Ideal Boilers Classic FF 330 Installation And Servicing

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Installation and servicing (40 pages)

User manual (4 pages)

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Summary of Contents for Ideal Boilers Classic FF 330

Page 1 When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not ENGINEERED FOR PEACE OF MIND use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
Page 2 GENERAL Table 1 - General Data Boiler Size FF 330 FF 340 FF 350 FF 360 FF 370 FF 380 FF 3 100 Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female) Flow connection 22mm 28mm copper copper (FEMALE) Return connection 22mm...
Page 3 Boiler Exploded View ..........11 Models G.C. Appliance No. Burner Exploded View ..........38 Classic FF 330 .... 41 391 54 Control Box Exploded View ........38 Classic FF 340 .... 41 391 95 Classic FF 350 .... 41 391 96 Electrical Connections ..........
Page 4: Location Of Boiler
GENERAL INTRODUCTION Detailed recommendations are contained in the following British Standard Codes of Practice: The Classic FF330-3100 is a range of automatically fully controlled, BS.6891 Low pressure installation pipes. wall mounted, balanced flue, fanned gas boilers. The heat exchanger is cast iron. The boiler casing is of white BS.6798 Installation of gas fired hot water boilers of rated input enamelled mild steel.
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. FF 370, FF 380 & FF3 100 ONLY must be fitted with the 22mm x 28mm copper sockets, provided in the Hardware Pack, (or equivalent 22mm x 28mm compression fittings ) and the pumped flow and return pipes run in 28mm pipe.
Page 6: Gas Supply
GENERAL If the appliance is to be installed in a room containing a bath or Table 3 - Balanced flue terminal position Approved Manufacturer’s Clearances shower then, providing waterjets are not going to be used for cleaning purposes (such as communal baths/showers), the Terminal Position Minimum Spacing appliance can be installed in Zone 3, as detailed in BS.7671.
Page 7: Water Treatment
GENERAL 2. If the boiler is to be installed in a cupboard or compartment, Table 5 - Water flow rate and pressure loss permanent air vents are required (for cooling purposes) in Boiler Size 3100 the cupboard/compartment, at both high and low levels. Boiler 8.8 11.7 14.6 17.6 20.5 23.4 29.3 The air vents must either communicate with room/internal...
Page 8: Low Head Installations
GENERAL Note. ELECTRICAL SUPPLY WARNING. The appliance MUST be efficiently earthed. Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or Wiring external to the appliance MUST be in accordance with the appliance control utilising mains electricity should be so situated current I.E.E.
Page 9 GENERAL SEALED SYSTEM REQUIREMENTS Non-return valve Automatic air vent Hosepipe (disconnect after filling) Hose unions Additional stop valve Temporary hose (disconnect Hose connector Double check valve after filling) assembly (note direction of flow) Note. 4. Expansion Vessel The method of filling, refilling, topping up or flushing sealed a.
Page 10 GENERAL SEALED SYSTEM REQUIREMENTS - continued 7. Mains Connection c. Through a temporary hose connection from a draw-off tap There must be no direct connection to the mains water supply supplied from a service pipe under mains pressure. Where or to the water storage tank supplying domestic water, even the mains pressure is excessive a pressure-reducing valve through a non-return valve, without the approval of the local shall be used to facilitate filling.
Page 11 INSTALLATION BOILER ASSEMBLY - Exploded view Classic FF 330 shown LEGEND 1A. Heat exchanger. Fan. Collector hood assembly. Flue baffles. Wall mounting plate. Combustion chamber. Tie rods. 44B. Programmer (optional). Main burner. 4A. Pumped flow pipe. Back panel. Control box .
Page 12 INSTALLATION UNPACKING Pack A Contents The boiler is supplied fully assembled in Pack A, together with The complete boiler a standard flue assembly for lengths up to 600mm (23 "), Installation & Servicing Instructions rear or side flue outlet, in Pack B. User's Instructions Unpack and check the contents.
Page 13: 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 to screws, 2 off avoid damage. a. Undo the 2 casing retaining screws (a) retaining the casing to the back panel. b.
Page 14 INSTALLATION 11 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 600mm (23 1/2") Refer to Frame 10. 2. When cutting the ducts, always use the cardboard support rings LEGEND provided.
Page 15: Fitting The Flue Assembly
INSTALLATION 14 CUTTING THE FLUE - wall thicknesses of 114 to 600mm Note. If the stand-off brackets are used it is essential that 30mm is added to the measured wall thickness when marking the flue (to allow for the thickness of the brackets). 1.
Page 16: Mounting The Boiler
INSTALLATION 18 MOUNTING THE BOILER Note. Have ready to hand the M8 screw, washer and rectangular plate supplied in the hardware pack. For downward routing of pipes the M5 spacer (supplied in the Downward Piping Kit) should now be fitted to the back of the boiler.
Page 17 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 ").
Page 18 INSTALLATION 25 FITTING THE FOAM SEAL 24 CUTTING THE FLUE 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 1. Measure the flue length required (i.e. the distance from from the groove near the terminal.
Page 19: 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 20: Connecting The Flue To The Boiler
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 21 INSTALLATION 34 FLUE EXTENSION DUCTS - continued General arrangement Flue length Note. Side flue shown. Extension Extension duct tube 1. A maximum of 2 extension ducts (plus the standard flue duct) may be used together. 2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided.
Page 22: Gas Connection
INSTALLATION 36 GAS CONNECTION 37 WATER CONNECTIONS Refer to 'Gas Supply ', page 6. 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 23 INSTALLATION 40 PICTORIAL WIRING LEGEND b - blue bk - black br - brown gy - grey or - orange pk - pink - red v - violet w - white y - yellow y/g - yellow/green 41 MID POSITION VALVE Pumped only Notes.
Page 24: 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 25: Commissioning And Testing
INSTALLATION 44 COMMISSIONING AND TESTING The Benchmark Log Book or equivalent self certification should be completed and signed to demonstrate compliance with Building Regulations. B. GAS INSTALLATION A. ELECTRICAL INSTALLATION 1. The whole of the gas installation, including the meter, MUST 1.
Page 26: Handing Over
INSTALLATION 46 INITIAL LIGHTING - continued 18. Swing the control box back into its working position and secure. 19. Remove the boiler casing. 20. Refit the controls pod to the boiler casing and tighten the 2 front fixing screws. 21. Refit the complete casing to the boiler.
Page 27: Boiler Casing Removal
SERVICING 49 SCHEDULE c. Clean the main burner. Refer to Frame 53. d. Clean the heat exchanger. Refer to Frame 52. To ensure the continued safe and efficient operation of the e. Clean the main and pilot injectors. Refer to Frame 53. appliance it is recommended that it is checked at regular f.
Page 28: 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 29: Gas Pressure Adjustment
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 61) and ensuring that there burner setting pressure and the heat input.
Page 30 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 31: Pilot Burner Replacement
SERVICING 60 LIMIT THERMOSTAT REPLACEMENT 1. Refer to Frame 56. 2. Remove the limit thermostat assembly from the boiler flow pipe. 3. Disconnect the electrical connectors 4. Replace and reassemble in reverse order, taking care to correctly position the limit thermostat as shown in the orientation diagram opposite.
Page 32: Ignition Electrode And Lead Replacement
SERVICING 62 IGNITION ELECTRODE AND LEAD REPLACEMENT 1. Refer to Frame 56. 2. Remove the burner and air box assembly. Refer to Frame 51. 3. Remove the electrode retaining nut. 4. Remove the pilot shield. 5. Remove the ignition electrode and integral lead. 6.
Page 33 SERVICING 65 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.
Page 34: Heat Exchanger Replacement
SERVICING 69 HEAT EXCHANGER REPLACEMENT 7. Remove the thermostat sensors from the pockets on the heat exchanger by removing the M3 screws and plates. Note. Refer to Frame 7 (Boiler assembly - Exploded view) for illustration of the procedure detailed below. 8.
Page 35: Fault Finding
FAULT FINDING START Reset the overheat 'stat. Set control Check mains supply and fuses. Is the mains on neon 'I3' illuminated? 'stat to maximum. Allow the boiler Check programmer and system to reach temperature - if the thermostats are all ON. overheat 'stat trips again, measure Check that boiler plug and socket flow temperature.
Page 36: Short List Of Parts
When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
Page 37 LIST OF PARTS 72 SHORT PARTS LIST 13 A cla 6113 73 BOILER CASING ASSEMBLY Classic Installation & Servicing...
Page 38: Burner Assembly - Exploded View
LIST OF PARTS 74 CONTROL BOX - Exploded View LEGEND 19. Control box. 21. Thermostat potentiometer. 23. Printed circuit board. 26. Thermostat knob. 58. Mains on/off switch. 75 BURNER ASSEMBLY - Exploded View LEGEND 10. Burner manifold 11. Air box and pilot assembly. 12.
Page 39 NOTES Classic Installation & Servicing...
Page 40 Gas only. They have been tested and conform with the provisions of BS. 6332 and BS. 5258. Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

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