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INSTALLATION

& SERVICING

MANUAL

Classic FF - Propane Installation

classic

the wall hung boiler

Wall hung, fanned flue,

gas fired boiler

Classic FF 250P-275P

Installers guide to central heating boilers

GENERAL

Table 1 - General Data

Boiler Size FF 250 P FF 260 P FF 275 P

Gas supply connection Rc 1/2 (1/2)

Flow connection 22mm 28mm copper

copper (FEMALE)

Return connection 22mm 28mm copper

copper (FEMALE)

Maximum static water head m (ft.) 30.5 (100)

Minimum static water head m (ft.) 0.45 (1.5)

Electrical supply 230 V ~ 50 Hz Boiler power consumption; 100W

Fuse rating External; 3A Internal; F1A to BS.4265

Water content litre (gal.) 3.65 (0.8) 4.65 (1.0)

Dry Weight

kg (lb) 46.6 (102.8) 52.6 (116.0)

Maximum installation weight kg (lb) 37.4 (82.5) 43.1 (95.0)

Boiler size Height mm (in.) 700 (27.5)

Width mm (in.) 380 (15.0)

Depth mm (in.) 300 (11.8)

Flue duct diameter mm (in.) 100 (4.0)

Table 2 - Performance Data

Boiler Size FF 250 P FF 260 P FF 275 P

Boiler input kW 18.3 20.9 26.7

(Btu/h) (62 500) (71 250) (91 250)

Gas consumption l/s (ft

Boiler output kW 14.7 16.7 21.4

Burner Setting mbar 35.3 35.0 35.0

pressure (HOT) (in.w.g.) (14.1) (14.0) (14.0)

Inlet pressure mbar (in.w.g.) 37.0 (14.8)

Seasonal efficiency (SEDBUK)* [80.0]% [76.8]% [75.7]%

*The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been certified by BGplc 0087.

/h) 0.20 (25.0) 0.22 (28.5) 0.29 (36.5)

(Btu/h) (50 000) (57 000) (73 000)

To obtain the gas consumption:

a. For l/s divide heat input (kW) by C.V. of the gas (MJ/m3)

b. For ft3/h divide heat input (Btu/h) by C.V. of the gas (Btu/ft3)

CAUTION.

this appliance, care should be taken when handling edges of sheet steel components.

To avoid the possibility of injury during the installation, servicing or cleaning of

Classic FF - Propane Installation

GENERAL

Classic FF

B.G. Certified - P.I. No. 87 AP 107

Destination Countries: GB and IE

Propane Gas only Appliance type: C12 & C

Data Badge: on top of the controls support

Models G.C. Appliance No.

Classic FF 250 P 41 387 07

Classic FF 260 P 41 387 08

Classic FF 275 P 41 387 09

CONTENTS

Air Supply. ..................................................................... 7

Boiler Clearances ......................................................... 5

Boiler Exploded View ................................................ 11

Burner Exploded View .............................................. .35

Control Box Exploded View ..................................... .35

Electrical Connections .............................................. 22

Electrical Regulations ................................................. 7

Extension Ducts - Fitting ........................................... 21

External Control ......................................................... 22

Fault Finding .............................................................. 34

Flue Installation ............................................................ 6

Rear installation ...................................................... 14

Side installation ...................................................... 17

Gas Safety ..................................................................... 4

Gas Supply ................................................................... 6

Health & Safety Document .......................................... 4

Initial lighting . ............................................................ 25

Installation .................................................................. 11

Mandatory Requirements ............................................4

Pump ............................................................................. 8

Servicing ..................................................................... 27

Short List of Parts ......................................................36

Spares Replacement .................................................. 29

System Diagrams ....................................................... 23

Terminal Guards. .......................................................... 6

Water and Systems ...................................................... 8

Water Treatment ........................................................... 7

Key to symbols

IE = Ireland

GB = United Kingdom (Countries of destination)

PMS = Maximum operating pressure of water

& C32 =

A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal, which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which, in this case, are concentric. The fan is up stream of the combustion chamber.

= An appliance designed for use on 3rd Family gas,

Group P only.

NOTE TO THE INSTALLER:

LEAVE THESE

INSTRUCTIONS ADJACENT TO THE GAS METER.

ALSO COMPLETE THE BENCHMARK LOG BOOK

AND GIVE THIS TO THE CUSTOMER.

BENCHMARK LOG BOOK DETAILS

Boiler Page

Make and model ........................................................3

Appliance Serial No. on Data Badge ....................... 11

Controls ....................................................... as applicable

For all boilers

Flushing to BS.7593 ..................................................7

Inhibitor ......................................................................7

Gas inlet working pressure ........................................ 6

Burner operating pressure .........................................2

Heat input .......................................... to be calculated

Temperature differential .............. measure and record

For combination boilers only ................... Not applicable

For domestic hot water mode .................. Not applicable

For condensing boilers ............................. Not applicable

For all boilers: complete, sign & hand over to customer

For assistance see Technical Helpline on the back page

Classic FF - Propane Installation

GENERAL

INTRODUCTION

The Classic FF250-275 Propane is a range of automatically

fully controlled, wall mounted, balanced flue, fanned gas boilers.

The heat exchanger is cast iron. The boiler casing is of white enamelled mild steel.

The boiler casing has a removable controls pod containing a drop-down door. The boiler thermostat is located behind the drop- down door.

Note.

These boilers cannot be used on systems which include gravity circulation.

If gravity circulation is required the Classic RS range of boilers is suitable.

See Frame 1 for details of the correct boiler tappings to use.

The boilers are supplied with a standard flue kit suitable for rear or side outlet applications from 114 mm (4

The boilers are suitable for connection to the following open vented or sealed systems:

z Fully pumped CH and indirect DHW

z Pumped heating only.

z Pumped indirect DHW only.

1/2") to 600 mm (23 1/2").

OPTIONAL EXTRA KITS

Downward Piping Kit

Programmer Kit.

Vertex Flue Kit. For vertical flue connection

Roof Flue Kit.

90° Flue Elbow Turret Kit

Sealed System Unit. Fits on top of the appliance.

Detailed recommendations are contained in the following British Standard Codes of Practice:

BS.5482 Domestic butane and propane burning appliances

BS.6891 Low pressure installation pipes.

BS.6798 Installation of gas fired hot water boilers of rated

input not exceeding 60 kW.

BS.5449 Forced circulation hot water systems.

BS.5546 Installation of gas hot water supplies for domestic

purposes (2nd and 3rd Family Gases).

BS.5440.1 Flues for gas appliances of rated input not

exceeding 60 kW.

BS.5440.2 Ventilation for gas appliances of rated input not

exceeding 60 kW.

BS.7593 Treatment of water in domestic hot water central

heating systems.

Health & Safety Document No. 635.

The Electricity at Work Regulations, 1989.

Manufacturer’s notes must NOT be taken in any way as overriding statutory obligations.

IMPORTANT. These appliances are certificated by the British Standards Institution for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances -unless covered by these ‘Installation and Servicing’ instructions or otherwise recommended by Caradon Plumbing Limited in writing. If in doubt please enquire.

Any direct reconnection of a control device not approved by Caradon Plumbing Limited could invalidate the BSI Certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation panels which can cause irritation to the skin. No asbestos, mercury or CFCs are included in any part of this boiler.

Extension ducts. Up to 3 m (118").

Current Gas Safety (Installation and Use) Regulations or rules in force.

It is law that all gas appliances are installed by a CORGI registered installer in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with.

The installation of the boiler MUST also be in accordance with the latest I.E.E (BS 7671) Wiring Regulations, local building regulations, bylaws of the local water authority, the Building Regulations and Building Standards (Scotland) and any relevant requirements of the local authority.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical wall, capable of adequately supporting the weight of the boiler and any ancillary equipment.

The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary - unless required by the local authority. The boiler must not be fitted

outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IG/UP/7:1998.

Bathrooms

The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. (BS 7671) Wiring Regulations and, in Scotland,

Classic FF - Propane Installation

BOILER WATER CONNECTIONS

This appliance in NOT suitable for use in a direct hot water system or for gravity circulation.

FF 275P boiler 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.

BOILER CLEARANCES

The following minimum clearances must be maintained for operation and servicing

Additional space will be required for installation, depending upon site conditions.

Side and Rear Flue

a. Provided that the flue hole is cut

accurately, e.g. with a core drill, the flue can be installed from inside the building.

Installation from inside ONLY

b. If a core boring tool is to be used

inside the building; the space in which the boiler is to be installed must be at least wide enough to accommodate the tool.

c. If using the Complete Sealed

System Unit then refer to the instructions packed with the unit for the necessary clearances.

GENERAL

Front clearance: 533mm (17 from the front of the boiler casing.

Minimum front clearance when built in to cupboard is 75 mm (3").

3/4")

Pelmet restrictions.

If the ability to fit or remove the casing during installation and subsequent servicing is impaired by pelmets etc. this operation can be made easier by first removing the controls pod casing in line with the following instructions:

a. Release the controls pod

casing fixing screws (a) 3 full turns only. Remove the pod by pulling it forward to disengage from the keyhole slots.

b. Undo the 2 screws (b)

retaining casing to the back panel.

c. The casing can now be

removed in the direction of the arrow, first lifting the casing slightly to disengage the casing top return from the back panel. (For this purpose a minimum clearance of 12mm is required between the top of the boiler and pelmet or other similar obstruction.

Classic FF - Propane Installation

GENERAL

the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower.

Where a room-sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

Where installation will be in an unusual location, special procedures may be necessary and BS.6798 gives detailed guidance on this aspect.

Compartment Installations

A compartment used to enclose the boiler should be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided it is modified for the purpose.

In both cases details of essential features of cupboards/ compartment design, including airing cupboard installation, are to conform to the following :

z BS. 6798.

z The position selected for installation MUST allow adequate

space for servicing in front of the boiler and for air circulation around the boiler, see section on 'Air Supply'.

z For the minimum clearances required for safety and

subsequent service, see the Wall mounting diagram, Frame

2. In addition, sufficient space may be required to allow lifting access to the wall mounting plate.

GAS SUPPLY

A local propane supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas.

Installation pipes, cylinders and pressure regulators MUST be fitted in accordance with BS. 5482.1.

Pipework from the supply to the boiler MUST be of an adequate size.

Bulk tank installations must comply with the Home Office code of practice for the storage of liquefied petroleum gas at fixed installations.

The complete installation MUST be tested for gas soundness and purged as described in the above code.

Table 3 - Balanced flue terminal position

Terminal Position Minimum Spacing

1. Directly below or alongside an opening

window, air vent or other ventilation opening 300 mm. (12")

2. Below guttering, drain pipes or soil pipes 25 mm. (1")

3. Below eaves 25 mm. (1")

4. Below balconies or a car port roof 25 mm. (1")

5. From vertical drain pipes or soil pipes 25 mm. (1")

6. From internal or external corners 25 mm. (1")

7. Above adjacent ground, roof or

balcony level 300 mm. (12")

8. From a surface facing the terminal 600 mm. (24")

9. From a terminal facing a terminal 1200 mm. (48")

10. From an opening in a car port

(e.g. door or window) into dwelling 1200 mm (48")

11. Vertically from a terminal on the same wall 1500 mm (60")

12. Horizontally from a terminal on the wall 300 mm (12")

4. Where the lowest part of the terminal is fitted less than 2m

(6'6") above a balcony, above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard. The minimum spacing in Table 3, Nos. 2,3, 4, 5 and 6 would be 75mm in order to allow a terminal guard to be fitted.

Terminals guards are available from boiler suppliers. Ask for Tower Flue Guard, Model K1. In case of difficulty seek advice from:

Tower Flue Components Ltd., Vale Rise, Tonbridge, Kent TN9 1TB (Model K1) Telephone No. 01732 351 555

Ensure that the guard is fitted centrally.

5. Where the terminal is fitted within 1000mm (39 plastic or painted gutter or 500mm (19 1/2") of painted eaves then an aluminium shield at least 1000mm (39 1/2") long should be fitted to the underside of the gutter or painted surface.

6. The air inlet/products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm (1") to combustible material. Detailed recommendations on the protection of combustible material are given in BS.5440: 1990.

1/2") of a

FLUE INSTALLATION

The flue must be installed in accordance with the recommendations of BS. 5440:1.

The following notes are intended for general guidance.

1. The boiler MUST be installed so that the terminal is exposed to external air.

2. It is important that the position of the terminal allows the free passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3.

7. Where it is essential that the terminal wall plate is fitted, i.e. wall thicknesses over 600mm (23 cut hole, the minimum spacing in Table 3 Nos. 2,3, 4, 5 and 6 would be 60mm (2 1/2") in order to allow the terminal wall plate to be fitted.

1/2") or with an inaccurately

IMPORTANT. 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, labelled 'unsafe' and corrective action taken.

TERMINAL

The terminal assembly can be adapted to accommodate various wall thicknesses, refer to Frame 10 'Unpacking'.

Classic FF - Propane Installation

GENERAL

AIR SUPPLY

Detailed recommendations for air supply are given in BS.5440:2. The following notes are for general guidance:

1. It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed.

2. If the boiler is to be installed in a cupboard or compartment, permanent air vents are required (for cooling purposes) in the cupboard/compartment, at both high and low levels. The air vents must either communicate with room/internal space, or be direct to outside air. The minimum effective areas of the permanent air vents, required in the cupboard/compartment, are specified as follows and are related to maximum rated heat input.

3. Both air vents MUST communicate with the same room or internal space or MUST be on the same wall to outside air.

4. In siting the air vents care must be taken to avoid the freezing of pipework.

Refer to Table 4 for details of air vent position and sizing.

Table 4 - High and low vent areas

Boiler Air from room/internal Air direct

space cm

FF 250 P 170 (26) 83 (13)

FF 260 P 198 (31) 102 (16)

FF 275 P 264 (41) 132 (21)

(in2 ) outside cm2 (in2)

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply. For the types of system and correct piping procedure refer to 'Introduction' and Frame 1.

The central heating system should be in accordance with BS. 6798 and, in addition, for Smallbore and Microbore systems, BS. 5449.

The domestic hot water system, if applicable, should be in accordance with the relevant recommendations of BS. 5546. Copper tubing to BS. 2871:1 is recommended for water carrying pipework.

The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper.

Single feed, indirect cylinders are not recommended and MUST NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating, nor are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any possible freezing - particularly where pipes run through roof spaces and ventilated under floor spaces.

The boiler must be vented (not on sealed system).

IMPORTANT

Draining taps MUST be located in accessible positions, which permit the draining of the whole system - including the boiler and hot water storage vessel. They should be at least 1/2" BSP nominal size and be in accordance with BS. 2879.

The boiler is fitted with a special drain plug which is provided to drain the BOILER ONLY in the event of the system drain plug being unable to do so. The hydraulic resistances of the boilers, at MAXIMUM OUTPUT with an 11 are shown in Table 5. Maximum boiler operating temperature should be 82 oC (180 oF).

C (20OF) temperature differential,

Classic FF - Propane Installation

Table 5 - Water flow rate and pressure loss

Boiler Size

Boiler kW 14.7 16.7 21.4 Output Btu/h 50 000 57 000 73 000

Water Flow l/min 19.0 22.8 30.3 Rate gal/h 250 300 400

Pressure mbar 31.5 41.7 77.0 Loss in w.g. 12.6 16.7 30.9

FF 250 P FF 260 P FF 275 P

WATER TREATMENT

These boilers incorporate a cast iron heat exchanger. As part of the installation the central heating system should be thoroughly flushed with appropriate water treatment in order to comply with BS7593:1992.

Caradon Plumbing Ltd recommend the use of Fernox or Betz Dearborn water treatment products which must be used in accordance with the manufacturers instructions. For further information contact :-

Fernox Manufacturing. Co. Ltd, Tandem House, Marlowe Way, Croydon, Surrey CRO 4XS, tel 0870 5601 5000 or

Betz Dearborn Ltd, Widnes, Cheshire, tel. 0151 424 5351

Important: Any other treatment for this product will render the

guarantee of Caradon Plumbing Ltd INVALID.

Notes.

1. If an inhibitor is used, and in hard water areas where treatment to prevent lime deposits is necessary, it is most important that the water treatment MUST be maintained at the correct concentrations recommended by the treatment manufacturer.

2. Artificially softened water must not be used in the system, under any circumstances

THERMOSTATIC RADIATOR VALVES

Caradon Plumbing Limited recommend that heating systems

utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS. 5449.

When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves. However, if the system employs thermostatic radiator valves on all radiators or two port valves without end switches then a bypass must be fitted to ensure a flow of water should all valves be in the closed position.

ELECTRICAL SUPPLY

WARNING. The appliance MUST be efficiently earthed.

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS 7671) Wiring Regulations and any local regulations which apply.

The point of connection to the mains should be readily accessible and adjacent to the boiler, except that for bathroom installations; the point of connection to the mains MUST be situated outside of the bathroom.

Note. Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.

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 should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.

There should be a minimum height - 450mm (18") of open vent above cistern water level. If this is impossible refer below.

The vertical distance between the highest point of the system and the feed/expansion cistern water level MUST not be less than 450mm (18").

Feed / expansion cistern

Water level (cold)

22mm Open vent

15mm Cold feed

450 (18") Mimimum

The pump MUST be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of providing an 11°C (20°F) temperature differential (e.g. Grundfos UPS 15/50 or equivalent). The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturers minimum requirements to avoid cavitation. Should these conditions not apply, either lower the pump position or raise the cistern above the minimum requirement specified by

Caradon Plumbing Limited.

Note.

A cold water feed must be available back to the boiler, when all automatic valves are in the closed position (Refer BS. 6798) and when close coupled the feed must not be in a vertical leg.

LOW HEAD INSTALLATIONS

The Classic range of boilers can be installed in low head situations by fitting a 'surge arrester' in the expansion pipe as shown.

The following conditions MUST be observed:

1. The surge arrester must be at least 42mm in diameter x 150mm long, thus ensuring a MINIMUM air gap and a MINIMUM depth of water below the static water level (cold) of 75mm.

Return

450 (18) Min.

200 (8) Min.

System return

Connections to boiler

Minimum Requirements

75 (3) Min.

Surge arrester

75 (3) Min.

Flow

Inverted cold feed entry

Feed / expansion

cistern

22 (3/4)

Open vent

150 (6") Max

System flow to pump

Cold

water

level

To pump

2. The static water level (cold) must be at least 200mm above the top of the horizontal flow pipe, fitted as shown. The vent connection MUST NOT be made immediately off the top of the boiler, as venting is made less efficient.

3. The maximum practical length of 15mm cold feed pipe should be used in order to reduce the effective volume of system water expanding into the feed/expansion cistern to a minimum.

Note. The pump manufacturers minimum requirements must be complied with.

Highest point of flow or return

All dimensions in mm (in.). NB. Imperial dimensions are approximate.

150

(6)

Max

Max. practical

length

Classic FF - Propane Installation

SEALED SYSTEM REQUIREMENTS

Safety valve

Drain cock

Pressure gauge

Pump

GENERAL

Air vent

HEATING

CIRCUIT

Make-up vessel

(max. capacity

3 litres)

Non-return

valve

Automatic

air vent

Hosepipe

(disconnect after filling)

Hose union

bib tap

Water supply

BOILER

cla1787

Expansion

vessel

Double check valve

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.

1. General

a. The installation must comply with the requirements of

BS.6798 and BS.5449.

b. The installation should be designed to work with flow

temperatures of up to 82oC.

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a working pressure of 3 bar (45 lb/in

) and temperature of 110oC. Care should be taken in making all connections so that the risk of leakage is minimised.

2. Safety Valve

A spring loaded safety valve complying with the relevant requirements of BS.6759 must be fitted in the flow pipe, as close to the boiler as possible and with no intervening valve or restriction. The valve should have the following features:

a. A non-adjustable pre-set lift pressure not exceeding 3 bar

(45 lb./in

)

b. A manual testing device.

c. Provision for connection of a discharge pipe. The valve or

discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4 bar (0-60 lb./in2) must be fitted to the system. The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.

BS.1010:2

Test cock

stop tap

Hose

connector

4. Expansion Vessel

a. A diaphragm type expansion vessel must be connected at

a point close to the inlet side of the pump, the connecting pipe being not less than 15mm (1/2" nominal) size and not incorporating valves of any sort.

b. The vessel capacity must be adequate to accept the

expansion of the system water when heated to 110oC (230oF)

c. The charge pressure must not be less than the static

water head above the vessel The pressure attained in the system when heated to 110oC (230oF) should be at least

0.35 bar (5lb/in2) less than the lift pressure of the safety valve.

For guidance on vessel sizing refer to the table in Frame 6. For further details refer to BS.5449 and the British Gas Corporation publication : Material and Installation Specifications for Domestic Central Heating & Hot Water.

5. Cylinder

The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge pressure of 0.35 bar (5lb./in excess of the safety valve setting. Single feed indirect

cylinders are not suitable for sealed systems.

6. Make-up Water

Provision must be made for replacing water loss from the system, either:

a. From a manually fitted make-up vessel with a readily

visible water level. The vessel should be mounted at least 150mm (6") above the highest point of the system and be connected through a non-return valve to the system, fitted at least 300mm (12") below the make-up vessel on the return side of the domestic hot water cylinder or radiators.

b. Where access to a make-up vessel would be difficult by

pre-pressurisation of the system. Refer to 'Filling.'

) in

Classic FF - Propane Installation

SEALED SYSTEM REQUIREMENTS - cont.

7. Mains Connection

There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the local water authority.

8. Filling

The system may be filled by one of the following methods:

a. Through a cistern, used for no other purposes, via a ball

valve permanently connected directly to a service pipe and / or a cold water distributing pipe.

The static head available from the cistern should be adequate to provide the desired initial system design pressure. The cold feed pipe from the cistern should include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during normal operation of the system if automatic water make-up is required.

b. Through a self-contained unit comprising a cistern,

pressure booster pump (if required) and, if necessary, an automatic pressure reducing valve and flow restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe.

This unit may remain permanently connected to the heating system to provide limited automatic water makeup. Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other

GENERAL

draw-off points at a lower level then a double check valve shall be installed upstream of the draw-off point.

c. Through a temporary hose connection from a draw-off tap

supplied from a service pipe under mains pressure. Where the mains pressure is excessive a pressure-reducing valve shall be used to facilitate filling.

The following fittings shall form a permanent part of the system and shall be fitted in the order stated:

A stop valve complying with the requirements of BS. 1010, Part 2 (the hose from the draw-off tap shall be connected to this fitting).

A test cock.

A double check valve of an approved type.

• Thoroughly flush out the whole of the system with cold water, without the pump in position.

• With the pump fitted, fill and vent the system until the pressure gauge registers 1.5 bar (21.5lb/in

Examine for leaks.

• Check the operation of the safety valve by manually raising the water pressure until the valve lifts. This should occur within ± 0.3 bar (± 4.3lb/in pressure.

• Release water from the system until the initial system design pressure is reached.

• Light the boiler and heat the system to the maximum working temperature. Examine for leaks.

• Turn off the boiler and drain the system while still hot.

• Refill and vent the system.

) of the pre-set lift

Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).

Safety valve setting 3.0 bar 2.5 bar 2.0 bar

Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 system pressure bar bar bar bar bar bar bar bar

Total water content of system Expansion vessel volume

(litres) (litres)

25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0

50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0

75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0

100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0

125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0

150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0

175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0

200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0

225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0

250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0

275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0

300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0

Multiplying factors for

other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20

Classic FF - Propane Installation

BOILER ASSEMBLY - Exploded view

Classic FF 30 shown

INSTALLATION

LEGEND

1A. Heat exchanger.

2. Flue baffles.

3. Tie rods.

4A. Pumped flow pipe.

5A. Pumped return pipe.

Classic FF - Propane Installation

6. Collector hood assembly.

7. Combustion chamber.

12. Main burner.

19. Control box .

24. Pressure switch.

30. Fan.

40. Wall mounting plate.

44B. Programmer (optional).

52. Back panel.

UNPACKING

INSTALLATION

Pack A Contents

The boiler is supplied fully assembled in Pack A, together with a standard flue assembly for lengths up to 600mm (23 or side flue outlet, in Pack B.

Optional extras, if ordered (Downward Piping Kit, Programmer Kit, complete Sealed System Unit, Extension Duct Kit D, Vertex Flue Kit G, Roof Flue Kit H and 90° Flue Elbow Kit F) are available in separate boxes.

Unpack and check the contents.

1/2"), rear

INSTALLATION

z The complete boiler

z Installation & Servicing Instructions

z User's Instructions

z Hardware Pack (listed below)

z Wall mounting template

z Wall mounting plate

z Side outlet terminal mounting plate

z Flue extension tube, 1 off

z Boiler sealing ring, 1 off

Wall mounting plate

Hardware Pack Contents

z 50mm x No. 14 wood screw, 4 off

z 50mm x No. 10 wood screw, 8 off

z Wall plug , 12 off

z Data badge indicator arrow, 1 off

z M8 washer, 1 off

Pack B Contents

z Duct cutting support, 1 off

(cardboard )

z Terminal wall plate, 1 off.

z Terminal grille assy, 1 off.

z Polyurethane foam seal 400 lg., 1 off.

z No. 8 x 8 lg. Pozi pan hd. screws, 3 off.

z 22mm x 28mm copper reducing socket

(FF 275 P ONLY), 2 off

z M5 wing nut, 3 off

z Sealing plate, 1 off

z M8 x 12 lg. screw, 1 off

Classic FF - Propane Installation

PACKAGING AND CASING REMOVAL

1. Unpack the boiler

2. Remove the casing as follows and place to one

side to avoid damage.

a. Undo the 2 casing retaining screws (a) retaining

the casing to the back panel.

b. Swing the bottom of the boiler casing up until the

controls pod casing has cleared the controls then unhook the top from the back panel.

3. Remove the boiler from its packaging base. The boiler may now be stood upright on its controls support protection frame to ease handling and installation.

4. Unpack the boiler terminal box and, if applicable, the extension flue box(es)

INSTALLATION

(a) Casing retaining screws, 2 off

INSTALLATION

DETERMINING THE FLUE LENGTH

It is MOST important that the boiler is installed in a vertical position.

REAR FLUE INSTALLATION

SIDE FLUE INSTALLATION

Flue length for rear

Packing base

Controls pod casing

FLUE KITS

Pack B: supplied as standard.

Pack D: optional extension kit for side flue or rear flue

outlet. Refer to 'Flue Extension Ducts'

1. A maximum of 3 extension ducts (plus the standard flue duct) may be used together.

2. Flue extensions of greater than 1m (39") should be supported with the bracket provided. If the stand off brackets have been used, it is necessary, in order to keep the flue aligned, to use the spacer bracket with the support bracket.

Flue length for side

Jacking screw for boiler alignment

Note.

Vertex and roof flue kits are available as optional extras for vertical flue installation, supplied with separate fitting instructions.

Classic FF - Propane Installation

Flue length

Up to 600 B Pack 1 off 150308

600 to 1550 B Pack 1 off + D Pack, 1 off 150308+153883

1550 to 2500 B Pack 1 off + D Pack, 2 off 150308+

2500 to 3000 B Pack 1 off + D Pack, 3 off 150308+

Accessories Product No.

153883, 2 off

153883, 3 off

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 provided.

WALL MOUNTING TEMPLATE

INSTALLATION

LEGEND

1. Terminal.

2. Weather seal.

3. Flue assembly.

4. Boiler sealing ring.

5. Flue extension tube.

Note. The template shows the positions for the fixing holes

and the flue hole centres for standard installation. Care must be taken to ensure the correct holes are drilled.

1. Separate the templates.

2. Tape the templates into the selected position.

3. Ensure squareness by hanging a plumb line as shown.

4. Mark onto the wall (if required) the following:

a. The wall mounting plate screw positions (choose one

from each group). Note. Mark the centre of the flue hole as well as the circumference.

b. The position of the flue duct hole.

c. Downward pipe routing bracket screw positions

5. Remove the templates from the wall.

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting operation, masonry

falling outside of the building does not cause damage or personal injury.

1. Cut the flue hole preferably with a 125mm (5") core boring tool ensuring that the hole is square to the wall. If the hole has been quite accurately cut with a drill, then making good the wall faces is not essential as seals are provided at both ends of the flue. However, both wall faces immediately around the cut hole should be flat; make good if necessary. For less accurate holes make good to approximately 125mm (5") diameter at the two wall faces.

2. Drill 4 holes for the wall mounting plate with an 8mm (5/16") masonry drill. If the stand-off brackets are used ensure the correct holes are chosen.

3. Insert the plastic plugs provided.

REAR FLUE OUTLET

Note. If the

terminal is to be sited within 2540mm 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

Classic FF - Propane Installation

INSTALLATION

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. 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.

4. Cut to length 'X', using the cardboard ring for support.

5. Remove cardboard ring and remove any burrs.

FITTING BOILER SEALING RING TO THE FLUE

1. Fit the boiler sealing ring inside the outer flue duct. Ensure

boiler sealing ring is fully engaged. Ensure the notch aligns with the groove on the outer flue duct. This ensures correct alignment of the flue terminal.

FITTING THE FLUE ASSEMBLY

1. Insert the flue extension tube into the flue assembly.

2. Insert the flue assembly through the hole sufficiently far

enough to allow the rubber seal to unfold completely and form an adequate seal on the outside wall.

2. Drill 3 holes 3.2mm (1/8") dia. through the outer flue duct and

boiler sealing ring. Do NOT drill the inner flue duct.

3. Insert the self tapping screws, provided, in order to fix the boiler sealing ring in position.

4. Stick the self adhesive foam strip, provided in the hardware pack, onto the flue immediately behind the boiler sealing ring.

3. Ensure the notch is at the top. This will aid the location of the studs into the boiler back panel.

WALL MOUNTING PLATE

1. Fix the mounting plate to the wall with the No.14 x 50mm

wood screws.

2. If the down ward routing of pipes is required, then the downward routing pipe brackets and M8 spacer (supplied in the Downward Piping Kit) should be fitted to the wall mounting plate now.

3. Fit the bottom 2 screws to secure the bracket(s) to the wall, through the wall mounting plate.

3. Check with a spirit level that the plate is vertical.

Classic FF - Propane Installation

REAR FLUE OUTLET

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. Lift the boiler onto the wall mounting plate hooks as shown.

Do not use the burner / controls for lifting

2. Fit the M8 screw washer and 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.

CONNECTING THE FLUE TO THE BOILER

INSTALLATION

1. Pull the flue through the wall mounting plate and

locate the 3 studs in the holes in the back panel.

2. Secure the flue to the boiler, using the three M5 wing nuts provided.

3. Pull the flue extension tube and engage onto fan, locate and secure with the M4 screw attached to the fan.

Note.

The sealing ring studs will locate in the back panel one way only. This will ensure that the terminal grille is correctly aligned.

TERMINAL WALL PLATE

This plate allows neat concealment and full compression of the rubber seal. Its use is not essential if the flue hole and flue ducts have been accurately cut and the outside wall face is flat.

1. Position the terminal wall plate over the terminal.

2. Mark and drill 4 fixing holes with an 7mm (

drill.

3. Insert the 4 plastic plugs provided.

4. Secure the plate with 4 of the No.10 x 2" screws provided.

Note. If the terminal is less than 2m (6' 6") above ground

level, an approved terminal guard should be fitted. Refer to the Contents List on Page 3.

9/32") masonry

REAR FLUE OUTLET

Classic FF - Propane Installation

INSTALLATION

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 1/2") Refer to Frame 10.

2. When cutting the ducts always use the cardboard support provided.

WALL MOUNTING TEMPLATE

Note. The template shows the positions for the fixing holes and the flue

hole centres for standard installation.

If the flow and return pipes are to be routed down behind the boiler, the downward routing pipe brackets (supplied in the Downward Piping Kit) must be used. These brackets are secured to the wall mounting plate and it is essential to use only those holes as shown on the wall mounting template.

Care MUST be taken to ensure the correct holes are drilled.

1. Separate the templates.

2. Tape both templates into the selected position locating template B

through an extended centre line as shown.

LEGEND

1. Terminal.

2. Weather seal.

Extended centre

3. Flue assembly.

4. Boiler sealing plate.

5. Flue extension tube.

line

Terminal mounting plate screw and flue duct hole positions

3. Ensure squareness by hanging a plumb line as shown.

4. Mark onto the wall (if required) the following:

a. The four wall mounting plate screw positions (choose one

from each group). If the downward routing pipe brackets are used ensure the correct holes are chosen.

b. The 4 screw positions for the side outlet plate.

c. The position of the flue duct hole (ensure that the correct

centre is marked depending on whether the downward routing pipe brackets are used or not).

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting operation, masonry falling

outside of the building does not cause damage or personal injury.

1. Cut the flue hole preferably with a 125mm (5") core boring tool ensuring that the hole is square to the wall. If the hole has been accurately cut with a drill, then making good the wall faces is not essential - as seals are provided at both ends of the flue. However, both wall faces immediately around the cut hole should be flat; make good if necessary. For less accurate holes make good to approximately 125mm (5") diameter at the 2 wall faces.

2. Drill 4 holes with an 8mm (5/16") masonry drill and insert the plastic plugs provided, for the wall mounting plate.

Note. Mark the centre of the hole as well as the circumference.

5. Remove both templates from the wall.

SIDE FLUE OUTLET

d. The side of the casing nearest the flue outlet.

3. Drill 4 holes with an 7mm (9/32") masonry drill and insert the plastic

plugs provided, for the side mounting plate .

Note. If the terminal is to be sited within 25-40mm 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.

Classic FF - Propane Installation

INSTALLATION

CUTTING THE FLUE For flue lengths 114 to 600mm ONLY

1. Measure the flue length required (i.e. the distance from

the side of the boiler to the outside face of the wall) Refer to Frame 11.

2. Mark the flue length required onto the flue, measuring from the groove near the terminal.

3. To ensure the tube is cut square, mark the flue all the way round.

4. Insert the cardboard support , and cut to length.

5. Remove cardboard support and remove any burrs.

FITTING THE FOAM SEAL

1. To determine the position for the foam seal measure the

wall thickness and mark it onto the flue, measuring from the groove near the terminal.

2. Wrap the self adhesive foam strip round the flue, ensuring that the foam is on the terminal side of the line. This seals the gap between the flue and the wall.

For flue lengths greater than 600mm refer to Frames 34 & 35 - Flue extension ducts.

FITTING BOILER SEALING RING TO THE FLUE

SIDE FLUE OUTLET

1. Fit the boiler sealing ring inside the outer flue duct.

Ensure boiler sealing ring is fully engaged. Ensure the notch aligns with the groove on the outer flue duct. This ensures correct alignment of the flue terminal.

2. Drill 3 holes 3.2mm ( and boiler sealing ring.

3. Insert the self tapping screws, provided, in order to fix the boiler sealing ring in position.

1/8") dia. through the outer flue duct

Do not drill the inner flue duct.

FITTING THE FLUE ASSEMBLY

1. Insert the flue assembly through the hole sufficiently far

enough to allow the rubber seal to unfold completely and form an adequate seal on the outside wall. This will also ensure the correct alignment of the flue terminal.

2. Ensure the notch is at the top. This will aid the location of the studs into the boiler back panel.

Flue assembly

Classic FF - Propane Installation

INSTALLATION

FITTING THE SIDE OUTLET PLATES

Note. If the boiler is fitted closer than 25mm to the side wall

the side outlet plate must be fitted now.

1. Split the side outlet plate into 2 down the split line.

2. Fit the 2 halves of the side outlet plate to the wall, ensuring they are behind the boiler sealing ring.

MOUNTING THE BOILER

WALL MOUNTING PLATE

1. Fix the mounting plate to the wall with the No.14 x 50mm

wood screws.

2. If the downward routing of pipes is required, then the downward routing pipe brackets and M8 spacer (supplied in the Downward Piping Kit) should be fitted to the wall mounting plate now.

3. Fit the bottom 2 screws to secure the bracket(s) to the wall, through the wall mounting plate.

4. Check with a spirit level that the plate is vertical.

Notes 1. Have ready to hand the M8 screw, washer and rectangular plate supplied in the hardware pack.

2. 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. The boiler is supplied for rear outlet installation. Remove the blanking plate from the direction required and use this to blank off the rear outlet.

2. Lift the boiler onto the wall mounting plate hooks as shown.

Do not use the burner/controls for lifting.

3. Fit the M8 screw, washer and 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.

SIDE FLUE OUTLET

Classic FF - Propane Installation

INSTALLATION

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.

3. Insert the flue extension tube into the flue.

4. Fit the 90° flue elbow, supplied with the boiler, onto the

fan in the direction required, after first removing the underside screw, which is not required. Secure in position with the screw attached to the fan.

5. Pull the flue extension tube and engage onto the fan elbow and secure with the screw attached to the elbow.

Note. The sealing ring studs will locate in the back panel one way only. This will ensure that the terminal grille is correctly aligned.

TERMINAL WALL PLATE

This plate allows neat concealment and full compression of the rubber seal. Its use is not essential if the flue hole and flue ducts have been accurately cut and the outside wall face is flat.

1. Position the terminal wall plate over the terminal.

2. Drill 4 fixing holes with a 7mm (

3. Insert the 4 plastic plugs provided.

4. Secure the plate with 4 of the No.10 x 2" screws

provided.

Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to the Contents List on Page 3.

FLUE EXTENSION DUCTS - For flue lengths greater than 600mm

9/32") masonry drill.

PACK D Flue extension duct kit contents

REAR & SIDE FLUE OUTLET

Classic FF - Propane Installation

INSTALLATION

FLUE EXTENSION DUCTS - continued

General arrangement

Note. Side flue shown.

1. A maximum of 3 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. If the stand-off brackets have been used it is necessary, in order to keep the flue aligned, to use the spacer bracket with the support bracket.

Flue length Accessories Product No.

Up to 600 B Pack 1 off see Frame 8

600 to 1550 B Pack 1 off + D Pack, 1 off see Frame 8

1550 to 2500 B Pack 1 off + D Pack, 2 off see Frame 8

2500 to 3000 B Pack 1 off + D Pack, 3 off see Frame 8

FITTING THE KIT

Extension

tube

Boiler

Flue length

Extension duct

Flue connector

Standard flue

Terminal grille

INSTALLATION

1. Remove the cardboard support aid from the

flue and place safely to one side.

2. Fit the inner flue extension duct onto the inner flue duct.

3. Fit the outer flue extension duct onto the outer air duct.

4. Drill one - 3.2mm ( outer air duct. Do not drill the inner flue

duct.

5. Insert the self tapping screw provided to fix the air duct in position.

6. Repeat steps 1-5 if a second flue extension is required.

1/8") dia. holes through the

Classic FF - Propane Installation

INSTALLATION

GAS CONNECTION

Refer to 'Gas Supply ', page 7. Refer to Frame 2 for gas inlet service dimensions.

A minimum pressure of 37 mbar MUST be available at the boiler inlet with the boiler operating. The main gas cock is on the left hand side of the gas control valve, as shown. To facilitate connection the gas cock may be removed from the gas control valve.

ELECTRICAL CONNECTIONS

WARNING. The appliance must be efficiently earthed.

A mains supply of 230 V ~ 50 Hz is required.

All external controls and wiring must be suitable for mains voltage.

INSTALLATION

Wiring should be in 3-core PVC insulating cable, not less than

0.75mm and local regulations.

Connection must be made in a way that allows complete isolation of the electrical supply - such as a double pole switch, having a 3mm (1/8") contact separation in both poles, serving only the boiler and system controls. The point of connection to the mains should be readily accessible.

(24 x 0.2mm) to BS. 6500 Table 16 Wiring Regulations

WATER CONNECTIONS

1. Remove the plastic plugs from the flow and

return pipes.

2. Make all water connections and check for water soundness.

LEGEND b blue bk black

Flow wiring diagram

br brown r red y yellow

w white gy grey or orange

v violet pk pink y/g yellow/green

Note. If the optional Programmer Kit is to be

fitted refer to the instructions provided with the kit and Frame 39.

1. Remove the control box securing screws. Swing the box down into the servicing position. Refer to Frame 46.

2. Route the mains cable into the box from the RHS of the boiler.

3. Connect the live, neutral and earth wires into the terminal strip as shown.

4. Secure the mains lead with the cable clamp.

5. On completion of all wiring connections,

relocate the control box and secure.

EXTERNAL CONTROLS

The wiring diagrams illustrated in Frames 39-41 cover the systems most likely to be fitted to this appliance.

For wiring external controls to the Classic FF boiler, reference should be made to the system wiring diagrams supplied by the relevant manufacturer, in conjunction with the wiring diagrams shown in Frames 41-43.

Difficulty in wiring should not arise, providing the following directions are observed:

1. Controls that switch the system on or off, e.g. a time switch, must be wired, in series, in the live mains lead to the boiler.

2. Controls that override an on/off control, e.g. frost thermostat, must be wired into the mains lead, in parallel, with the control(s) to be overridden. Refer to Frame 43.

3. Controls that switch the circulation pump only on and off, e.g. a room thermostat, must be wired, in series, with the pump in the live pump lead.

4. If a proprietary system is used, follow the instructions supplied by the manufacturer.

5. System designs featuring controls or wiring arrangements which allow the boiler to fire when there is no pump circulation taking place should not be fitted.

Advice on required modifications to the wiring may be obtained from the component manufacturers.

Notes.

1. Connection between a frost thermostat and the time

control should be made without disturbing other wiring.

2. A frost thermostat should be sited in a cool place in the house, but where it can sense heat from the system.

Classic FF - Propane Installation

PICTORIAL WIRING

LEGEND

gy grey

b blue

bk black

br brown

r red

y yellow

w white

y/g yellow/green

or orange

v violet

p pink

INSTALLATION

MID POSITION VALVE

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 fully controlled system - set the boiler thermostat to maximum.

4. Switchmaster 'Midi' is similar in operation, but the wiring differs slightly; see manufacturer's literature.

LEGEND

b blue

bk black

br brown

r red

w white

y/g yellow/green

or orange

gy grey

Pumped only

Classic FF - Propane Installation

TWO SPRING CLOSED VALVE

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 fully controlled system - set the boiler thermostat to maximum.

4. Switchmaster valve has grey & orange

INSTALLATION

auxiliary switch leads but the grey wire must be connected to the live supply.

INSTALLATION

Pumped only

LEGEND

b blue

bk black

br brown

r red

y yellow

FROST PROTECTION

w white

y/g yellow/green

or orange

v violet

pk pink

gy grey

Central heating systems fitted wholly inside the house do not

normally require frost protection as the house acts as a 'storage

heater' and can normally be left at least 24 hrs. without frost

damage. However, if parts of the pipework run outside the house

or if the boiler will be left off for more than a day or so, then a

frost 'thermostat should be wired into the system.

This is usually done at the programmer, in which case the

programme selector switches are set to OFF and all other

controls MUST be left in the running position.

The frost 'thermostat should be sited in a cold place but where

it can sense heat from the system.

Wiring should be as shown, with minimal disturbance to other

wiring of the programmer.

Designation of the terminals will vary but the programmer and

thermostat manufacturer's leaflets will give full details.

If a boiler is installed in a garage it may be necessary to fit a pipe

thermostat.

Diagram A shows a double pole frost 'thermostat, which should

suffice for all systems which do not use the OFF terminals of the

programmer.

Diagram B shows a 'change-over' frost 'stat, which will cover

most systems which do use CH OFF. If, however, on such a

system the HW pipework is in an isolated part of the house, a

second frost 'stat may be used to protect it. If in doubt, ask your

installer for advice.

Classic FF - Propane Installation

INSTALLATION

COMMISSIONING AND TESTING

(a) Electrical Installation

1. Checks to ensure electrical safety should be carried out

by a competent person.

2. ALWAYS carry out preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit using a suitable test meter.

WARNING. Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors, extinguish naked lights and DO NOT SMOKE.

INITIAL LIGHTING

TO LIGHT THE BOILER

1. Check that all the drain cocks are closed, and any valves in

the flow and return are open.

2. Check that the gas service cock (B) is OPEN and the boiler mains On/Off switch is OFF.

3. If the boiler output is to be set to minimum or mid, affix the appropriate indicator label supplied in the hardware pack to the data badge, located on the controls support.

4. Fitting the Boiler Casing

The boiler casing must be refitted with the controls support casing attached for alignment purposes. Lift the boiler casing up to the boiler assembly, with the casing top angled forward. Hook the top edge of the boiler casing into the channel on the top of the boiler assembly. Swing the bottom of the casing down and secure with the 2 captive screws.

The casing must seat correctly and compress the sealing strip to make an airtight joint. Visually check the side seals but, if side clearances are limited, then check that the top and bottom edges of the casing are correctly located.

Note. If the Sealed System Unit is fitted remove the unit casing in order to inspect the top casing seal.

To gain access to the gas valve:

a. Remove the controls support casing. Release the controls

support front fixing screws 3 turns only. Remove the pod by pulling it forward to disengage from the keyhole slots.

b. Remove the control box securing screws and swing it

down into the servicing position. See diag. B Frame 46.

5. Slacken the screw in the burner pressure test point (F) and connect a gas pressure gauge via a flexible tube.

6. Swing the control box back into its working position.

(b) Gas 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.

2. Purging air from the gas installation may be expedited by loosening the union on the gas service cock on the boiler and purging until gas is detected.

3. Retighten the union and check for gas soundness.

LEGEND

A Sightglass. B Gas service cock. C Inlet pressure test point. D Thermostat knob

7. Press the overheat thermostat reset button (J).

8. Switch the electricity supply ON and check that all external

controls are calling for heat.

9. Set the boiler thermostat knob (D) to position 6 and the boiler Mains On/Off switch to ON. The fan will start. After the fan has run for a few seconds the pilot solenoid valve should open and the intermittent spark commence, continuing until the pilot is established. The main burner will then cross-light smoothly. If this sequence does not occur, refer to the Fault Finding section.

10. Test for gas soundness around ALL boiler gas components using leak detection fluid.

11. Operate the for 10 minutes to stabilise the burner temperature.

12. The boiler is pre-set at the factory to its highest nominal rating but can be range- rated to suit the system design requirements. Refer to Table 2 (page 2):

a. Set the mains On/Off switch to OFF.

b. Switch the electricity supply OFF.

c. Swing the control box down into the servicing position.

d. Remove the main burner adjuster cover.

e. Turn the adjusting screw clockwise to INCREASE the

pressure, or anticlockwise to DECREASE the pressure.

f. Swing the control box back into its working position.

g. Switch the electricity supply ON.

h. Set the mains On/Off switch to ON and check the new

setting pressure.

13. If necessary repeat steps 12a to h until the required pressure is achieved. Record this value in the Benchmark log book.

14. Set the main On/Off switch to OFF.

15. Switch the electricity supply OFF.

16. Swing the control box down into the servicing position.

17. Refit the main burner pressure adjuster cover.

18. Remove the pressure gauge and tube. Retighten the

sealing screw in the pressure test point. Ensure a gas tight seal is made.

E Main burner pressure adjuster. F Burner pressure test point. H Boiler mains on/off switch. J Overheat thermostat reset

button.

INSTALLATION

Classic FF - Propane Installation

INSTALLATION

INITIAL LIGHTING - continued

19. Swing the control box back into

its working position and secure.

20. Remove the boiler casing.

21. Refit the controls support to the

boiler casing and tighten the 2 front fixing screws.

22. Refit the complete casing to the boiler.

23. Close the pod door.

INSTALLATION

GENERAL CHECKS

Make the following checks for correct operation:

1. Set the boiler thermostat knob to position 6 and operate the

Mains on/off switch. Check that the main burner lights and extinguishes in response.

2. The correct operation of ANY programmer and all other system controls should be proved. Operate each control separately and check that the main burner or circulating pump, as the case may be, responds.

3. Check that the casing is sealed correctly and compressing the sealing strip all around the casing.

4. Water Circulating System

a. With the system HOT, examine all water connections for

soundness.

b. With the system still hot, turn off the gas, water and

electricity supplies to the boiler and drain down in order to complete the flushing process.

c. Refill and vent the system, clear all air locks and again

check for water soundness.

d. Balance the system.

5. Finally set the controls to the user's requirements.

The temperatures quoted below are approximate and vary between installations:

Knob Setting Flow Temperature

°C °F

1 54 130

2 60 140

3 66 150

4 71 160

5 77 170

6 82 180

WARNING. The boiler MUST NOT be

operated with the casing removed.

HANDING OVER

After completing the installation and commissioning of

the system the installer should hand over to the

householder by the following actions:

1. Hand the User's Instructions to the Householder and explain

his or her responsibilities under the current Gas Safety (Installation and Use) or rules in force.

2. Draw attention to the Lighting Instruction label affixed to the controls pod door.

3. Explain and demonstrate the lighting and shutting down procedures.

4. The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the Householder, to ensure the greatest possible fuel economy, consistent with household requirements of both heating and hot water consumption. Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions.

5. Explain the function and the use of the boiler thermostat and external controls.

6. Explain the function of the boiler overheat thermostat and emphasise that if cutout persists, the boiler should be turned off and the local heating installer consulted.

7. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system.

8. If any Programmer Kit is fitted, then draw attention to the Programmer Kit User's Instructions and hand them to the Householder.

9. After installation, commissioning and customer hand-

over instructions please complete the appliance log book and leave this with the customer.

10. Stress the importance of regular servicing by a Corgi

registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR.

Classic FF - Propane Installation

INSTALLATION

SCHEDULE

To ensure the continued safe and efficient operation of the appliance, it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage, but should be carried out at least annually. It is the law that any service work must be carried out by CORGI registered installer.

As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Caradon Ideal Services, details of which are outlined in the household pack supplied with this boiler.

a. Light the boiler and carry out a pre-service check, noting

any operational faults. Operate the boiler for at least 20 minutes. Check the gas consumption.

b. Connect a suitable gas analyser to the sampling point on

the top RHS of the back panel. For correct boiler operation the CO/CO2 content of the flue gas should not be greater than 0.004 ratio. If this is the case and the gas input is at least 90% of the nominal, then no further action need be taken. If not, proceed to paragraph c.

c. Clean the main burner. Refer to Frame 53.

d. Clean the heat exchanger. Refer to Frame 52.

e. Clean the main and pilot injectors. Refer to Frame 53.

f. Remove any debris from inside the base of the casing.

g. Check that the flue terminal is unobstructed and that the flue

system is sealed correctly.

h. If the appliance has been installed in a compartment, check

that the ventilation areas are clear.

The servicing procedures are covered more fully in Frames 50 to 54 and must be carried out in sequence.

WARNING

Disconnect the electrical supply and turn off gas supply.

IMPORTANT. After completing the servicing or exchange of components always test for gas soundness and carry out functional checks as appropriate.

When work is complete the casing MUST be correctly refitted, ensuring that a good seal is made.

he boiler must NOT be operated if the casing is not fitted.

Note. In order to carry out either servicing or replacement of components, the boiler casing must be removed (Frame 50).

INSTALLATION

BOILER CASING REMOVAL

1. If the Classic Sealed System Unit is fitted lift off the casing.

2. Open the controls pod door and release the 2 captive screws

at the bottom of the casing. Swing the bottom of the boiler casing out until the controls pod casing has cleared the controls, then unhook the casing top from the back panel. Retain the casing in a safe place. Where the removal of the casing is impaired by a pelmet, the instruction in Frame 2 should should be followed.

3. Isolate the gas supply at the service cock fitted to the boiler.

BURNER AND AIR BOX REMOVAL

1. Remove the screw retaining the front burner support

bracket to the combustion chamber. Remove the M5 pozi situated at the LH bottom rear of the burner and pull the burner downwards to disengage the retention tab. Remove burner to a safe place for inspection and cleaning.

2. Remove the control box fixing screw. Pull the box forward and downward to disengage.

3. Pull the HT lead connection off the printed circuit board and pull the lead upwards through the bottom panel grommet.

4. Remove the four screws retaining the air box /pilot assembly to the vertical manifold and carefully remove the assembly

Classic FF - Propane Installation

SERVICING

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.

3b. Side or top flue

Slacken off two M4 screws securing the flue elbow and flue connector. Disconnect the flue connector from the elbow and slide into the flue. Remove the flue elbow.

4. Disconnect the silicon rubber tube from the rear of the collector hood.

5. Slacken the two M5 nuts on the front tie rods, releasing the tie rods from the combustion chamber.

6. Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood/fan assembly.

7. Check that the fan impeller runs freely. Remove any debris from the impeller with a soft brush.

8. Remove the flue baffles.

9. Remove all loose deposits from the heat exchanger,

particularly between the fins, using a suitable brush.

10. Reassemble in reverse order, ensuring the fan leads and 3 sensing tubes are reconnected.

CLEANING THE BURNER AND PILOT ASSEMBLY

1. Brush off any deposits that may have fallen on to the

burner head, ensuring that the flame ports are

SERVICING

unobstructed, and remove any debris that may have collected. Note. Brushes with metallic bristles must not be

used.

2. Remove the main burner injector and ensure that there is no blockage or damage. Clean or renew as necessary.

3. Refit the injector, using an approved jointing compound sparingly.

4. Inspect the pilot burner and ignition / detection electrode. Ensure that they are clean and in good condition.

REASSEMBLY

Reassemble the boiler in the following order:

1. Refit the flue baffles.

2. Inspect the collector hood rope gasket and replace, if

necessary, ensuring that the self adhesive rope is fitted centrally onto the lip of the collector hood / fan assembly. The boiler efficiency will be adversely affected if incorrectly fitted. Refit the collector hood and retain with the 2 front tie rods and the rear central fixing screw. Tighten the nuts and screw. Ensure that the sealing gasket is compressed. Refit the pressure pipe.

3. Refit the positive pressure tubes on the top of the fan housing. Reconnect the electrical leads.

Check that:

a. The pilot burner injector is not blocked or damaged. Refer

to Frame 60 for removal details.

b. The pilot burner is clean and unobstructed.

c. The ignition / detection electrode is clean and undamaged.

d. The ignition / detection lead is in good condition.

e. The spark gap is correct (Frame 60). Clean or renew as

necessary.

Note. The pilot shield is located around the pilot assembly bracket and is located by the electrode retaining nut.

5. Reconnect the gas supply and the electrical wiring. Refer to Frames 36 & 38.

6. Check the sightglass in the boiler casing. Clean or renew as necessary. Refer to Frame 57.

7. Check for gas soundness. Check the gas service cock and pressure test point.

8. Refit the boiler casing (Refer to Frame 45, item 4). Note that it is not necessary to disturb the controls casing pod.

9. Close the controls pod door.

4. Refit the air box assembly and burner. Ensure that the

burner front fixing is refitted.

Classic FF - Propane Installation

GAS PRESSURE ADJUSTMENT

SERVICING

PILOT

The pilot is factory set to maximum and no further adjustment is possible. If after removing and checking the injector (as detailed in Frame 60) and ensuring that there is an inlet pressure of 37 mbar available, the pilot does not light then contact Caradon Plumbing Limited.

Relight in accordance with 'Initial Lighting' - refer Frame 45.

REPLACEMENT OF PARTS

GENERAL

When replacing any component:

1. Isolate the electricity supply.

2. Turn OFF the gas supply.

3. Remove the boiler casing - refer to Frame 50.

IMPORTANT. When work is complete the casing must

be correctly refitted, ensuring that a good seal is made.

MAIN BURNER

After any servicing, reference should be made to Table 2 which quotes details of the rated output with the related burner setting pressure and the heat input.

Note. In order to assist fault finding the control box printed circuit board is fitted with 2 indicator lights which represent the following boiler conditions:

Neon I3. Mains electricity ON.

Neon SG1. Flashes to indicate spark operation (stops after

detection).

The boiler MUST NOT be operated if the casing is not fitted.

SIGHTGLASS REPLACEMENT

1. Refer to Frame 56.

2. Unfasten the two nuts and washers holding the sightglass

assembly to the casing front panel.

3. When fixing the new assembly, ensure that the parts are in the correct order. The frame must have the return edge at the bottom.

4. Retighten the 2 nuts to ensure an airtight seal. Do NOT overtighten.

6. Replace the boiler casing. Refer to Frame 54.

OVERHEAT THERMOSTAT REPLACEMENT

1. Refer to Frame 56 & 39.

2. Remove the control box fixing screws.

3. Swing the control box down into the servicing position.

4. Pull off the electrical connections at the thermostat. Remove the

5. Fit the new thermostat and re-assemble in reverse order.

6. Check the operation of the boiler.

SERVICING

backnut retaining the thermostat to the bracket. Withdraw the thermostat phial from the heat exchanger pocket.

Classic FF - Propane Installation

SERVICING

THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and 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. Remove the backnut securing the thermostat

control to the control box.

3. Pull off the Molex connector from printed circuit board.

4. Replace and reassemble in reverse order.

Thermistor sensor lead

5. Pull the sensor lead connector off the printed

circuit board.

6. Remove the sensor from the heat exchanger pocket and unclip from the back panel.

7. Remove the strain relief bush from the back panel base.

8. Remove the sensor lead through the grommet in the control box.

9. Replace and reassemble in reverse order.

SERVICING

On/off switch

10. Disconnect the electrical connectors from the

rear of the switch.

11. Press in the 2 side retaining clips and remove the switch.

12. Reassemble in reverse order.

PILOT BURNER REPLACEMENT

1. Refer to Frame 56.

2. Remove the burner and air box assembly.

Refer to Frame 51.

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. Replace the pilot burner and retain with the M4 screw previously removed. Ensure that the copper sealing washer is replaced when refitting the pilot injector.

6. Replace the electrode and pilot shield, retaining both with the electrode nut. Check the spark gap.

7. Reassemble in reverse order.

8. Check the operation of the boiler.

9. The pilot is factory set to maximum and no further adjustment

is possible. Ensure that there is an inlet pressure of 20 mbar available. Also check burner ignition and cross-lighting.

Classic FF - Propane Installation

SERVICING

SPARK 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 spark electrode and integral lead.

6. Refit the new electrode and lead in reverse order.

Ensure that the pilot shield is replaced.

7. Check the spark gap. Refer to Frame 60.

8. Reassemble in reverse order.

9. Check the operation of the boiler.

MAIN BURNER & MAIN BURNER INJECTOR REPLACEMENT

1. Refer to Frame 56.

2. Remove the screw retaining the front burner support strap

to the combustion chamber.

3. Remove the M5 pozi screw, situated at the left hand bottom rear of the burner. Pull the burner downwards to disengage the retention tab and remove the burner.

4. At this stage the main burner injector can be removed, checked, cleaned or replaced as required. Ensure that an approved jointing compound us used sparingly.

5. Fit the new burner, ensuring that the retention tab is correctly located in the air box slot and reassemble in reverse order.

6. Check the burner for cross-lighting and flame stability.

GAS CONTROL VALVE REPLACEMENT

Note. Refer also to Frame 71 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 56.

2. Remove the burner and air box assembly. Refer to

Frame 51.

3. Remove the fixing screws. Swing the control box down into the servicing position.

4. Disconnect the gas control valve electrical leads.

5. Undo the gas cock union .

6. Whilst supporting the gas control valve, remove the 2

screws retaining the manifold to the back panel.

SERVICING

7. Remove the gas control / manifold assembly.

8. Remove the 4 screws retaining the manifold to the gas

control valve, and fit the manifold to the new valve. Ensure that the new control is fitted the correct way round (an arrow engraved on back indicates the direction of flow).

9. Transfer the gas cock union to the new gas control valve, using an approved jointing compound.

10. Re-assemble in reverse order.

11. Check the operation of the boiler.

Classic FF - Propane Installation

SERVICING

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. Side or top flue. Slacken off two M4 screws securing the flue elbow

and flue connector. Disconnect the flue connector from the elbow and slide into the flue. Remove the flue elbow.

5. Disconnect the silicon rubber tube from the rear of the collector hood.

6. Slacken the two M5 nuts on the front tie rods, releasing the tie rods

from the combustion chamber.

7. Remove the M5 central fixing screw at the rear of the collector hood and remove collector hood / fan assembly.

8. Remove the three M4 screws retaining the fan to the collector hood.

9. Fit the new fan and re-assemble in reverse order, ensuring the fan

leads, and 3 sensing tubes are reconnected.

10. Check the operation of the boiler.

AIR PRESSURE SWITCH (APS) REPLACEMENT

1. Refer to Frame 56.

2. Remove the APS fixing screw.

3. Remove both sensing tubes from the APS.

4. Remove the 3 electrical connections from the APS.

SERVICING

5. Fit the new APS and reassemble in reverse order.

6. Check the operation of the boiler.

PRINTED CIRCUIT BOARD (PCB) REPLACEMENT

Note. Refer to Frame 72 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 56.

2. Remove the fixing screws and swing the control box down

into the servicing position.

3. Disconnect the detection lead from the PCB.

4. Unplug all the Molex connectors from the PCB.

5. Disengage the PCB from the mounting posts and withdraw

from the control box.

6. Fit the new PCB and re-assemble in reverse order.

7. Check the operation of the boiler.

Fuse.

To change the fuse, prise it out of the holder and disengage the fuse. Refer to Frame 72 for fuse location.

COMBUSTION CHAMBER INSULATION REPLACEMENT

1. Refer to Frame 56.

2. Remove the burner and air box assembly.

Refer to Frame 51.

3. Remove the 4 tie rods.

4. Remove the combustion chamber.

5. Remove the 2 side panel retaining brackets.

6. Remove the side insulation panels.

7. Remove the front and rear insulation panels.

8. Fit the new front and rear insulation panels.

9. Fit the new side panels and retain with the brackets and screws previously removed.

10. Re-assemble in reverse order.

Classic FF - Propane Installation

HEAT EXCHANGER REPLACEMENT

SERVICING

Note. Refer to Frame 7 (Boiler Assembly - Exploded view) for

illustration of the procedure detailed below.

1. Refer to Frame 56.

2. Remove the burner /air box assembly. Refer to Frame 51.

3. Drain the system.

4. Disconnect the water connections. If compression fittings

are used then cut the pipes both above and below the fittings, in order to allow the heat exchange assembly to be removed. Remove the heat exchanger drain plug and drain the residual water into a suitable receptacle.

5. Remove the fan / collector hood assembly. Refer to Frame

52.

6. Remove the combustion chamber by unscrewing the 4 tie rods.

7. Remove the thermostat sensors from the pockets on the heat exchanger by removing the M3 screws and plates.

CASING SEAL REPLACEMENT

1. Refer to Frame 56.

8. Slacken 3 turns only the 4 heat exchanger / interpanel

retaining screws.

9. Lift the heat exchanger / interpanel assembly upward and forward to disengage key hole fixings. Pull the assembly downward to clear the water pipes from the back panel.

10. Remove the 2 rubber sealing grommets from the top of the back panel to facilitate fitting the new assembly.

11. Fit the new heat exchanger assembly, complete with water pipes, and hang it on the key hole slots and screws. Retighten the screws.

12. Replace the 2 rubber sealing grommets.

13. Reassembly in reverse order.

14. Remake all water connections, ensuring that the

compression fittings (if used) are correctly refitted.

15. Fully test all functions, including water and gas soundness.

2. Remove the old seal from the bottom edge of the

casing and also from the edges of the boiler back panel.

3. Fit the new self adhesive seals.

4. Replace the boiler casing.

PROGRAMMER REPLACEMENT (IF FITTED)

1. Refer to Frame 56.

2. Remove the fixing screws and swing the

control box down into the servicing position.

3. Pull off the terminal connections from back of programmer.

4. Compress the lugs at each side of the programmer and withdraw it from the control panel.

SERVICING

5. Fit the new programmer in reverse order.

6. Set the programmer to the desired

programme and check the operation of the boiler.

Classic FF - Propane Installation

FAULT FINDING

START

Check that the mains on neon

'I3' is illuminated.

YES

Is there a live supply to both

terminals of overheat 'stat?

YES

Check that the boiler thermostat

is set at maximum and the mains

on/off switch is ON.

Is the fan turning ?

YES

Is there a supply on the fan

connector at PCB ('Molex '

marked 'FAN'?).

YES

Is there a supply at

the fan ?

Check mains supply and fuses.

Check programmer and system

thermostats are all ON. Check that

boiler plug and socket are OK and

Can the overheat 'stat

Remove the sensor

(NTC) from the PCB.

Has the fuse blown on PCB ?

Is there a live supply on the

violet lead to pressure switch?

Change fan

Rectify bad connection

fully connected.

be reset when the

system is cold ?

Is the fan turning ?

YES

Is there a live

supply on the red

lead to pressure

switch?

YES

Reset the overheat 'stat. Set control

'stat to maximum. Allow the boiler to

reach temperature - if the overheat

'stat trips again, measure flow

temperature.

If above 90°C replace control 'stat.

If below 90°C replace overheat 'stat.

Replace the overheat thermostat

Replace the sensor

Replace fuse BUT, before

attempting to start boiler, check

for short between live and

neutral, also between live and

earth, on all items plugged into

PCB

Check all connections to PCB.

If no error found, replace PCB.

Check connections and leads to

pressure switch/boiler thermostat

and check that fan is operating.

Is the ignition electrode sparking?

Does the pilot light ?

Is there a gas supply

to the boiler?

YES

Is the pilot injector

blocked?

YES

Ensure pilot and

main gas valve

leads are not

crossed over.

Is there a supply

voltage at pilot

gas valve?

YES

FAULT FINDING

Replace

gas valve

YES

Does the

spark stop

after pilot is

lit?

Check the polarity of

the mains supply.

Check the continuity of

the ignition lead from

connector to electrode.

Does the spark now

cease when gas is lit ?

Check all connections to PCB. If no fault found, replace PCB

YES

Is there a regular

spark from tube 'SG1'

on the PCB?

YES

Is the boiler casing

correctly fitted?

Does main burner

cross-light from pilot?

Is there a supply on terminals

of main gas valve?

Is the main burner

injector clear?

YES

Replace main gas

solenoid valve

YES

Check connections to pressure

switch. If no faults found, change

pressure switch.

Check gap at ignition electrode.

Check electrode and lead are

undamaged, and not close to

earthed metalwork.

Check all connections to PCB.

If no fault found change PCB.

Check pressure switch sensing

pipes for blockages, bad

connections and reversed

connection.

Is pressure difference at switch

greater than 0.9 mbar?

YES

Change

pressure switch

Change fan

Classic FF - Propane Installation

SHORT LIST OF PARTS

BURNER ASSEMBLY - Exploded View

LEGEND

10. Burner manifold

11. Air box and pilot assembly.

CONTROL BOX - Exploded view

12. Main burner.

13. Main burner injector.

16. Pilot shield.

17. Gas control valve.

42. Gas service cock.

LEGEND

19. Control box.

21. Thermostat potentiometer.

23. Printed circuit board.

26. Thermostat knob.

58. Mains on/off switch.

Classic FF - Propane Installation

SHORT LIST OF PARTS

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.

The list is extracted from the British Gas List of Parts, which contains all available spare parts.

The full list is held by British Gas, Caradon Plumbing Limited distributors and merchants.

Key No. GC Part No. Description Qty. Product No.

9 308 365 Sightglass assembly kit 1 079602

13 Main burner

173 115 AEROMATIC No. AC 19/123 296; FF 250 P & FF 260 P 1 112699 173 116 AEROMATIC No. AC 19/123 295; FF 275 P 1 112700

14 Main burner injector

389 612 BRAY Cat. 10 - size 520; FF 250 P 003 861 389 540 BRAY Cat. 16 - size 600; FF 260 P 1 112 701 398 043 BRAY Cat. 10 - size 800; FF 275 P 1 004 858

15 397 925 Pilot burner injector: Propane 459 00421-003 (stamped 20/23P) 1 005 018

16 173 117 Pilot burner head with injector: Propane 1 079 625

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

18 379 921 Gas control valve HONEYWELL VR 4601 EA, 230 V 1 111 074

19 308 549 Ignition electrode complete with lead and backnut 410 mm long 1 111 881

20 E02 653 Controls box assembly, including thermostat, knob, PCB,

potentiometer and on/off switch 1 151 252

24 308 283 Thermostat knob 1 079601

25 386 149 Automatic ignition printed circuit board

PACTROL PCB No. 25 B 1 079716

27 385 861 Pressure switch assembly:

HONEYWELL YAMATAKE C6065 F 1373:2 1 155 412

28 E02 661 Fan assembly: SIFAN No. WFFB 0221-039 1 151 586

33 Boiler casing assembly complete with sightglass assy, insulation

and M5 x 16 dogpoint pozipan head screws 1 075 391

36 308 541 Controls casing door with Lighting Instr. 1 079 941

37 Casing sealing pack complete with screws 1 075 392

51 386 144 Overheat thermostat, RANCO LM7 - P8508 1 113 200

56 - Controls casing bottom panel 1 138 267

Classic FF - Propane Installation

BOILER CASING ASSEMBLY

SHORT LIST OF PARTS

SHORT PARTS LIST

Classic FF - Propane Installation

NOTES

Classic FF - Propane Installation

NOTES

Classic FF - Propane Installation

The code of practice for the installation,

commissioning & servicing of central heating systems

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 system specifiers.

For details of courses please ring: ............. 01482 498 432

THIS SYMBOL IS YOUR ASSURANCE OF QUALITY

These appliances are designed for use with Propane Gas only. They have been tested and conform with the provisions of BS. 6332 and BS. 5258.

Caradon Plumbing Ltd.

Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

Caradon Plumbing Ltd.

improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

P.O. Box 103, National Ave.,

pursues a policy of continuing

Propane Gas

FF.87/AP/107 RS.87/AP/108

CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001:1994 Quality System accepted by BSI.

May 2001 UIN 156857 A02

appliances are

service listed by

British Gas

Ideal Installer/Technical Helpline: 01482 498663

www.idealboilers.com

ideal Classic FF 250 P User guide

Specifications and Main Features

Frequently Asked Questions

User Manual