Ideal Boilers Classic FF 230 Installation And Servicing Manual
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Ideal Boilers Classic FF 230 Installation And Servicing Manual

Ideal Boilers Classic FF 230 Installation And Servicing Manual

Wall hung, fanned flued, gas fired boiler
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Summary of Contents for Ideal Boilers Classic FF 230

  • Page 2 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. Classic LXFF, FF Installation...
  • Page 3 GENERAL Table 1 - General Data Boiler Size FF 230 FF 240 FF 250 FF 260 FF 270 FF 280 FF 2 100 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 4: Table Of Contents

    Classic LXFF 280 41 387 29 Electrical Regulations ..........8 Standard models G.C. Appliance No. Extension Ducts - Fitting ........... 19 Classic FF 230 41 387 01 External Control ............21 Classic FF 240 41 387 02 Classic FF 250 41 387 03 Fault Finding ..............

  • Page 5: Location Of Boiler

    GENERAL INTRODUCTION The installation of the boiler MUST also be in accordance with the latest I.E.E (BS.7671) Wiring Regulations, local building The Classic FF230-2 100 (standard) and the Classic LX FF 230- regulations, bylaws of the local water authority, the Building 280 (deluxe casing) is a range of automatically fully controlled, Regulations and Building Standards (Scotland) and any relevant wall mounted, balanced flue, fanned gas boilers.

  • Page 6: 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 270, FF 280 & FF2 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 7: Gas Supply

    GENERAL Where a room-sealed appliance is installed in a room containing 3, Nos. 2,3, 4, 5 and 6 would be 75mm in order to allow a a bath or shower then the appliance and any electrical switch or terminal guard to be fitted. appliance control utilising mains electricity should be so situated Table 3 - Balanced flue terminal position that it cannot be touched by a person using the bath or shower.

  • Page 8: Classic Lxff

    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 280 2 100 2. If the boiler is to be installed in a cupboard or compartment, permanent air vents are required (for cooling purposes) in Boiler 8.8 11.7 14.6 17.6 20.5 23.4 29.3...

  • Page 9: Low Head Installations

    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 10: Classic Ff

    INSTALLATION BOILER ASSEMBLY - Exploded view Classic FF 230 shown LEGEND 14. Combustion chamber. Fan /collector hood assembly. Sealing plates, 3 off 15. Main burner. Inter-panel. Back panel. 16. Boiler drain point. Pumped return pipe. 10. Controls support. 17. Flue baffles.
  • Page 11 INSTALLATION UNPACKING Pack A Contents The complete boiler The boiler is supplied fully assembled in Pack A, together with Installation & Servicing Instructions a standard flue assembly for lengths up to 600mm (23 "), User's Instructions rear or side flue outlet, in Pack B. Hardware Pack (listed below) Optional extras, if ordered (Downward Piping Kit, Programmer Wall mounting template...

  • Page 12: Determining The Flue Length

    INSTALLATION PACKAGING AND CASING REMOVAL STANDARD MODEL DELUXE MODEL (LX) 1. Unpack the boiler. 1. Unpack the boiler. 2. Remove the casing as follows and place to one side to 2. Remove the casing as follows and place to one side to avoid damage.

  • Page 13: Wall Mounting Template

    INSTALLATION FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 600mm (23 ") Refer to Frame 8. 2. When cutting the ducts, always use the cardboard support rings provided. LEGEND 1.

  • Page 14: Fitting The Flue Assembly

    INSTALLATION 12 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 15: Mounting The Boiler

    INSTALLATION 16 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. 1.
  • Page 16 INSTALLATION 19 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 8.
  • Page 17 INSTALLATION 22 CUTTING THE FLUE 23 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).

  • Page 18: Fitting The Side Outlet Plates

    INSTALLATION 26 FITTING THE SIDE OUTLET PLATES 27 WALL MOUNTING PLATE 1. Fix the mounting plate to the wall with the No.14 x 50mm Note. If the boiler is fitted closer than 25mm to the side wall wood screws. the side outlet plate must be fitted now. 2.

  • Page 19: Connecting The Flue To The Boiler

    INSTALLATION 29 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 32 FLUE EXTENSION DUCTS - continued Flue length General arrangement Extension Note. Side flue shown. 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 21: Electrical Connections

    INSTALLATION 34 GAS CONNECTION 35 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 INSTALLATION 38 PICTORIAL WIRING LEGEND blue bk black brown yellow white orange violet pink grey y/g yellow/green 39 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 40 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: Fault Finding

    INSTALLATION Gas Installation 42 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

    INSTALLATION 44 INITIAL LIGHTING - continued Deluxe Model (LX) Standard Model 45 GENERAL CHECKS d. Balance the system. Make the following checks for correct operation: 5. Finally, set the controls to the user's requirements. 1. Set the boiler thermostat knob to position 6 and operate The temperatures quoted below are approximate and vary the mains on/off switch.

  • Page 26: Gas Supply

    SERVICING 47 SCHEDULE 48 BOILER CASING REMOVAL To ensure the continued safe and efficient operation of the 1. If the Classic Sealed System Unit is fitted (Standard boiler appliance, it is recommended that it is checked at regular only), lift off the casing. intervals and serviced as necessary.

  • Page 27: Cleaning The Fan Assembly / The Flueways

    SERVICING 50 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: Initial Lighting

    SERVICING 53 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 58) and ensuring that there is burner setting pressure and the heat input.

  • Page 29: Pilot Burner Replacement

    SERVICING 57 THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and ON/OFF SWITCH REPLACEMENT Refer also to Frame 54. Remove the control box fixing screw (A). Pull the box forward and downward to disengage. Thermostat control 1. Pull the knob off the shaft. 2.

  • Page 30: Ignition Electrode And Lead Replacement

    SERVICING 59 IGNITION ELECTRODE AND LEAD REPLACEMENT 1. Refer to Frame 54. 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 62 FAN REPLACEMENT 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. 3b.

  • Page 32: Heat Exchanger Replacement

    SERVICING 66 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 5 (Boiler assembly - Exploded view) for 8. Slacken 3 turns only the 4 heat exchanger / inter-panel illustration of the procedure detailed below.

  • 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 2. Appliance G.C. Number The list is extracted from the British Gas List of Parts, which contains all avail- 3.

  • Page 35: Burner Assembly - Exploded View

    SHORT LIST OF PARTS 69 BURNER ASSEMBLY - Exploded View 12. Air box and pilot assembly. LEGEND 17. Pilot shield. (Numbers up to 51 relate to the B.G. spares list) 13. Main burner. 18. Gas control valve. 11. Burner manifold 14.
  • Page 36 SHORT LIST OF PARTS 71 BOILER CASING ASSEMBLY Standard model Deluxe model (LX) 72 SHORT PARTS LIST Classic LXFF, FF Installation...
  • Page 37 Classic LXFF, FF Installation...
  • Page 38 Technical Training The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and The code of practice for the installation, system specifiers. commissioning & servicing of central heating systems For details of courses please ring: ....
  • Page 39 YOUR FEEDBACK and your chance to win a free boiler At Ideal we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service. We will be giving away a free boiler for the five best ideas every year (to be selected by our Technical Director).

  • Page 40: Further Information

    Further information If you would like information about Ideal Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing Limited, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Installer details...

This manual is also suitable for:

Classic ff 240Classic ff 270Classic ff 250Classic ff 280Classic ff 2 100Classic ff 260

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