
to boiler

Inverted cold 
feed entry

System 
flow to 
pump

150 (6")
Max

15mm
Cold 
feed

450 (18")
Mimimum

450 (18")
Mimimum

22mm
Open vent

Feed / expansion 
cistern

Water 
level
(cold)

Surge 
arrester

75 (3)
Min.

450
(18)
Min.

200
(8)
Min.

Highest 
point of 
flow or 
return

150

(6)

Max

Max. practical 

length

To pump

Cold

water 

level

Feed / expansion

cistern

75 (3) Min.

Flow

Return

22 (3/4)

Open vent

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 at least 42mm in

diameter x 150mm long, thus ensuring a
MINIMUM air gap and a MINIMUM depth of water
below the static water level (cold) of 75mm.

2. The static water level (cold) must be at least

200mm above the top of the horizontal flow pipe,
fitted as shown. The vent connection MUST NOT
be made immediately off the top of the boiler, as
venting is made less efficient.

3. The maximum practical length of 15mm cold feed

pipe should be used in order to reduce the
effective volume of system water expanding into
the feed/expansion cistern to a minimum.

Note. 

The pump manufacturers minimum

requirements must be complied with.

All dimensions in mm (in.). NB.  Imperial dimensions are approximate.

4

LOW HEAD INSTALLATIONS

ELECTRICAL SUPPLY

WARNING. The appliance MUST be efficiently earthed.

Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS 7671) Wiring Regulations and any local
regulations which apply.  For Ireland reference should be made
to the current ETCI rules for electrical installations.

The point of connection to the mains should be readily
accessible and adjacent to the boiler, except that for bathroom
installations; the point of connection to the mains MUST be
situated outside of the bathroom.

Note.

Where a room sealed appliance is installed in a room containing
a bath or shower then the appliance and any electrical switch or
appliance control utilising mains electricity should be so situated
that it cannot be touched by a person using the bath or shower.

Summary of Contents for FF 350

Page 1: ......

Page 2: ...37 4 82 5 43 1 95 0 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 Boiler Size FF 350 P FF 360 P FF 380 P Boiler input kW 18 3 21 9 29 3...

Page 3: ...AVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER ALSO COMPLETE THE BENCHMARK LOG BOOK AND GIVE THIS TO THE CUSTOMER Classic FF Data Badge on top of the controls support B G Certified P I No 87AP107 De...

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

Page 5: ...lled must be at least wide enough to accommodate the tool c If using the Complete Sealed System Unit then refer to the instructions packed with the unit for the necessary clearances Pelmet restriction...

Page 6: ...tted 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...

Page 7: ...al heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water When thermostatic radiator valves are used the space heating tempe...

Page 8: ...ctical length To pump Cold water level Feed expansion cistern 75 3 Min Flow Return 22 3 4 Open vent The Classic range of boilers can be installed in low head situations by fitting a surge arrester in...

Page 9: ...nsion 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 incorporating va...

Page 10: ...stop valve 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 sy...

Page 11: ...330 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...

Page 12: ...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...

Page 13: ...trols pod casing 1 Unpack the boiler 2 Remove the casing as follows and place to one side to avoid damage a Undo the 2 casing retaining screws a retaining the casing to the back panel b Swing the bott...

Page 14: ...ote Check all of the hole positions BEFORE drilling 11 FLUE ASSEMBLY Exploded View 2 When cutting the ducts always use the cardboard support rings provided 1 An optional flue duct extension kit is req...

Page 15: ...e duct and boiler sealing ring Do NOT drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 4 Stick the self adhesive foam strip provi...

Page 16: ...mounting plate and locate the 3 studs in the holes in the back panel 2 Secure the flue to the boiler using the three M5 wing nuts provided 3 Pull the flue extension tube and engage onto fan locate and...

Page 17: ...the wall Note If the terminal is to be sited within 25 40mm of a corner or vertical pipe refer to Table 3 then the hole MUST be accurately cut 23 PREPARING THE WALL IMPORTANT Ensure that during the cu...

Page 18: ...not drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 1 To determine the position for the foam seal measure the wall thickness an...

Page 19: ...gular plate to retain the boiler 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 If the downward routing of pipes is required then the downward routing pipe brackets and M8 sp...

Page 20: ...ews provided Note If the terminal is less than 2m 6 6 above ground level an approved terminal guard should be fitted Refer to the Contents List on Page 3 1 Pull the flue through the side outlet plate...

Page 21: ...tandard flue Terminal grille Extension tube Boiler Flue length Accessories Product No Up to 600 B Pack 1 off see Frame 10 600 to 1550 B Pack 1 off D Pack 1 off see Frame 10 1550 to 2500 B Pack 1 off D...

Page 22: ...ructions supplied by the manufacturer 5 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 Advi...

Page 23: ...ntrolled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see manufacturer s literature 41 MID POSITION VALVE Pumped only 40 PICT...

Page 24: ...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 p...

Page 25: ...he unit casing in order to inspect the top casing seal To gain access to the gas valve a Remove the controls support casing Release the controls support front fixing screws 3 turns only Remove the pod...

Page 26: ...s necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 5 Explain the function and the use of the boiler thermostat an...

Page 27: ...stered installer In IE service work must be carried out by a Competent Person As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefi...

Page 28: ...61 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 condition e The spark gap is cor...

Page 29: ...t 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 spark operat...

Page 30: ...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 sens...

Page 31: ...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 opera...

Page 32: ...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 operation of the boiler 64 GAS CONTROL VALVE REPLACEME...

Page 33: ...n 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...

Page 34: ...hole fixings Pull the assembly downward to clear the water pipes from the back panel 10 Remove the 2 rubber sealing grommets from the top of the back panel to facilitate fitting the new assembly 11 F...

Page 35: ...s 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 Che...

Page 36: ...ilot burner injector Propane stamped 20 23P 1 171 436 15 173 117 Pilot burner head with injector Propane 1 171 440 17 Gas control valve 1 172 006 18 308 317 Ignition electrode complete with lead and b...

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

Page 38: ...ometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 75 BURNER ASSEMBLY Exploded View CL1870 Solenoid valve Sealing gasket Sealing gasket 10 11 13 12 16 42 17 LEGEND 10 Burner man...

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

Page 40: ...ation 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 specifie...

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