1. Manuals
  2. Brands
  3. Stelrad Manuals
  4. Boiler
  5. IDEAL CLASSIC COMBI NF 80
  6. Installation & servicing

Stelrad IDEAL CLASSIC COMBI NF 80 Installation & Servicing

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Installation & Servicing
Models covered by these instructions
NF 80
IDEAL
CLASSIC COMBI NF 80
Wall Mounted, Fanned, Balanced Flue Gas Boilers.
CAUTION:
To avoid the possibility of injury during the installation, servicing or cleaning of this appliance, care should be taken when handling edges
of sheet steel components.
IMPORTANT:
This appliance is for use with NATURAL GAS ONLY.
NOTE:
TO THE INSTALLER. Leave these instructions adjacent to the gas meter or with the User.
GENERAL
PERFORMANCE DATA
IDEAL CLASSIC COMBI
(47-415-07)
NF 80

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IDEAL CLASSIC COMBI NF 80 and is the answer not in the manual?

Questions and answers

Related Manuals for Stelrad IDEAL CLASSIC COMBI NF 80

Summary of Contents for Stelrad IDEAL CLASSIC COMBI NF 80

  • Page 1 Installation & Servicing Models covered by these instructions IDEAL CLASSIC COMBI NF 80 (47-415-07) NF 80 IDEAL CLASSIC COMBI NF 80 Wall Mounted, Fanned, Balanced Flue Gas Boilers. CAUTION: To avoid the possibility of injury during the installation, servicing or cleaning of this appliance, care should be taken when handling edges of sheet steel components.
  • Page 2 (1038 Btu/ft The Ideal Classic Combi NF 80 is a cast-iron, fanned, balanced flue combination boiler. Central heating (C.H.) output is spot rated at 23.4 kW (80 000 Btu/h) with ON/OFF thermostatic control & is suitable for use with heating loads down to 4.4 kW (15 000 Btu/h).

  • Page 3: Operation

    OPERATION Domestic hot water (D.H.W.) With no call for either D.H.W. or C.H., the boiler will periodically fire at low gas rate for a few seconds in order to maintain the D.H.W. calorifier in a pre-heated condition. NOTE: The D.H.W. ‘pre-heat’ operates 24 hours a day, unless an external programmer is fitted when it can be timed. When there is demand for D.H.W., the boiler fires at full gas rate, the diverter valve remains de-energised and the full output from the boiler is directed to the D.H.W.

  • Page 4: Gas Supply

    Details of the essential features of cupboards/compartment design, including airing cupboard installation, are given in BS.6798. In siting the boiler, the following limitations MUST be observed: 1. The position selected for installation MUST allow adequate space for servicing in front of the boiler and for air circulation around the boiler. For the minimum clearances required for safety and subsequent service, refer to the wall mounting template and Frames 1 and 4.

  • Page 5: Air Supply

    Kent, TN9 1TB (Model K1) Telephone No. 0732 351555 Ensure that the guard is fitted centrally. 5. Where the terminal is fitted within 850 mm (34 in.) of a plastic or painted gutter or 450 mm (18 in.) of painted eaves then an aluminium shield at least 750 mm (30 in.) long should be fitted to the underside of the gutter or painted surface.

  • Page 6: Electrical Supply

    Draining taps should be at least 1/2 in. BSP nominal size and be in accordance with BS. 2879. Maximum recommended system hydraulic losses are given in Table 6, below. Table 6 - WATER FLOW RATE & PRESSURE LOSS System Load 23.4 19.0 (Btu/h)

  • Page 7: Hardware Pack

    HARDWARE PACK Sealing tape for side outlet plate. Sealing tape for rear outlet plate. Aluminium foil for air duct seal. 50 mm × No. 14 wood screws. 8 off (for wall mounting plate). 50 mm × No. 10 wood screws, 8 off (for side outlet plate & terminal wall plate). Wall plugs, 16 off.
  • Page 8 (b) Release the controls pod fixing screws (b) 3 full turns only. Remove the pod by pulling it forward to disengage from the keyhole slots. (c) Undo the 4 screws (c) retaining the casing to the back panel. (d) Remove the casing in the direction of the arrows. 6.

  • Page 9: Boiler Clearances

    BOTTOM WATER CONNECTIONS BOILER CLEARANCES The following minimum clearances must be maintained for operation & servicing, (see diagram). Dimension Side flue Rear flue ‘A’ 425 mm 390 mm 25 mm flue side ‘B’ 25 mm both sides 40 mm non flue side Additional space will be required for installation, depending upon site conditions.
  • Page 10 If a core boring tool is to be used inside the building then the space in which the boiler is to be installed must be at least wide enough to accommodate the tool. All installations Once the boiler has been installed the side clearances may be reduced to 5 mm. Front clearance: 450 mm (17 ¾...

  • Page 11: Wall Mounting Template

    6 FLUE ASSEMBLY - Exploded View 1. An optional duct extension kit is required for wall thicknesses greater then 406 mm (16 in.). Refer to ‘Extension Ducts’. 2. When cutting the ducts, always use the cardboard support rings provided. 7 WALL MOUNTING TEMPLATE 1.
  • Page 12 NOTE: If the terminal is to be sited within 25 -40 mm of a corner or vertical pipe (refer to Table 3.) then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided. The terminal wall plate need not be fitted. NOTE: Check all of the hole positions BEFORE drilling.

  • Page 13: Fitting The Flue Assembly

    3. Using the sliding collar as a template at the duct join, mark the positions of the 3 fixing screws. NOTE: If the duct join is too close to the rubber weather seal to permit access for drilling, mark the hole positions at the mid-point of the duct. 4.

  • Page 14: Wall Mounting Plate

    2. Seal the gap between the flue assembly and the wall with the foam rubber strip provided. Weather seal. Apply soap solution to ease fitting through the wall sleeve. 3. Locate the wall mounting plate over the flue assembly. Engage the flue duct collar lugs with the wail mounting plate slots & rotate the flue assembly to lock.
  • Page 15 NOTE: If the terminal is less than 2 m (6.6 ft.) above ground level, an approved terminal guard should be fitted. Refer to Page 5. 15 PRE-PIPING IMPORTANT: For installations with bottom water connections ONLY the following pipe runs MUST be made BEFORE the boiler is mounted on the wall. 1.

  • Page 16: Electrical Connections

    16 PRE-WIRING The mains supply and other external wiring may now be made, if required. BEFORE the boiler and Combi modules are mounted on the wall. Refer to Frames and 19. NOTE: It is possible to make the electrical connections after the boiler is mounted on the wall, if required, by removing the pressure switch bracket in order to gain access to the terminal box.

  • Page 17: Wiring The Boiler

    18 WIRING THE BOILER Flow, Pictorial and Schematic wiring diagrams are shown in frames of these instructions. A wiring diagram is also included in the Lighting Instruction label. Connecting the mains supply. 1. Remove the securing screw and lift off the terminal box cover. 2.

  • Page 18: Mounting The Boiler

    Diagram 1 shows a double pole frost ‘stat which should suffice for all systems which do not use the ‘off’ terminals of the programmer. Diagram 2 shows a ‘changeover’ frost ‘stat which will cover most systems which do use ‘C.H. Off’ NOTE: Secure any leads with the cable clamps provided.
  • Page 19 3. Pull off the silicon rubber pipe connection on top of the fan. Taking care not to damage the glass fibre gasket, remove the fan to a safe place. NOTE: Always take care when handling the fan. to preserve the balance of the impeller. 4.
  • Page 20 DO NOT USE THE BURNER/CONTROLS ASSEMBLY FOR LIFTING. DO NOT REST THE BOILER ON THE ASSEMBLY - AS DAMAGE MAY RESULT. 21 SEALING THE BOILER AND FLUE 1. Stretch the rubber gasket over the air duct spigot. 2. Fit the locking collar as shown and rotate it to engage with the locking slots in the flue assembly. 3.
  • Page 21 3. Tape both templates into the selected position locating template ‘B’ via an centre extended centre line as shown. 4. Ensure squareness by hanging a plumbline as shown. 5. Mark onto the wall the mounting plate screw positions (choose 1 from each group) and lower fixing screw position. 6.
  • Page 22 25 CUTTING THE DUCT ASSEMBLY FLUE LENGTHS OF 114 TO 216 mm ONLY. 1. Separate the duct assembly. 2. Push the sliding collar to the end of the duct and measure off dimension ‘Y’ (wall thickness plus boiler spacing). 3. Cut to length ‘Y’, using the cardboard duct rings for support. NOTE: Cut the inner flue tube 6 mm (1/4 in.) longer than the outer air tubes.
  • Page 23 6. Seal the air duct joint with the aluminium tape provided in the Hardware Pack. FOR FLUE LENGTHS ABOVE 406 mm, REFER TO ‘Flue Extension Ducts’ (Frames 36 & 37). 27 FITTING THE FLUE ASSEMBLY FROM EITHER THE INSIDE OR OUTSIDE OF THE BUILDING. 1.
  • Page 24 29 FITTING THE STAND-OFF BRACKETS INSTALLATIONS WITH BOTTOM WATER CONNECTIONS ONLY Secure the two stand-off brackets to the wall mounting plate, using the eight M 6 nuts, screws and shake proof washers provided, such that the plate is located BEHIND the front returns of the brackets - as shown. NOTE: If the clearances above and below the boiler are less than the length of the pipes to be fitted behind the wall mounting plate then refer to Frame...
  • Page 25 1. Position the terminal wall plate over the terminal. 2. Drill 4 fixing holes with an 8 mm (5/16 in.) masonry drill. 3. Insert the four plastic plugs provided. 4. Secure the plate with four of the No. 10 × 2in. screws provided. NOTE: If the terminal is less than 2 m (6.6 ft.) above ground level, an approved terminal guard should be fitted.
  • Page 26 5. Lift the boiler onto the wall mounting plate as shown. The air duct spigot engages in the hole in the side panel. IMPORTANT: The boiler module MUST be positioned CENTRALLY on the wall mounting plate. Refer to the index mark on the back panel DO NOT USE THE BURNER/CONTROLS ASSEMBLY FOR LIFTING.
  • Page 27 6. Fit the M8 screw, plain washer and large 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. Refer Frame 7.

  • Page 28: General Arrangement

    (a) For R.H. side outlet ONLY. Cut the side outlet flue pipe connector at the scribed line. (b) Fit the flue pipe connector onto the fan outlet elbow. (c) Ensure that the flue baffles are fully pushed down in the heat exchanger. (d) Refit the fan assembly onto the collector hood, fully engaging the flue pipe connector into the flue pipe.

  • Page 29: Fitting The Kit

    37 FITTING THE KIT IMPORTANT: Read in conjunction with Frame 1. Separate the Flue duct assembly. 2. Insert the appropriate extension duct(s) with the plain end(s) toward the terminal. 3. Re-assemble the terminal and the duct assemblies. 4. Push the sliding collar back to the boiler end of the duck or to its intended position. 5.
  • Page 30 9. Drill through the holes of the collar into the air duct with a 3.2 mm. drill and lock the sliding collar into position with 3 of the self tapping screws provided. NOTE: If the flue duct assembly locking screws restrict the sliding collar then use the collar locking screws to lock the whole assembly. LIANCES FITTED WITH A REAR OUTLET FLUE: PLEASE REFER TO FRAME 6 (PAGE 9).
  • Page 31 8. Offer the Combi module on top of the boiler module and engage the Combi module RETURN pipe within the brass compression elbow (A). 9. Swing the Combi module into position, as shown, & snap the Combi module FLOW pipe into the plastic/elbow (B), ensuring that it is pushed fully home (to the index mark on the Combi module FLOW pipe).
  • Page 32 14. Hang the C.H. expansion vessel in the servicing position and connect the flexible pipe, using the sealing washer provided. Ensure that the pipe is positioned at 90° to the vessel, as shown. 38 A PRESSURE GAUGE HEIGHT ADJUSTMENT It may be found necessary to adjust the position of the pressure gauge in order for it to locate centrally in the aperture provided in the module casing. This can be eased by checking the dimension from the bottom of the pressure gauge bezel and the top of the boiler casing, at the point when the expansion vessel is fitted.

  • Page 33: Flow Wiring Diagram

    2. Fit the rubber gasket, provided, & plug the by-pass solenoid lead (from the wall plate) into the valve. Tighten the securing screw. 3. Connect the earth lead, from the wall plate wiring harness, to the earth post on the underside of the boiler back panel. 4.

  • Page 34: Pictorial Wiring Diagram

    41 PICTORIAL WIRING DIAGRAM...

  • Page 35: Schematic Wiring Diagram

    42 SCHEMATIC WIRING DIAGRAM 43 GAS CONNECTION Refer to ‘Gas Supply’ (page 3) and Frame 4 (page 8) for gas inlet service dimensions 1. A MINIMUM working gas pressure of 20 mbar (8 in. w.g.) MUST be available at the boiler inlet. 2.
  • Page 36 When filling: (a) Set the diverter valve manual lever to the OPEN position. When filling is complete, return the lever to its CLOSED position, (b) The cap on the automatic air vent MUST be loose at all times. When filling there may be a slight water leak from the vent, therefore electrical connections should be protected.
  • Page 37 1. Connect the hot and cold water supply pipes to the boiler, as shown, or to the pipework previously fitted (installations with BOTTOM CONNECTIONS ONLY. Refer to Frame 15). 2. Open the domestic hot water draw-off taps, clear air locks and check for water soundness. 3.

  • Page 38: System Requirements

    NOTE: Ensure that the expansion vessel is orientated as shown to facilitate the fitting of the Combi module cover. 47 SYSTEM REQUIREMENTS Central Heating NOTE: (a) Any connection for filling or replenishing of a sealed primary circuit from a supply pipe is conditional upon a water undertaking seeking and obtaining consent for a relaxation of its Byelaws 3 and 8 (1) from the Secretary of State.

  • Page 39: System Requirements. Central Heating

    11.0 10.9 12.9 11.9 14.0 12.5 14.7 15.6 18.4 18.8 22.1 For other system volumes - multiply by the factor across: 0.063 0.074 48 SYSTEM REQUIREMENTS. Central Heating 5. Mains Connection. There must be no direct connection to the mains water supply or to any water storage tank supplying domestic water, even through a non-return valve, without the approval of the Local Water Authority.
  • Page 40 10 % of the boiler output is achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves. 9. Open Vented Systems. The Ideal Classic Combi NF 80 is designed for use with sealed systems, but can also be connected to open vented systems if required.

  • Page 41: Commissioning And Testing

    Domestic Hot Water Requirements. The Ideal Classic Combi NF 80 is suitable for connection to most types of washing machine and dish washing appliances. When connecting to suitable showers, ensure that: The cold inlet to the boiler is fitted with an approved anti-vaccuum or syphon non-return valve.
  • Page 42 WARNING: DO NOT OPERATE THE BOILER WITH THE CASING REMOVED - AS DAMAGE TO THE CONTROL BOX MAY RESULT. 5. Slacken the screw in the burner pressure test nipple (I) and connect a gas pressure gauge via a flexible tube. 6.

  • Page 43: General Checks

    (b) The diverter valve energises - no resistance should be felt when the manual lever is moved by hand (Frame 44). (c) The fan starts and the main burner cross-lights smoothly at maximum rate. NOTE: The burner may fire initially at low rate but should increase to maximum rate after 1 - 2 mins. 2.
  • Page 44 It is absolutely ESSENTIAL to ensure, in practice, that products of combustion discharging from the terminal cannot re-enter the building, or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration or forced ventilation/air conditioning. If this should occur, the appliance MUST be turned OFF IMMEDIATELY and the Local Region of British Gas plc. called to investigate. WARNING: DO NOT operate the boiler with the casing removed.
  • Page 45 Release the securing screw and withdraw the cover b) Boiler module casing 1. Open the controls pod door. 2. Release the 4 captive screws at the top and bottom of the casing. Lift the casing off the boiler and retain in a safe place. 3.
  • Page 46 4 CLEANING THE BURNER AND PILOT ASSEMBLY 1. Brush off any deposits that may have fallen on to the burner head, ensuring the flame ports are unobstructed and remove any debris that may have collected. NOTE: Brushes with metallic bristles MUST NOT be used. 2.

  • Page 47: Cleaning The Flueways

    6 CLEANING THE FLUEWAYS 1. Pull off the silicon rubber negative pressure tube on the L.H. side aluminium pipe. 2. Remove the rear central fixing screw and both front tie rods. Lift off the collector hood. 3. Remove the flue baffle clips and remove the flue baffles. 4.

  • Page 48: Gas Pressure Adjustment

    9 GAS PRESSURE ADJUSTMENT PILOT Light the boiler and check that the pilot flame envelopes the ignition/detection electrode. The pilot is factory set to maximum and no further adjustment is possible. However, if the pilot flame length is incorrect then remove and inspect the pilot injector. Refer to Frame Re-light in accordance with ‘Initial Lighting’.
  • Page 49 12 D.H.W. PRE-HEAT, CONTROL, OVERHEAT AND C.H. CONTROL THERMOSTAT REPLACEMENT 1. Refer to Frame 2. Release the retaining screw and hang the CH expansion vessel in the servicing position - Refer to Frame 46 of the ‘Installation’ section. 3. Remove the two securing screws and withdraw the faulty thermostat. 4.
  • Page 50 1. Refer to Frame 2. Remove the burner and air box assembly. Refer to Frame 3. Remove the electrode retaining nut and remove the pilot shield and electrode. 4. Unscrew the central pilot fixing screw and lift the pilot clear, of the pilot injector. The pilot injector may now be unscrewed if required. 5.
  • Page 51 17 COMBUSTION CHAMBER INSULATION REPLACEMENT 1. Refer to Frame 2. Remove the burner and air box assembly. Refer to Frame 3. Remove the two front tie rods. 4. Remove the two side panel retaining brackets. 5. Remove the side insulation panels. 6.

  • Page 52: Fan Unit Replacement

    6. Whilst supporting the gas control valve, remove the two screws retaining the manifold to the back panel. 7. Withdraw the gas control/manifold assembly from the boiler. 8. Remove the four screws securing the burner manifold to the bypass valve. 9.

  • Page 53: Pressure Switch Replacement

    22 PRESSURE SWITCH REPLACEMENT 1. Refer to Frame 2. Pull both of the sensing tubes off the pressure switch. 3. Remove the 2 screws securing the pressure switch to the bracket and withdraw the switch. 4. Remove the pressure switch cover by removing the fixing screw. 5.
  • Page 54 2. Remove the control box lid. a. Remove the control box lid fixing screws. Pull the lid forward and upward to disengage the catches and remove the lid. b. Unclip and remove the front panel by lifting it upwards. 3. Disconnect the two electrical leads from the switch. 4.

  • Page 55: Diverter Valve Actuator Replacement

    3. Withdraw the P.C.B. and unplug the 8 electrical leads (‘A’ to ‘H’). 4. Fit the new P.C.B. 27 and re-assemble in reverse order. 26 DIVERTER VALVE ACTUATOR REPLACEMENT 1. Refer to Frame 10 (the Combi module cover only need be removed). 2.
  • Page 56 5. SET THE MANUALLY OPERATED VALVE LEVER TO OPEN. 6. Release the two captive screws (B) and lift the actuator off the valve body. NOTE: At this stage, if required, the Syncron motor may be replaced. Refer to the instructions supplied with the replacement motor. 7.

  • Page 57: Draining The Boiler

    28 D.H.W. FILTER REPLACEMENT 1. Refer to Frame 10 (the Combi module cover only need be removed). 2. Remove the D.H.W. flow switch - Refer to Frame 3. Prise the filter from the housing in the flow switch inlet, and clean or renew as necessary. 4.

  • Page 58: Pressure Gauge Replacement

    30 PRESSURE GAUGE REPLACEMENT 1. Refer to Frame 2. Drain the boiler - Refer to Frame 3. Release the retaining screw and hang the C.H. expansion vessel in the servicing position. Refer to Frame 46 of the ‘Installation’ section. 4. Disconnect the pressure gauge capillary from the safety valve. 5.
  • Page 59 32 D.H.W. CALORIFIER REPLACEMENT 1. Refer to Frame 2. Drain the boiler - Refer to Frame 3. Remove the C.H. expansion vessel - Refer to Frame 4. Remove the 2 securing screws and withdraw the pipe support bracket. 5. Close the D.H.W. inlet isolating valve. 6.

  • Page 60: Pump Replacement

    33 DIVERTER VALVE (COMPLETE) REPLACEMENT 1. Refer to Frame 2. Drain the boiler - Refer to Frame 3. Remove the C.H. expansion vessel - Refer to Frame 4. Remove the automatic air vent. Refer to Frame 5. Disconnect the diverter valve lead at the ‘in-line’ connector. 6.
  • Page 61 7. Slide the cable entry out, and withdraw the cable from the terminal box. NOTE: If required, the pump head only may now be replaced. a. Remove the 4 socket screws and withdraw the pump head. b. Fit the new head and re-assemble in reverse order. To remove the complete pump proceed as follows.
  • Page 62 36 AUTOMATIC AIR VENT REPLACEMENT 1. Refer to Frame 2. Drain the boiler - Refer to Frame 3. Unscrew the automatic air vent from the boiler flow header applying an appropriate counter force to the boss in order to prevent damage. 4.
  • Page 63 1. Refer to Frame 2. Drain the boiler - Refer to Frame 3. Remove the C.H. expansion vessel - Refer to Frame 4. Remove the automatic air vent - Refer to Frame 5. Remove the 2 securing screws and withdraw the pipe support bracket. Refer to Frame 6.
  • Page 64 21. Fully test all functions, including water and gas soundness. 39 BOILER CASING SEAL REPLACEMENT 1. Refer to Frame 2. Remove the old seal from the bottom edge of the casing (shown) and, also, from the bottom edges of the boiler back panel (refer to Frame 41).
  • Page 65 41 BOILER MODULE - Exploded View...

  • Page 66: Burner Assembly - Exploded View

    42 BURNER ASSEMBLY - Exploded view...
  • Page 67 43 CONTROL BOX ASSEMBLY - Exploded View...

  • Page 68: Domestic Hot Water Mode

    Before attempting to rectify any electrical fault, ALWAYS carry out the preliminary electrical system checks using a suitable test meter. Detailed instructions on the replacement of faulty parts are contained within the ‘Servicing’ section of this publication. NOTE: 1. Ensure that the boiler and system is full of water, free from air locks and that the pump is running. 2.

  • Page 70: Pre-Heat Mode

    45 PRE-HEAT MODE Start from Cold. Turn the CH/HW switch to HW ONLY, and any time clock ON. Ensure that all DHW taps are OFF. Re-connect the DHW preheat switch. Turn the burner ON/OFF switch ON. Switch ON the mains supply.

  • Page 72: Central Heating Mode

    46 CENTRAL HEATING MODE Start from Cold. Turn the CH/HW switch to CH & HW, and any time clock and room thermostat ON. Ensure that all DHW taps remain OFF. Turn the burner ON/OFF switch ON. Switch ON the mains supply.

  • Page 74: Spare Parts

    SPARE PARTS Details of the British Gas Lists are held by Gas regions, CARADON Distributors and by Merchants. Ideal Classic Combi NF 80 Combination Gas Boiler. When ordering spares please quote: 1. Boiler Model 2. Appliance G.C. Number 3. Description...
  • Page 75 5. Quantity 48 BOILER CASING ASSEMBLY CARADON HEATING pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. CARADON HEATING Limited, Sales and Marketing, P.O. Box 103, National Avenue, Kingston upon Hull, North Humberside, HU5 4JN.

This manual is also suitable for:

47-415-07

Table of Contents