Ideal Boilers Classic FF 380 P Installation And Servicing Download | Manualshive

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Summary of Contents for Classic FF 380 P

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Page 2: ...b 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 Btu h 62 500 74 700 100 000 Gas consumption l s ft3 h 0 20 25 0 0 23 29 2 0 30 38 1 Boiler output kW 14 7 17 6 23 5 Btu h 50 000 60 000 80 000 Burner Setting mbar 35 9 35 8 34 8 pressure HOT in w g 1...

Page 3: ...EAVE 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 Destination Countries GB IE Models G C Appliance No Classic FF 350 P 41 392 06 Classic FF 360 P 41 392 07 Classic FF 380 P 41 392 08 Propane Gas only BENCHMARK LOG BOOK DETAILS Boiler Page Make and mod...

Page 4: ...rvicing 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 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 handli...

Page 5: ...alled 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 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 lin...

Page 6: ...itted 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 7 Where it is essential that the terminal wall plate is fitted i e wall thicknesses over 600mm 23 1 2 or with an inaccuratel...

Page 7: ...ral 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 temperature control over a living dining area or hallway having a heating requirement of at least 10 of the boiler heat output should be achieved using a room thermostat whilst other rooms are individuall...

Page 8: ...actical 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 ...

Page 9: ...ansion 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 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 ab...

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 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 restr...

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

Page 12: ...0 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 Wall mounting plate Hardware Pack Contents 50mm x No 14 wood screw 4 off 50mm x No 10 wood...

Page 13: ...ntrols 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 bottom of the boiler casing up until the controls pod casing has cleared the controls then unhook the top from the back panel 3 Remove the boiler from its packaging base The boiler may now be stood uprig...

Page 14: ...Note 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 required for wall thicknesses greater than 600mm 23 1 2 Refer to Frame 10 LEGEND 1 Terminal 2 Weather seal 3 Flue assembly 4 Boiler sealing ring 5 Flue extension tube 13 PREPARING THE WALL IMPORTANT Ens...

Page 15: ...ue 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 provided in the hardware pack onto the flue immediately behind the boiler sealing ring 1 Insert the flue extension tube into the flue assembly 2 Insert the flue assembly through the hole sufficiently far ...

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 secure with the M4 screw attached to the fan 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 n...

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 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 core boring tool ensuring that the hole is square to the...

Page 18: ...o 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 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: ...ngular 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 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 s...

Page 20: ...rews 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 and locate the 3 studs in the hole in the side of the boiler 2 Secure the flue to the boiler using the three M5 nuts provided 3 Insert the flue extension tube into the flue 4 Fit the 90 flue elbow su...

Page 21: ...Standard 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 Pack 2 off see Frame 10 2500 to 3000 B Pack 1 off D Pack 3 off see Frame 10 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto the...

Page 22: ...tructions 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 Advice on required modifications to the wiring may be obtained from the component manufacturers Notes 1 Connection between a frost thermostat and the time control should be made without disturbing other ...

Page 23: ...ontrolled 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 PICTORIAL WIRING 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 whit...

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 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 programmer and the...

Page 25: ...the 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 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 Frame 46 4 Slacken the screw in the bur...

Page 26: ...ns 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 and external controls 6 Explain the function of the boiler overheat thermostat and After completing the installation and commissioning of the system the installer should hand over to the householder by...

Page 27: ...istered 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 benefits of the Caradon Ideal Services details of which are outlined in the household pack supplied with this boiler a Light the boiler and carry out a pre service check noting any operational faults Opera...

Page 28: ...e 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 correct Frame 61 Clean or renew as necessary Note The pilot shield is located around the pilot assembly bracket and is located by the electrode retaining nut 54 REASSEMBLY Reassemble the boiler in the f...

Page 29: ...lt 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 operation stops after detection The boiler MUST NOT be operated if the casing is not fitted 1 Refer to Frame 56 2 Unfasten the two nuts and washers holding the sightglass assembly to the casing front panel...

Page 30: ...l 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 and...

Page 31: ...g 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 R...

Page 32: ...d 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 REPLACEMENT Note Refer also to Frame 75 of Exploded Views for illustration 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 fixing sc...

Page 33: ...on 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 the collector hood and remove collector hood fan assembly 8 Remove the three M4 screws retaining the fan to the collector hood 9 Fit the new fan and reassemble in reverse order ensuring the fan lead...

Page 34: ...y 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 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 Reassembly in reverse order ...

Page 35: ...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 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 crosse...

Page 36: ...Pilot 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 backnut 410 mm long 1 171 442 19 Controls box assembly including PCB 1 171 894 23 Automatic ignition printed circuit board 1 171 450 24 E83 653 Pressure switch assembly 1 171 454 26 308 283 Thermostat...

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: ...iometer 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 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 ...

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

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 498432 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 prov...

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