copper
Maximum static water head m (ft.)30.5 (100)
Minimum static water head m (ft.) 0.45 (1.5)
Electrical supply230 V 50 Hz Boiler power consumption; 100W
Fuse ratingExternal; 3A Internal; F1A to BS.4265
Water contentlitre (gal.)2.7 (0.6)3.65 (0.8)3.65 (0.8)
Dry Weightkg (lb)40.9 (90.3)46.6 (102.8)46.6 (102.8)
Maximum installation weight kg (lb)31.4 (69.3)37.4 (82.5)37.4 (82.5)
Key to symbols
IE= Ireland
GB = United Kingdom
PMS = Maximum operating pressure of water
=
C
12
A room sealed appliance designed for connection via
ducts to a horizontal 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 down stream of the combustion
chamber.
I
= An appliance designed for use on 2nd Family gas,
2H
Group H only.
Natural Gas only
CONTENTS
Air Supply. ..................................................................... 7
Water and Systems ..................................................... 7
Water Treatment .......................................................... 7
For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the
manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark log book.
BENCHMARK LOG BOOK DETAILS
BoilerPage
Make and model .......................................................3
Appliance serial no. on data badge ........................ 11
For assistance see Technical Helpline on the back page
complete, sign & hand over to customer
Page
3
GENERAL
INTRODUCTION
The Classic FF340-360 LF are automatically fully controlled, wall
mounted, 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.
range of boilers is suitable.
See Frame 1 for details of the correct boiler tappings to use.
The boiler is supplied with a standard flue kit suitable for rear or
side outlet applications from 2.5m (98
the necessary extension ducts.
The boilers are suitable for connection to the following open
vented or sealed systems:
Downward Piping Kit.
Programmer Kit.
90° Flue Elbow Kit
Ideal Sealed System Unit - this fits on top of the appliance.
Suitable for standard boiler only.
Extension ducts - up to 4.5m (176").
Turret Outlet Kit.
BS.6891Low pressure installation pipes.
BS.6798Installation of gas fired hot water boilers of rated input
not exceeding 70 kW.
BS.5449Forced circulation hot water systems.
BS.5546Installation of gas hot water supplies for domestic
purposes (2nd Family Gases).
BS.7593Treatment of water in domestic hot water central
heating systems.
BS.5440.1 Flues for gas appliances of rated input not exceeding
70 kW.
BS.5440.2 Ventilation for gas appliances of rated input not
exceeding 70 kW.
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 Ideal Limited in writing.
If in doubt please enquire.
Any direct reconnection of a control device not approved by
Caradon Ideal 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.
CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS OR RULES IN FORCE.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
•Gas Safety (Installation and Use) Regulations
•The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (northern Ireland).
•The Water Fittings Regulations or Water byelaws in
Scotland.
•The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent
Person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
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
IGE/UP/7:1998.
Bathrooms
This range of appliances is rated IP 1XB.
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, 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. For Ireland reference should be made
to the current ETCI rules for electrical installations and
I.S.813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (such as communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
......continued on page 6.
NOTE TO THE INSTALLER:
LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
4
Classic FF 340 - 360 LF -
Installation & Servicing
1
BOILER WATER CONNECTIONS
This appliance in NOT suitable for use in a direct
hot water system or for gravity circulation.
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.
Front ViewSide View
Pumped
flow pipe
12 (1/2")
141
(5 9/16")
Pumped
return
pipe
380
(15")
300
(12")
GENERAL
44 (1 3/4")
100
(4")
Front clearance: 533mm (21")
from the front of the boiler casing.
Minimum front clearance when
built in to cupboard is 75 mm (3").
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.
Gas
connection
20 (3/4")
Jacking
screw
133 (5 1/4")
Classic FF 340 - 360 LF -
700
(27 1/2")
Gas
connection
300 (12")
44 (1 3/4")
Installation & Servicing
Flue
terminal
Clas 1768
5
GENERAL
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 MUST 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 :
! BS. 6798.
! The position selected for installation MUST allow adequate
space for servicing in front of the boiler and for air circulation
around the boiler. Refer to 'Air Supply' on page 7.
! For the minimum clearances required for safety and
subsequent service refer to the wall-mounting diagram,
Frame 2. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
The boiler is to be installed only on a gas supply with a governed
meter.
A gas meter can only be connected by the local gas supplier or a
CORGI registered engineer. In IE by a Competent Person.
An existing meter should be checked, preferably by the gas supplier,
to ensure that the meter is adequate to deal with the rate of gas
supply required. A MINIMUM pressure of 20 mbar MUST be available
at the boiler inlet with the boiler operating.
Installation pipes MUST be fitted in accordance with BS. 6891. In
IE refer to I.S. 813:2002. Pipework from the meter to the boiler
MUST be of an adequate size.
The complete installation MUST be tested for gas soundness and
purged as described in the above code.
FLUE INSTALLATION
Pluming may occur at the terminal so terminal positions which
would cause a nuisance should be avoided.
The flue must be installed in accordance with the
recommendations of BS.5440-1: 2000. In IE refer to I.S. 813:2002.
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.
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.
Table 3 - Balanced flue terminal position
Approved Manufacturer’s Clearances
Terminal PositionMinimum Spacing
1a. Directly BELOW an opening, air brick,
opening window, etc.300 mm (12")
1b. Directly ABOVE an opening, air brick,
opening window, etc.300 mm (12")
1c. HORIZONTALLY to an opening,
air brick, opening window, etc.300 mm (12")
2. Below guttering, drain pipes or soil
pipes25 mm ( 1")
3. Below eaves25 mm ( 1")
4. Below balconies or a car port roof25 mm ( 1")
5. From vertical drain pipes or soil pipes25 mm ( 1")
6. From an internal or external corner or
to a boundary alongside the terminal25 mm ( 1")
7. Above adjacent ground, roof or
balcony level300 mm (12")
8. From a surface or a boundary facing
the terminal.600 mm (24")
9. From a terminal facing a terminal1200 mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling1200 mm (48")
11. Vertically from a terminal on the
same wall1500 mm (60")
12. Horizontally from a terminal on the wall300 mm (12")
Terminals guards are available from boiler suppliers - ask
for TFC Flue Guard, Model K1. In case of difficulty seek
advice from:
5. The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of any building.
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.5440-1:2000.
In IE refer to
I.S.813:2002.
7. Where it is essential that the terminal wall plate is fitted, i.e.
wall thicknesses over 600mm (23 1/2") or with an inaccurately
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.
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.
6
Classic FF 340 - 360 LF -
Installation & Servicing
GENERAL
AIR SUPPLY
Detailed recommendations for air supply are given in
BS.5440:2. In IE refer to I.S. 813:2002.
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 in Table 4 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
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.
Boilers not fitted to a sealed system must be vented.
IMPORTANT
A minimum length of 1m of copper pipe MUST be fitted to both
flow and return connections from the boiler before connection to
any plastic piping. This applies to ALL types of installation.
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
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 resistance of the boilers, at
MAXIMUM OUTPUT with an 11
are shown in Table 5.
Maximum boiler operating temperature should be 82 oC (180 oF).
Output
Water Flowl/min15.219.022.8
Rategal/h200250300
Pressurembar20.431.541.7
Lossin wg 8.312.616.7
Btu/h x 1000
405060
WATER TREATMENT
These boilers incorporate a cast iron heat exchanger.
IMPORTANT. The application of any other treatment to this
product may render the guarantee of Caradon Ideal Limited
INVALID.
Caradon Ideal Limited recommend Water Treatment in
accordance with the
Treatment in Central Heating Systems.
Caradon Ideal Limited recommend the use of Fernox, GE Betz
Sentinel or Salamander water treatment products, which must
be used on accordance with the manufacturers instructions.
For further information contact:
Fernox Manufacturing Co. Ltd, Cookson Electronics, Forsyth Road,
1. It is most important that the correct concentration of the water
treatment products is maintained in accordance with the
manufacturers' instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
BS7593:1992 details the steps necessary to clean a
domestic heating system.
3. In hard water areas, treatment to prevent limescale may be
necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before
the system has been thoroughly flushed.
BOILER CONTROL INTERLOCKS
Caradon Ideal 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.
Central heating systems controls should be installed to ensure
the boiler is switched off when there is no demand for heating or
hot water.
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 circuit must be fitted with an automatic bypass valve to
ensure a flow of water should all valves be in the closed position.
Guidance Notes on Water
Classic FF 340 - 360 LF -
Installation & Servicing
7
GENERAL
ELECTRICAL SUPPLY
WARNING.
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. For Ireland reference should be made
to the current ETCI rules for electrical installations.
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.
3
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").
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
Ideal Limited.
The appliance MUST be efficiently earthed.
OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED
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.
See Frame 39 for details.
Feed / expansion
cistern
Water
level
(cold)
22mm
Open vent
System
return
Connections
to boiler
15mm
Cold
feed
Inverted cold
feed entry
450 (18")
Mimimum
450 (18")
Mimimum
150 (6")
Max
System
flow to
pump
A cold water feed must be available back to the boiler, when
Note.
all automatic valves are in the closed position (refer to 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.
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.
Return
450
(18)
Min.
Minimum Requirements
75 (3)
Min.
Surge
200
(8)
Min.
arrester
75 (3) Min.
Flow
Highest
point of
flow or
return
Feed / expansion
cistern
22 (3/4)
Open vent
150
(6)
Max
Max. practical
Cold
water
level
To pump
length
Note.
The pump manufacturers minimum
requirements must be complied with
8
All dimensions in mm (in.). N.B. Imperial dimensions are approximate
Classic FF 340 - 360 LF -
Installation & Servicing
Non-return
valve
Automatic
air vent
Hose unions
Additional
stop valve
Hose connector
Hosepipe
(disconnect
after filling)
Double check valve
assembly
(note direction of flow)
Temporary hose
(disconnect
after filling)
ecl6060
5
SEALED SYSTEM REQUIREMENTS
GENERAL
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 82
o
C.
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 preset 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
(0-60lb./in
2
) 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.
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 110
0.35 bar (5lb/in
2
) less than the lift pressure of the safety
o
C (230oF) should be at least
valve.
For guidance on vessel sizing refer to Table 6, Frame 6. For
further details refer to BS.5449. For IE refer to the current
edition of I.S. 813.
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 340 - 360 LF -
Installation & Servicing
9
GENERAL
6
SEALED SYSTEM REQUIREMENTS - continued
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
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 Table 6, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).
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/in2.) of the pre-set lift
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
).
Table 6
Safety valve setting3.0 bar2.5 bar2.0 bar
Vessel charge and initial0.51.01.50.51.01.50.51.0
system pressurebarbarbarbarbarbarbarbar
Total water content of systemExpansion vessel volume
! 50mm x No. 14 wood screw, 4 off
! 50mm x No. 10 wood screw, 8 off
! Wall plug, 12 off
Pack B Contents
!Duct cutting support, 2 off
(cardboard )
!Terminal wall plate, 1 off.
!Terminal grille assy., 1 off.
!Polyurethane foam seal 400 lg., 1 off.
!No. 8 x 8 lg. Pozi pan hd. screws, 3 off.
! M8 washer, 1 off
! M5 wing nut, 3 off
! Sealing plate, 1 off
! M8 x 12 Hx. Hd. screw, 1 off
12
Classic FF 340 - 360 LF -
Installation & Servicing
9
PACKAGING AND CASING REMOVAL
1. Unpack the boiler.
INSTALLATION
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).
10
DETERMINING THE FLUE LENGTH
It is MOST IMPORTANT that the boiler is installed
in a vertical position.
Flue length
2.5 Min
Rear flue installation
4.5 Max
(a) Casing retaining
screws, 2 off
INSTALLATION
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 Frame 34 'Flue
Extension Ducts'
Side flue installation
Flue length
2.5 Min
4.5 Max
Clas 1770
1. A maximum of 5 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
2500 to 3450B Pack 1 off + D Pack, 3 off150308+
3450 to 4400B Pack 1 off + D Pack, 4 off150308+
4400 to 4500B Pack 1 off + D Pack, 5 off150308+
mm
AccessoriesProduct No.
153883, 3 off
153883, 4 off
153883, 5 off
Jacking screw for boiler alignment
Classic FF 340 - 360 LF -
Installation & Servicing
13
INSTALLATION
11
INSTALLING THE CONVERSION KIT
To convert your existing Classic FF into a Classic FF LF you will need the contents of the kit, detailed below:
1. Remove the 2 silicon rubber tubes from the fan sensing points.
2. Disconnect the fan leads.
3. Disconnect the silicon rubber tube from the rear of the collector
hood.
4. Slacken the two M5 nuts on the front tie rods, releasing the tie
rods from the combustion chamber.
5. Remove the M5 central fixing screw at the rear of the collector
hood and remove collector hood / fan assembly.
6. Remove the three M4 screws (from the inside) retaining the fan
to the collector hood.
Keep the fan safe at one side and discard the old collector
hood.
Installing the new collector hood
Fasten the fan with the 3 new screws and washers,
provided, to the new collector hood assembly.
Assemble reverse order, ensuring the fan leads, and 3
sensing tubes are reconnected.
Affixing the data plate
Before applying the data plate you must first cut it so
that when it’s applied over the original data plate the
bottom line of information is still showing. Once cut,
peel off the back to show the adhesive side and carefully
stick over the original data plate (on top of the controls
support; see below).
14
Classic FF 340 - 360 LF -
Installation & Servicing
12
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.
INSTALLATION
1
5
2
2. When cutting the
ducts, always use
the cardboard
support rings
provided.
13
WALL MOUNTING TEMPLATE
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.
flue hole as well as the circumference.
b. The position of the flue duct hole.
c. Downward pipe routing bracket screw positions.
1832
la
C
Mark the centre of the
3
4
LEGEND
1. Terminal
2. Weather seal.
3. Flue assembly
4. Boiler sealing ring
5. Flue extension tube
5. Remove the templates from the wall.
14
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 (
masonry drill. If the stand-off brackets are used ensure the
correct holes are chosen.
3. Insert the plastic plugs provided.
Classic FF 340 - 360 LF -
Installation & Servicing
5/16")
Note.
Check all of the hole
positions BEFORE drilling
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.
REAR FLUE OUTLET
15
INSTALLATION
NOTCH
15
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.
16
FITTING THE BOILER SEALING RING TO THE FLUE
1. Fit the boiler sealing ring inside the outer flue duct. Ensure
the 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.
17
FITTING THE FLUE ASSEMBLY
1. Insert the flue extension tube into the flue assembly.
2. Insert the flue assembly through the hole 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.
2
3
NOTCH
1
3. Ensure the notch is at the top. This will aid the location of
the studs into the boiler back panel.
18
WALL MOUNTING PLATE
1. Fix the mounting plate to the wall with the No.14 x 50mm wood
screws.
2. If 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.
REAR FLUE OUTLET
16
Classic FF 340 - 360 LF -
Cla 1831
Installation & Servicing
19
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.
INSTALLATION
20
CONNECTING THE FLUE TO THE BOILER
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 the
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.
21
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 (
3. Insert the 4 plastic plugs provided.
4. Secure the plate with 4 of the No.10 x 2" screws provided.
If the terminal is less than 2m (6' 6") above ground level,
Note.
an approved terminal guard should be fitted. Refer to the
Contents List on Page 3.
Classic FF 340 - 360 LF -
Installation & Servicing
9/32") masonry drill.
REAR FLUE OUTLET
17
22
FLUE ASSEMBLY - Exploded view
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.
Clas 1833
INSTALLATION
1
2
5
4
3
LEGEND
1. Terminal
2. Weather seal.
3. Flue assembly
4. Boiler sealing plate
5. Flue extension tube
23
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 with 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.
3. Ensure squareness by hanging a plumb line as shown.
4. Mark onto the wall (if required) the following:
a. The 4 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.
SIDE FLUE OUTLET
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).
24
PREPARING THE WALL
Extended centre
line
Note.
Mark the centre of the hole as well as the
circumference.
d. The side of the casing nearest the flue outlet.
5. Remove both templates from the wall.
Terminal
mounting
plate screw
and flue
duct hole
positions
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 (
plugs provided, for the wall mounting plate.
3. Drill 4 holes with a 7mm (9/32") masonry drill and insert the plastic
plugs provided, for the side mounting plate.
If the terminal is to be sited within 25-40mm of a corner or vertical pipe (refer
Note.
5/16") masonry drill and insert the plastic
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.
18
Classic FF 340 - 360 LF -
Installation & Servicing
INSTALLATION
NOTCH
25
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 10.
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 duct ring for support and cut to
length.
5. Remove cardboard duct ring and remove any burrs.
26
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.
27
FITTING BOILER SEALING RING
TO THE FLUE
1. Fit the boiler sealing ring inside the outer flue duct.
Ensure the 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
28
FITTING THE FLUE ASSEMBLY
1. Insert the flue assembly through the hole 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.
.
SIDE FLUE OUTLET
1
NOTCH
2
Classic FF 340 - 360 LF -
Installation & Servicing
Cla 1834
Flue assembly
19
29
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.
INSTALLATION
30
WALL MOUNTING PLATE
1. Fix the mounting plate to the wall with the No.14 x 50mm
wood screws.
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.
2. If 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.
31
MOUNTING THE BOILER
Notes1.
1. The boiler is supplied for
SIDE FLUE OUTLET
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.
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.
Note.
Before fully tightening
the M8 screw check the boiler
alignment using a spirit level
and adjust as necessary with
the jacking screw.
20
Classic FF 340 - 360 LF -
Installation & Servicing
INSTALLATION
32
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.
The sealing ring studs will locate in the back
Note.
panel one way only. This will ensure that the terminal
grille is correctly aligned.
33
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.
If the terminal is less than 2m (6' 6") above
Note.
ground level, an approved terminal guard should be
fitted. Refer to the contents list on Page 3.
34
FLUE EXTENSION DUCTS - For flue lengths greater than 600mm
9/32") masonry drill.
PACK D Flue extension duct kit contents.
Classic FF 340 - 360 LF -
Installation & Servicing
REAR & SIDE FLUE OUTLET
21
INSTALLATION
35
FLUE EXTENSION DUCTS - continued
General arrangement
Side flue shown.
Note.
1. A
maximum
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 lengthAccessoriesProduct No.
2500 to 3450B Pack 1 off + D Pack, 3 offsee Frame 10
3400 to 4400B Pack 1 off + D Pack, 4 offsee Frame 10
of 5 uncut extension ducts (plus the standard
Extension tube
Boiler
Flue length
Extension duct
Standard flue
Terminal grille
4400 to 4500B Pack 1 off + D Pack, 5 offsee Frame 10
br brown
br brown
LEGEND
LEGEND
LEGEND
36
FITTING THE KIT
bblue
bblue
bblue
bk black
bk black
bk black
br brown
gy grey
gy grey
gy grey
or orange
or orange
or orange
pk pink
pk pink
pk pink
rred
rred
rred
vviolet
vviolet
vviolet
w white
w white
w white
y/g yellow/green
y/g yellow/green
y/g yellow/green
Cla 1800
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.
duct.
1/8") dia. holes through the
Do not drill the inner flue
REAR & SIDE FLUE OUTLET
22
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.
Classic FF 340 - 360 LF -
Installation & Servicing
INSTALLATION
37
GAS CONNECTION
Refer to 'Gas Supply ', page 6.
Refer to Frame 2 for gas inlet service dimensions.
A minimum pressure of 20 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.
39
ELECTRICAL CONNECTIONS
38
WATER CONNECTIONS
1. Remove the plastic plugs from the flow and
return pipes.
2. Make all water connections and check for water
soundness.
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.
Wiring should be in 3-core PVC insulated & sheathed cable, not
less than 0.75mm
2
(24 x 0.2mm) to BS. 6500 Table 16 Wiring
Regulations and local regulations. For IE reference should be
made to the current ETCI rules for electrical installations.
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 or a plug and socket, serving
only the boiler and system controls. The means of isolation must be
accessible to the user after installation.
LEGEND
bblue
bk black
br brown
gy grey
or orange
pk pink
rred
vviolet
w white
y/g yellow/green
Flow wiring diagram
Programmer unit
B
L
br
yor
Off On Off On
HW CH
r
w
Connect
to
Air
pressure
switch
r
com
L
8 Pin connector to
system controls
Limit
thermostat
ALL EARTHS must be connected
(Not all earths are shown for clarity)
Optional Programmer Kit
N
b
B
L
v
r
y
NC
NO
Switch
O/heat thermostat
L
br
br
bk
L
NTC
NC
C
P.C.B. 25
NO
bk
bk
Thermostat sensor
bk
N
E
FAN
GV 1
GV 2
or
pk
w
Combined spark &
sensing electrode
Boiler
gy
bk
br
b
y/g
Fan
Pilot gas
Main gas
INSTALLATION
If an optional programmer is to be fitted
Note.
refer to the instructions provided with the kit
and Frame 40.
N
b
Cla 2642
1. Remove the control box securing screws.
Swing the box down into the servicing
position. Refer to Frame 47.
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.
40
EXTERNAL CONTROLS
External wiring must be in accordance with the current I.E.E.
(BS 7671) Wiring Regulations. For Ireland reference should be
made to the current ETCI rules for electrical installations.
The wiring diagrams illustrated in Frames 42-44 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 42-44.
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.
Classic FF 340 - 360 LF -
Installation & Servicing
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 44.
3. If a proprietary system is used, follow the instructions
supplied by the manufacturer.
4. 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.
Connection between a frost thermostat and the time control
1.
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.
23
41
PICTORIAL WIRING
INSTALLATION
LEGEND
bblue
bk black
br brown
gy grey
or orange
pk pink
rred
vviolet
w white
y/g yellow/green
INSTALLATION
42
MID POSITION VALVE
Pumped only
Notes.
Some earth wires are omitted for
1.
clarity. Ensure proper earth continuity
when wiring.
2.
Numbering of terminals on thermostats
is specific to the manufacturer.
3.
This is a fully controlled system - set
the boiler thermostat to maximum.
4.
Switchmaster 'Midi' is similar in
operation but the wiring differs slightly see the manufacturer's literature.
LEGEND
bblue
bk black
br brown
gy grey
or orange
pk pink
rred
vviolet
w white
y/g yellow/green
24
Classic FF 340 - 360 LF -
Installation & Servicing
43
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 a fully controlled system - set the
boiler thermostat to maximum.
4.
Switchmaster valve has grey and orange
auxiliary switch leads but the GREY wire
must be connected to the incoming live
supply.
LEGEND
bblue
bk black
br brown
gy grey
or orange
pk pink
rred
vviolet
w white
y/g yellow/green
INSTALLATION
Pumped only
INSTALLATION
44
FROST PROTECTION
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 340 - 360 LF -
Installation & Servicing
25
INSTALLATION
45
COMMISSIONING AND TESTING
The Benchmark Log Book or equivalent self certification should be completed and signed to demonstrate compliance with
Building Regulations.
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.
INSTALLATION
46
WARNING.
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. 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.
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 diagram B.
4. Slacken the screw in the burner pressure test point (F) and
connect a gas pressure gauge via a flexible tube.
5. Swing the control box back into its working position.
6. Press the overheat thermostat reset button (J).
7. Switch the electricity supply ON and check that all external
controls are calling for heat.
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.
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.
In IE refer to I.S.813:2002.
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
8. 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.
9. Test for gas soundness around ALL boiler gas components
using leak detection fluid.
10.Operate the for 10 minutes to stabilise the burner
temperature.
11. The boiler is preset at the factory to its nominal rating.
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
pressure, or
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.
12.If necessary repeat steps 11a to h until the required
pressure is achieved. Record this value in the Benchmark
log book.
13.Set the main On/Off switch to OFF.
14.Switch the electricity supply OFF.
15.Swing the control box down into the servicing position.
16.Refit the main burner pressure adjuster cover.
17.Remove the pressure gauge and tube. Retighten the
sealing screw in the pressure test point. Ensure a gas tight
seal is made.
18.Swing the control box back into its working position and
secure.
19.Remove the boiler casing.
20.Refit the controls support to the boiler casing and tighten the
2 front fixing screws.
21.Refit the complete casing to the boiler.
22.Close the pod door.
anticlockwise
E Main burner pressure adjuster.
F Burner pressure test point.
H Boiler mains on/off switch.
J Overheat thermostat reset
button.
clockwise
to DECREASE the pressure.
to INCREASE the
26
Classic FF 340 - 360 LF -
Installation & Servicing
INSTALLATION
47
INITIAL LIGHTING - continued
48
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 SettingFlow Temperature
°C°F
154130
260140
366150
471160
577170
682180
WARNING.
The boiler MUST NOT be operated with the
casing removed.
INSTALLATION
49
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) Regulations 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
Classic FF 340 - 360 LF -
Installation & Servicing
off and a CORGI registered installer consulted. In IE
contact a Competent Person.
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 is fitted draw attention to the
Programmer User's Instructions and hand them to the
Householder.
9. After installation, commissioning and customer hand-over,
please complete the
leave this with the customer. For IE, it is necessary to complete
a "Declaration of Conformity" to indicate compliance to I.S.
813:2002.
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. In IE
servicing work must be carried out by a Competent Person.
11. 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 scheme, details
of which are outlined in the household pack supplied
with this boiler.
appliance log book and
27
INSTALLATION
50
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. In IE service work must be carried
out by a Competent Person.
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
INSTALLATIONINSTALLATION
the CO/CO
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 54.
d. Clean the heat exchanger. Refer to Frame 53.
e. Clean the main and pilot injectors. Refer to Frame 54.
content of the flue gas should not be greater
2
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 51
to 55 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.
T
he boiler must NOT be operated if the casing is not fitted.
Note.
components, the boiler casing must be removed. Refer to
Frame 51.
.
In order to carry out either servicing or replacement of
51
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 pack 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 be followed.
3. Isolate the gas supply at the service cock fitted to the boiler.
52
BURNER AND AIR BOX REMOVAL
1. Remove the screw retaining the front burner support strap
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 the
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 4 screws retaining the air box/pilot assembly
to the vertical manifold and carefully remove the assembly.
28
Classic FF 340 - 360 LF -
Installation & Servicing
INSTALLATION
53
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.
INSTALLATIONINSTALLATION
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.
54
CLEANING THE BURNER AND PILOT ASSEMBLY
1. Brush off any deposits that may have fallen on to the
burner head (ensuring the flame ports are 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 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.
55
RE-ASSEMBLY
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 on to 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.
4. Refit the air box assembly and burner. Ensure that the burner
front fixing is refitted.
Check that:
a. The pilot burner injector is not blocked or damaged. Refer
to Frame 62 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 62). Clean or renew as
necessary.
The pilot shield is located around the pilot assembly
Note.
bracket and is located by the electrode retaining nut.
5. Reconnect the gas supply and the electrical wiring.
Refer to Frames 37 & 39.
6. Check the sightglass in the boiler casing. Clean or
renew as necessary. Refer to Frame 58.
7. Check for gas soundness. Check the gas service cock
and pressure test point.
8. Refit the boiler casing (Refer to Frame 46, item 3 ).
Note that it is not necessary to disturb the controls
casing pod.
9. Close the controls pod door.
Classic FF 340 - 360 LF -
Installation & Servicing
29
56
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 61) and ensuring that there is
an inlet pressure of 20 mbar available, the pilot does not
light then contact Caradon Ideal Limited.
Relight in accordance with 'Initial Lighting', Frame 46.
REPLACEMENT OF PARTS
57
GENERAL
When replacing any component:
1. Isolate the electricity supply.
2. Turn OFF the gas supply.
3. Remove the boiler casing. Refer to Frame 51.
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. Any required
adjustments should be made by using the pressure
adjustment screw.
Refer to 'initial Lighting', Frame 46.
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 ignition operation (stops after
detection).
The boiler MUST NOT be operated if the casing is not fitted.
58
SIGHTGLASS REPLACEMENT
SERVICING
1. Refer to Frame 57.
2. Unfasten the 2 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 55.
59
OVERHEAT THERMOSTAT REPLACEMENT
1. Refer to Frame 57.
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 backnut retaining the thermostat to the bracket. Withdraw
the thermostat phial from the heat exchanger pocket.
5. Fit the new thermostat and reassemble in reverse order.
6. Check the operation of the boiler.
30
Classic FF 340 - 360 LF -
Installation & Servicing
SERVICING
60
THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and ON/OFF SWITCH
REPLACEMENT
Refer also to Frame 57.
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 the printed circuit
board.
4. Replace and reassemble in reverse order.
Thermistor sensor lead
5. Pull the sensor lead connector off the printed circuit
board and cut the cable strap securing the thermistor
harness to the bottom panel of the control box (if fitted)
and remove the strap.
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, ensuring the
new cable strap is
fitted and securing the
thermistor harness.
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.
Classic FF 340 - 360 LF -
Installation & Servicing
31
SERVICING
61
LIMIT THERMOSTAT REPLACEMENT
1. Refer to Frame 57.
2. Remove the limit thermostat assembly from the boiler
flow pipe.
3. Disconnect the electrical connectors
4. Replace and reassemble in reverse order, taking care to
correctly position the limit thermostat as shown in the
orientation diagram opposite.
SERVICING
62
PILOT BURNER REPLACEMENT
1. Refer to Frame 57.
2. Remove the burner and air box assembly. Refer to Frame
52.
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 (injector if necessary) and retain
with the M4 screw previously removed. Ensure 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 there is an inlet
pressure of 20 mbar available. Also check burner
ignition and cross-lighting.
32
Classic FF 340 - 360 LF -
Installation & Servicing
SERVICING
63
IGNITION ELECTRODE AND LEAD REPLACEMENT
1. Refer to Frame 57.
2. Remove the burner and air box assembly. Refer to Frame 52.
3. Remove the electrode retaining nut.
4. Remove the pilot shield.
5. Remove the ignition 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 62.
8. Reassemble in reverse order.
9. Check the operation of the boiler.
64
MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT
1. Refer to Frame 57.
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 downward 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
a new copper sealing washer is used.
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.
65
GAS CONTROL VALVE REPLACEMENT
Note.
Refer also to Frame 76 of 'Exploded Views' for
illustration of the procedure detailed below.
1. Refer to Frame 57.
2. Remove the burner and air box assembly. Refer to
Frame 52.
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. Reassemble in reverse order.
11. Check the operation of the boiler.
Classic FF 340 - 360 LF -
Installation & Servicing
33
SERVICING
66
FAN REPLACEMENT
1. Refer to Frame 57
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 reassemble in reverse order, ensuring the fan
leads, and 3 sensing tubes are reconnected.
10. Check the operation of the boiler.
67
AIR PRESSURE SWITCH (APS) REPLACEMENT
1. Refer to Frame 57.
2. Remove the APS fixing screw.
3. Remove both sensing tubes from the APS.
4. Remove the 3 electrical connections from the APS.
5. Fit the new APS and reassemble in reverse order.
SERVICING
6. Check the operation of the boiler.
68
PRINTED CIRCUIT BOARD (PCB) REPLACEMENT
Note.
Refer to Frame 75 of 'Exploded Views' for
illustration of the procedure detailed below.
1. Refer to Frame 57.
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 reassemble 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 75 for fuse location.
69
COMBUSTION CHAMBER INSULATION REPLACEMENT
1. Refer to Frame 57.
2. Remove the burner and air box assembly.
Refer to Frame 52.
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.
34
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. Reassemble in reverse order.
Classic FF 340 - 360 LF -
Installation & Servicing
SERVICING
70
HEAT EXCHANGER REPLACEMENT
Note.
Refer to Frame 7 (Boiler assembly - Exploded view) for
illustration of the procedure detailed below.
1. Refer to Frame 57.
2. Remove the burner / air box assembly. Refer to Frame 52.
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 exchanger 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 53.
6. Remove the combustion chamber by unscrewing the 4 tie
rods.
71
CASING SEAL REPLACEMENT
7. Remove the thermostat sensors from the pockets on the
heat exchanger by removing the M3 screws and plates.
8. Slacken 3 turns only the 4 heat exchanger / inter-panel
retaining screws.
9. Lift the heat exchanger / inter-panel assembly upward and
forward to disengage key hole fixings. Pull the assembly
downwards 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. Reassemble 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.
1. Refer to Frame 57.
2. Remove the old seal from the casing surround and
thoroughly clean the casing surfaces.
3. Fit the new self adhesive seals.
4. Replace the boiler casing.
72
PROGRAMMER REPLACEMENT (IF FITTED)
1. Refer to Frame 57.
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.
SERVICING
4. Compress the lugs at each side
of the programmer and withdraw
it from the control panel.
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 340 - 360 LF -
Installation & Servicing
35
FAULT FINDING
START
Is the mains on neon 'I3' illuminated?
YES
Is there a live supply on EITHER
terminal of overheat 'stat?
NO
YES
Is there a live supply on BOTH
terminals of overheat 'stat?
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'
NO
marked 'FAN'?).
YES
Is there a supply at the fan?
YES
Change
fan
Is the ignition electrode sparking?
YES
NO
Rectify bad
connection
NO
Check mains supply and fuses.
Check programmer and system
thermostats are all ON.
Check that boiler plug and socket
NO
NO
are OK and fully connected.
Can the overheat 'stat
be reset when the
system is cold ?
Remove the sensor
(NTC) from the PCB.
Is the fan turning ?
NO
NO
Has the fuse blown on PCB ?
NO
Is there a live supply on the
violet lead to pressure switch?
YES
Is there a live supply on the red
lead to the pressure switch?
YES
Is there a live supply on
BOTH terminals of limit stat?
YES
NO
YES
YES
YES
NO
NO
NO
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. If no fault found
change pressure switch.
Check PCB by substitution
Change limit thermostat
Does the pilot light ?
NO
Is there a gas
supply to the
boiler?
YES
Is the pilot
injector blocked?
NO
Ensure pilot and
main gas valve
leads are not
crossed over.
Is there a supply
voltage at pilot
gas valve?
YES
Replace
gas valve
FAULT FINDING FAULT FINDING FAULT FINDING
YES
Does the spark
stop after the
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?
NO
Check all connections to PCB.
If no fault found, replace PCB
NO
Is there a regular spark from
tube 'SG1' on the PCB?
NO
Is the boiler casing
correctly fitted?
YESNO
Does main burner
cross-light from pilot?
YES
NO
Is there a supply on terminals
of main gas valve?
NO
Is the main burner
injector clear?
YES
YES
Replace main gas
solenoid valve
YES
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
NO
Change
fan
36
Classic FF 340 - 360 LF -
Installation & Servicing
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 Ideal Limited distributors and
merchants.
When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
35Boiler casing assembly complete with sightglass assy, insulation
& M5 x 16 dogpoint pozi pan hd1171471
37Controls casing door with Lighting Instructions1171475
39E85-313Casing seal pack complete with screws1171479
45E83-682Overheat thermostat1171950
59Limit thermostat1173353
Classic FF 340 - 360 LF -
Installation & Servicing
37
73
SHORT PARTS LIST
9
12
LIST OF PARTS
13
13 A
14
15
17
24
74
BOILER CASING ASSEMBLY
26
30
18
39
19
23
59
45
cla 6113
38
Classic FF 340 - 360 LF -
Installation & Servicing
75
CONTROL BOX - Exploded View
LIST OF PARTS
LEGEND
19.Control box.
21.Thermostat potentiometer.
23.Printed circuit board.
26.Thermostat knob.
58.Mains on/off switch.
76
BURNER ASSEMBLY - Exploded View
LEGEND
10.Burner manifold
11. Air box and pilot assembly.
12.Main burner.
13.Main burner injector.
16.Pilot shield.
17.Gas control valve.
42.Gas service cock.
Classic FF 340 - 360 LF -
Installation & Servicing
39
The code of practice for the installation,
commissioning & servicing of central heating systems
THIS SYMBOL IS YOUR
ASSURANCE OF QUALITY
These appliances are designed for use with Natural
Gas only. They have been tested and conform with the
provisions of BS. 6332 and BS. 5258.
Technical Training
The Ideal Boilers 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
CERTIFIED PRODUCT
Manufactured under a BS EN ISO 9001: 1994
Quality System accepted by BSI
Caradon Ideal Limited pursues a policy of continuing
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, Kingston upon Hull,
I
deal Installer/Technical Helpline: 01482 498663
www.idealboilers.com
March 2003UIN157 026 A03
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