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IDEAL Response FF80 Installation And Servicing

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  • Page 2 Its compact size - up to half that of other combis - makes the Response ideal for any kitchen. It can be installed inside a standard size kitchen wall unit without insulation and with minimal ventilation or it can be mounted to sit flush with the front face of adjacent kitchen units.

  • Page 3: Performance Data

    11.7 (40 000) Gas consumption (Hot) l/s (ft 0.568 (220) 0.359 (139) Table 3 - Performance Data - DOMESTIC HOT WATER Response FF80 (Maximum) Burner pressure (HOT) mbar (in.w.g.) 14.8 (5.9) Input based on nett CV kW (Btu/h) 26.4 (90 000)
  • Page 4 Response FF80 Natural gas only G.C. Appliance No. 47 415 09 B.G. Certified P.I. No. 87AR183 Destination Countries: GB, IE. NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER Response FF80 - Installation...

  • Page 5: Table Of Contents

    GENERAL INTRODUCTION CONTENTS Response FF80 are wall mounted, low water content, balanced flue combination gas boilers of type C intended for use with gas group I2 Air Supply ..............6 Central heating (CH) output modulates between 11.7 kW Boiler Dimensions/Clearances ........5 (40,000 Btu/h) minimum and 17.6 kW (60,000 Btu/h) maximum.
  • Page 6 GENERAL BOILER WATER CIRCUIT DIAGRAMS Response FF80 - Installation...

  • Page 7: Boiler Dimensions/Clearances

    Distance X is 20mm for DHW pipes & safety valve outlet. 10mm in an adequately ventilated enclosed cupboard. Distance X is 23.5mm for CH pipes & gas inlet. However, 150 mm must be available for servicing. Response FF80 - Installation...

  • Page 8: Air Supply

    135 (21) connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Limited in writing. If in doubt please enquire. AIR SUPPLY Any direct connection of a control device not approved by Detailed recommendations for air supply are given in BS.5440:2.

  • Page 9: Flue Installation Reqirements

    11. Vertically from a terminal on the water. same wall 1500 mm (60") Any soldered joints on potable water pipework MUST NOT be 12. Horizontally from a terminal on the wall 300 mm (12") made with solder containing lead. Response FF80 - Installation...

  • Page 10: Electrical Supply Reqirements

    SEALED SYSTEM REQUIREMENTS - Central Heating N.B. Ideal Response FF80 combination boilers are suitable for 3. Flow Temperature fully pumped pressurised sealed systems only.
  • Page 11 None None None None 11.7 10.5 13.9 10.6 12.4 16.1 12.2 14.2 18.4 Multiply this factor by system volume and 0.067 0.074 0.088 deduct 8 litres to obtain size of additional vessel for other system volumes. Response FF80 - Installation...
  • Page 12 GENERAL SEALED SYSTEM REQUIREMENTS - Central Heating - continued 7. Thermostatic radiator valves. Caradon Ideal Limited support the recommendations made by leading manufacturers of domestic heating controls that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms...

  • Page 13: Boiler Exploded Diagram

    19. Safety valve. 59. Turret clamp. Air pressure switch. 27. Burner sensing pipe. 20. DHW expansion vessel 64. Controls panel assy. PCB 37. Fan sensing pipe. 21. CH expansion vessel 29. Sensing pipe clamp. 66. Transformer. PCB 38. Response FF80 - Installation...

  • Page 14: Installation

    PACKAGING AND FRONT PANEL REMOVAL 1. Remove the lid. 2. The top tray contains: Flue turret Mounting frame Hardware pack Stand-off channels Wall mounting template Installation instructions These contents can be removed, leaving the boiler in its protective package. Response FF80 - Installation...
  • Page 15 1800mm (70 ") One Pack D 3000mm (118 ") Two Pack D Pack B - supplied as standard. For side flue option Pack D - optional extra kit, to extend the flue. PROCEED TO FRAME 20 Response FF80 - Installation...

  • Page 16: Flue Fitting Rear Outlet

    (refer to Table 4) then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided. (The terminal wall plate cannot be fitted close to a corner). Response FF80 - Installation...
  • Page 17 BEFORE the plate is screwed to the wall. Showing the use of 'stand-off' channels, to enable upward pipework. Response FF80 - Installation...
  • Page 18 2. Pass the cut flue through the prepared hole, ensuring that the groove is uppermost. 3. Pull the flue back to compress the rubber seal and fix in place with the clamping/sealing rings. Note. To facilitate turret fixing or removal do NOT make good the wall. Response FF80 - Installation...
  • Page 19 • For standard installations use the short wood screw. • If the 'stand-off' option is used secure the support bracket, using the spacer bracket and long wood screw. Response FF80 - Installation...
  • Page 20 4. Secure the plate with 4 of the No.10 x 2" screws provided in boiler h/ware pack. Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to 'Flue Installation', Page 7. Response FF80 - Installation...

  • Page 21: Side Outlet

    Extended the centre line as shown. Mark the flue duct centre from the corner (see diagram and template). Note. Mark the centre of the hole as well as the circumference. 4. Remove template from the wall. Response FF80 - Installation...
  • Page 22 Note. If the clearances above and below the boiler are less than the length of the pipes it will be necessary to position the pipes behind the wall mounting plate BEFORE the plate is screwed to the wall. Response FF80 - Installation...
  • Page 23 3. Pull the flue back to compress the rubber seal and fix in place with the clamping/sealing rings. Note. To facilitate turret fixing or removal do NOT make good the wall. Response FF80 - Installation...
  • Page 24 • For standard installations use the short wood screw. • If the 'stand-off' option is used secure the support bracket, using the spacer bracket and long wood screw. Response FF80 - Installation...
  • Page 25 4. Secure the plate with 4 of the No.10 x 2" screws provided in the boiler hardware pack. Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to 'Flue Installation', Page 7. Response FF80 - Installation...

  • Page 26: Extension Ducts - Fitting

    Do not drill the inner flue duct. 8. Insert the self tapping screws provided, to fix the connector in position. 9. Repeat steps 1 - 8 if a second flue extension is required. Response FF80 - Installation...

  • Page 27: Service Connections

    If pipes are run vertically within the boiler back space provided by optional stand-off channel positions they must avoid any obstructions imposed by the channels and by a rear facing flue, should this position be selected. Response FF80 - Installation...
  • Page 28 DHW output. 37 SAFETY VALVE DRAIN The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage to electrical components and wiring. Response FF80 - Installation...

  • Page 29: 38 Electrical Connections

    Note. Ensure that the lengths of the current conductors are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor. Response FF80 - Installation...

  • Page 30: Electrical Diagrams

    - white 41 FUNCTIONAL FLOW WIRING DIAGRAM LEGEND - blue bk - black br - brown - red - orange - white - yellow m - mauve pk - pink gy - grey g/y - green/yellow Response FF80 - Installation...

  • Page 31: Commissioning And Testing

    Earths are not shown for clarity but must never be omitted. External wiring must be in accordance with the current I.E.E. (BS.7671) Wiring Regulations. Ideal Programmer Kit This is supplied with its own instructions. External Programmers These should be of the single channel type (as this boiler does not incorporate a pre-heat facility for the instantaneous hot water service).

  • Page 32: Initial Lighting

    15. Refit the boiler front panel, using the screw previously pressure gauge via a flexible tube. removed. Be sure to select the correct pressure test point. Refer to Tables 2 & 3 on page 3 for pressures. 16. Switch the boiler on again. Response FF80 - Installation...

  • Page 33: Handing Over

    (refer to 5. Advise the user of the precautions necessary to prevent 'CAUTION' in User's Instructions, page 2). damage to the system and to the building, in the event of Response FF80 - Installation...

  • Page 34: Servicing

    1. Turn off the gas supply at the gas service cock and 3. Remove the screws and pull out the tabs from the slots. disconnect the electricity supply. 2. Remove the screw and lift off the boiler front panel. Response FF80 - Installation...

  • Page 35: Burner Removal And Cleaning

    2. Take care to clean debris from the ledge inside the 7. Check the spark and electrode gaps are correct. combustion chamber. 8. Check that the spark and detection leads are in good condition and renew as necessary Response FF80 - Installation...

  • Page 36: Replacement Of Components

    Note. In order to assist fault finding, the printed circuit boards are fitted with indicator lights . Full details are found in the Fault- Finding section. IMPORTANT. When work is complete the sealing panel must be correctly fitted, ensuring that a good seal is made. THE BOILER MUST NOT BE OPERATED IF THE SEALING PANEL IS NOT FITTED. Response FF80 - Installation...
  • Page 37 4. Disconnect the leads from the thermostat. 5. Release the 2 securing screws and remove the old thermostat. 6. Fit the new thermostat, reconnect and re-assemble in reverse order. 7. Reconnect the supply and test fire the boiler. Response FF80 - Installation...
  • Page 38 4. Slide out the spark generator in the direction of the arrow. 5. Fit the new spark generator and re-assemble in reverse order. 6. Check the ignition and operation of the burner. Response FF80 - Installation...
  • Page 39 Refer to Frame 49. 3. Hold the injector pipe securely and unscrew the injector. 4. Check that the new injector is of the correct size and fit it, using a suitable jointing compound, sparingly. 5. Re-assemble in reverse order. Response FF80 - Installation...
  • Page 40 3 studs in place. 11. Transfer the gas cock union and elbow assembly to the new gas valve, reusing the 4 M5 x 10 screws, together with the new 'O' ring seal provided. Response FF80 - Installation...
  • Page 41 9. Fit the filling loop. Fill the boiler with water and pressure to 1 bar (as appropriate). Reconnect services. 10. After satisfactory test firing and removal of air from the system, remove the filling loop. Response FF80 - Installation...
  • Page 42 5. Disconnect the sensing tube and remove the switch. 6. Fit the new switch and re-assemble in reverse order. 7. Make sure that the 2 brown wires are fitted to terminals 1 and 3 (either to either). Response FF80 - Installation...
  • Page 43 If necessary, remove the fan (see Frame 66) to access to use a spanner on the hexagon nut behind the vessel. 6. Replace with new sealing gasket and vessel. Reassemble in reverse order and test fire. Response FF80 - Installation...
  • Page 44 1bar (or as required). 14. Restore services and operate the heating controls to test-fire the boiler. 15. Vent air and top up the pressure again, if required. 16. Remove the filling loop. Response FF80 - Installation...
  • Page 45 'O' ring seal to the burner base may now be carefully withdrawn downwards. 10. Disconnect the spark electrode leads and the flame sensing electrode lead at the burner base - refer to Frame 59. 11. Remove the 3 screws securing the burner assembly and Response FF80 - Installation...

  • Page 46: Water Pressure Switch

    6. Compress the clips on the sides of the programmer and withdraw it from the retaining bracket. 7. Fit the new programmer and re-assemble in reverse order. 8. Check the operation of the new programmer. Response FF80 - Installation...
  • Page 47 Locate the leads from the transformer to PCB 38 and disconnect the white 'Molex' connector from the PCB. 4. Release the transformer mounting screws. 5. Fit the replacement transformer and complete the reassembly in reverse order. Response FF80 - Installation...
  • Page 48 C8. Fill, pressurise and test. B4. Disconnect the flue, if RH exit, and remove to the right C9. Remove the filling loop. (general details are reverse of Frames 18 & 28). Response FF80 - Installation...

  • Page 49: Fault Finding

    Foot Note: Presence of Live supply on a terminal may be checked with a multimeter set to the appropriate AC range (apply the other probe of the meter to mains neutral, e.g. on terminal N of the programmer terminal strip). Response FF80 - Installation...
  • Page 50 At room temperature expect 9,000 to 11,000 Ohms lead to the flow switch at PCB At 60°C. expect 2,000 to 2,500 Ohms Change faulty At 85°C. expect 1,000 to 1,500 Ohms flow switch Does boiler now give CH ? Response FF80 - Installation...
  • Page 51 Check for moisture on At room temperature expect 9,000 to 11,000 Ohms PCB 38. At 60°C. expect 2,000 to 2,500 Ohms If no fault found check PCB 38 by substitution. At 85°C. expect 1,000 to 1,500 Ohms Response FF80 - Installation...
  • Page 52 Foot Note: Presence of live supply on a terminal may be checked with a multimeter set to the appropriate AC range (apply the other probe of the meter to mains neutral, e.g. on terminal N of the programmer terminal strip). Response FF80 - Installation...
  • Page 53 Is there Live on the other end of the wire pressure obstructed air duct (i.e. at the supply connector of PCB 37) ? switch or terminal grille Check lead. Return to Find bad connection main menu or renew lead Response FF80 - Installation...
  • Page 54 Remove connectors. With mains OFF, Change lead assembly Return check continuity of leads from each socket to main unit back to the corresponding terminals in menu the control box. Are leads in good order ? Check gas valve by substitution Response FF80 - Installation...
  • Page 55 With gas OFF, do another ignition cycle. Is the spark OK now ? Re-assemble and Fit a new Return to main restore gas supply. ignition menu electrode Boiler should now light and the assembly 'Burner On' neon illuminate Response FF80 - Installation...
  • Page 56 Use a multimeter (set to measure 230 V AC or more), connecting the black lead to a reliable Earth point (not Neutral for this particular test). You should find 230 V on terminal L and zero (or a small reading) on terminal N. N.B. Some meters may trip residual current devices during this test. Response FF80 - Installation...
  • Page 57 Replace safety valve and outside the building). correctly set and in the refill / repressurise closed position ? Has it been discharging water ? Recheck for leaks on Clear and readjust the valve. pipes and radiators Repressurise the system Response FF80 - Installation...
  • Page 58 56. Sensing pipe 'O' ring (burner mounting end). 2A. Gas valve. 28. Fan pressure sensing pipe. 57. Gas manifold gasket. Detection electrode. 53. Fan/Burner mounting 'O' ring. 58. Gas valve gasket. Spark electrode. 54. Fan 'O' ring. 67. Gas cock 1/2". Response FF80 - Installation...

  • Page 59: Short List Of Parts

    SHORT LIST OF PARTS 89 CONTROLS AREA - General Arrangement Response FF 80 7. PCB 38. 5. Air pressure switch. 66. Mains transformer. 6. PCB 37. Response FF80 - Installation...

  • Page 60: Short List Of Parts

    The list is extracted from the British Gas List of Parts which contains all 3. Description. available spare parts. 4. Quantity. The full list is held by British Gas, Caradon Ideal distributors and merchants. 5. Product No. Key No. G.C. Part No.
  • Page 61 Sensing pipe 'O' ring (manifold block end) 139945 E00-095 Sensing pipe 'O' ring (burner mounting end) 112341 E00-096 Gas manifold gasket 112043 E00-097 Gas valve gasket 111733 E00-104 Controls panel assembly 075196 E00-105 Transformer assembly 139716 Response FF80 - Installation...
  • Page 62 90 SHORT PARTS LIST 91 BOILER CASING ASSEMBLY Technical Training The Caradon Ideal 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: ......
  • Page 63 Response FF80 - Installation...
  • Page 64 Response FF80 - Installation...

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