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
1
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)
3
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
2
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
32
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 =
C
12
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,
I
3P
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
3
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.
4
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
1
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.
2
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
5
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.
6
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)
2
(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).
o
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.
.
7
GENERAL
3
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
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.
4
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.
8
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
5
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
2
) 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
2
)
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.'
2
) in
Classic FF - Propane Installation
9
6
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.
2.
2
).
) 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
10
Classic FF - Propane Installation
7
BOILER ASSEMBLY - Exploded view
Classic FF 30 shown
INSTALLATION
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.
11
8
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
12
Classic FF - Propane Installation
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