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Summary of Contents for IDEAL Classic Slimline FF 230
- Page 1 INSTALLATION & SERVICING M A N U A L Classic Slimline the wall hung boiler Wall hung, fanned flue, gas fired boiler FF 230 - 260...
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Page 2: Table Of Contents
GENERAL Classic Slimline FF Natural Gas only CONTENTS Data Badge: on top of the controls support Air Supply..............6 B.G. Certified - P.I. No. 87 BL 43 Destination Countries: GB & IE Appliance type: C Boiler Clearances ............5 Slimline models G.C. -
Page 3: Make And Model
GENERAL Table 1 - General Data Boiler Size FF 230 FF 240 FF 250 FF 260 Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female) Flow connection 22mm copper Return connection 22mm copper Maximum static water head m (ft.) 30.5 (100) Minimum static water head m (ft.) -
Page 4: Gas Safety
GENERAL INTRODUCTION BS.5449 Forced circulation hot water systems. BS.5546 Installation of gas hot water supplies for domestic The Classic Slimline FF230-260 is a range of automatically fully purposes (2nd Family Gases). controlled, wall mounted, balanced flue, fanned gas boilers. BS.7593 Treatment of water in domestic hot water central The heat exchanger is cast iron. -
Page 5: Boiler Water Connections
GENERAL BOILER WATER CONNECTIONS This appliance in NOT suitable for use in a direct hot water system or for gravity circulation. 2 BOILER CLEARANCES Front clearance: 533mm (21") from the front of the boiler casing. The following minimum clearances must be maintained Minimum front clearance when for operation and servicing. -
Page 6: Gas Inlet Working Pressure
GENERAL Where a room-sealed appliance is installed in a room containing a Table 3 - Balanced flue terminal position bath or shower then the appliance and any electrical switch or Terminal Position Minimum Spacing appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower. -
Page 7: Flushing To Bs.7593
GENERAL Table 5 - Water flow rate and pressure loss 1. It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed. Boiler Size 2. If the boiler is to be installed in a cupboard or compartment, Boiler 11.7 14.6... -
Page 8: Pump
GENERAL OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED. The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry Feed / expansion should be inverted and MUST be positioned between the 450 (18") cistern Mimimum... - Page 9 GENERAL SEALED SYSTEM REQUIREMENTS Note. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority. non-return valve and a stop valve with an automatic air vent 1.
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Page 10: Installation
INSTALLATION SEALED SYSTEM REQUIREMENTS continued Safety valve setting 3.0 bar Sizing procedure for expansion vessels: Vessel charge and initial system pressure The volume of the expansion vessel (litres) Total water content of system Expansion vessel volume (litres) fitted to a sealed system shall not be less than that given by the table opposite, multiplied by a 25 litres factor of 0.8 (for flow temperature of less than... -
Page 11: Appliance Serial No. On Data Badge
INSTALLATION BOILER ASSEMBLY - Exploded view Classic FF 230 shown LEGEND Heat exchanger. Collector hood assembly. Flue baffles. 30. Fan. Combustion chamber. 40. Wall mounting plate. Hook bolts 12. Main burner. Flow pipe assy. 52. Back panel. 19. Control box . Return pipe assy. -
Page 12: Determining The Flue Length
INSTALLATION PACKAGING AND CASING REMOVAL 1. Unpack the boiler. (a) Casing retaining 2. Remove the casing as follows and place to one side screws, 2 off to avoid damage. a. Undo the 2 casing retaining screws (a) retaining the casing to the back panel. b. -
Page 13: Rear Installation
INSTALLATION 11 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 600mm (23 ") Refer to Frame 10. 2. When cutting the ducts, always use the cardboard support rings LEGEND provided. -
Page 14: Fitting The Flue Assembly
INSTALLATION 14 CUTTING THE FLUE - wall thicknesses of 114 to 600mm 1. Measure and note the wall thickness X. 2. Mark the wall thickness onto the flue. 3. To ensure the tube is cut square, mark the flue all the way round. -
Page 15: Mounting The Boiler
INSTALLATION 18 MOUNTING THE BOILER 1. Lift the boiler onto the wall mounting plate as shown. Do not use the burner / controls for lifting 2. Fit an additional No.14 x 50mm woodscrew through the slot in the boiler back panel above the flue into the wall plug. -
Page 16: Side Installation
INSTALLATION 21 FLUE ASSEMBLY - Exploded view For wall thickness 114mm to 600mm 1. An optional flue duct extension kit is required for lengths (distance from the outside wall to the relevant side of the boiler casing) greater than 600mm (23 ") Refer to Frame 10. - Page 17 INSTALLATION 24 CUTTING THE FLUE 25 FITTING THE FOAM SEAL For flue lengths 114 to 600mm ONLY 1. To determine the position for the foam seal measure the wall thickness and mark it onto the flue, measuring from 1. Measure the flue length required (i.e. the distance from the side of the boiler to the outside face of the wall).
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Page 18: Fitting The Side Outlet Plates
INSTALLATION 28 FITTING THE SIDE OUTLET PLATES 29 WALL MOUNTING PLATE Note. If the boiler is fitted closer than 25mm to the side wall 1. Fix the mounting plate to the wall with the No.14 x 50mm the side outlet plate must be fitted now. wood screws. -
Page 19: Extension Ducts - Fitting
INSTALLATION 31 CONNECTING THE FLUE TO THE BOILER 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. - Page 20 INSTALLATION 34 FLUE EXTENSION DUCTS - continued Flue length General arrangement Note. Extension Extension duct Side flue shown. tube A maximum of 1 extension duct (plus the standard flue duct) may be used together. Boiler Flue connector Standard flue Terminal grille Flue length Accessories Product No.
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Page 21: Gas Connection
INSTALLATION 36 GAS CONNECTION 37 WATER CONNECTIONS Refer to 'Gas Supply ', page 7. 1. Remove the plastic plugs from the flow and Refer to Frame 2 for gas inlet service dimensions. return pipes. A minimum pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating. -
Page 22: System Diagrams
INSTALLATION 40 PICTORIAL WIRING LEGEND blue bk black brown yellow white orange violet pink grey y/g yellow/green 41 MID POSITION VALVE Pumped only Notes. 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring. 2. Numbering of terminals on thermostats is specific to the manufacturer. -
Page 23: Frost Protection
INSTALLATION 42 TWO SPRING CLOSED VALVE Pumped only Notes. 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring. 2. Numbering of terminals on thermostats is specific to the manufacturer. 3. This is a fully controlled system - set the boiler thermostat to maximum. -
Page 24: Gas Installation
INSTALLATION Gas Installation 44 COMMISSIONING AND TESTING (a) Electrical Installation 1. The whole of the gas installation, including the meter, MUST be inspected and tested for soundness, and purged in accordance with the recommendations of BS. 6891. 1. Checks to ensure electrical safety should be carried out by a competent person. -
Page 25: Handing Over
Caradon Ideal Services, details of which are outlined in the household pack 5. Explain the function and the use of the boiler thermostat supplied with this boiler. -
Page 26: Servicing
SERVICING 49 SCHEDULE f. Remove any debris from inside the base of the casing. To ensure the continued safe and efficient operation of the appliance, it is recommended that it is checked at regular g. Check that the flue terminal is unobstructed and that the flue intervals and serviced as necessary. -
Page 27: Cleaning The Fan Assembly / The Flueways
SERVICING 52 CLEANING THE FAN ASSEMBLY / THE FLUEWAYS 1. Remove the 2 silicon rubber tubes from the fan sensing points. 2. Disconnect the fan leads. 3a. Rear flue Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue. -
Page 28: Spares Replacement
SERVICING 55 GAS PRESSURE ADJUSTMENT PILOT MAIN BURNER The pilot is factory set to maximum and no further After any servicing, reference should be made to Table 2 adjustment is possible. If, after removing and checking the which quotes details of the rated output with the related injector (as detailed in Frame 59) and ensuring that there is burner setting pressure and the heat input. -
Page 29: Pilot Burner Replacement
SERVICING 59 THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD & ON/OFF SWITCH REPLACEMENT Refer also to Frame 56. A. Remove the fixing screws B. Swing the control box down into the servicing position. Thermostat control 1. Pull the knob off the shaft. 2. -
Page 30: Ignition Electrode And Lead Replacement
SERVICING 61 IGNITION ELECTRODE AND LEAD REPLACEMENT 1. Refer to Frame 56. 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. - Page 31 SERVICING 64 FAN REPLACEMENT 1. Refer to Frame 56. 2. Remove the 2 silicon rubber tubes from the fan sensing points. 3. Disconnect the fan leads. 4a. Rear flue. Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue. 4b.
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Page 32: Heat Exchanger Replacement
SERVICING 68 HEAT EXCHANGER REPLACEMENT 8. Slacken 3 turns only the 4 heat exchanger / inter-panel Note. Refer to Frame 8 (Boiler assembly - Exploded view) for retaining screws. illustration of the procedure detailed below. 9. Lift the heat exchanger / inter-panel assembly upward and 1. -
Page 33: Fault Finding
FAULT FINDING Check mains supply and fuses. Reset the overheat 'stat. Set control START Check programmer and system 'stat to maximum. Allow the boiler to Check that the mains on neon thermostats are all ON. Check that reach temperature - if the overheat 'I3' is illuminated. -
Page 34: Short List Of Parts
SHORT LIST OF PARTS When ordering spares please quote: The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance. 1. Boiler Model The list is extracted from the British Gas List of Parts, which contains all avail- 2. - Page 35 SHORT LIST OF PARTS 70 BOILER CASING ASSEMBLY 71 SHORT PARTS LIST Classic Slimline FF Installation & Servicing...
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Page 36: Burner Exploded View
LIST OF PARTS 72 BURNER ASSEMBLY - Exploded View 12. Main burner. LEGEND 10. Burner manifold 13. Main burner injector. 17. Gas control valve. 11. Air box and pilot assembly. 16. Pilot shield. 42. Gas service cock. 73 CONTROL BOX - Exploded View LEGEND 19. - Page 37 NOTES Classic Slimline FF Installation & Servicing...
- Page 38 NOTES Classic Slimline FF Installation & Servicing...
- Page 39 NOTES Classic Slimline FF Installation & Servicing...
- Page 40 Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001:1994 Quality System accepted by BSI. March 2001 156 647 A01 Ideal Installer/Technical Helpline: 01482 498663 www.idealboilers.com...
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