ideal Classic FF 350P User guide
GENERAL
Table 1 - General Data
Boiler Size FF 350 P FF 360 P FF 380 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 350 P FF 360 P FF 380 P
Boiler input kW 18.3 21.9 29.3
(Btu/h) (62 500) (74 700) (100 000)
3
Gas consumption l/s (ft
Boiler output kW 14.7 17.6 23.5
Burner Setting mbar 35.9 35.8 34.8
pressure (HOT) (in.w.g.) (14.4) (14.4) (14.0)
Inlet pressure mbar (in.w.g.) 37.0 (14.8)
Seasonal efficiency (SEDBUK)* Band D [82.0]% [80.4]% [80.4]%
/h) 0.20 (25.0) 0.23 (29.2) 0.30 (38.1)
(Btu/h) (50 000) (60 000) (80 000)
* 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 a notified body.
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.
appliance, care should be taken when handling edges of sheet steel components
2
To avoid the possibility of injury during the installation, servicing or cleaning of this
Classic FF -
Propane Installation & Servicing
GENERAL
Classic FF
Data Badge: on top of the controls support
B.G. Certified - P.I. No. 87AP107
Destination Countries: GB & IE
Models G.C. Appliance No.
Classic FF 350 P ........................... 41 392 06
Classic FF 360 P ........................... 41 392 07
Classic FF 380 P ........................... 41 392 08
Key to symbols
IE = Ireland
GB = United Kingdom
PMS = Maximum operating
C
C
I
pressure of water
& C32 = A room sealed
12
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.
= A room sealed appliance designed for connection via
72
concentric vertical ducts and a draught diverter
located in the roof space to a secondary flue. The
combustion air is taken from the roof space. The fan
is down stream of the combustion chamber.
= An appliance designed for use on 3rd Family gas,
3P
Group P only.
Propane Gas only
Appliance type:
C12 & C
C
32,
(360P,380P only)
72
CONTENTS
Air Supply. ..................................................................... 7
Boiler Clearances .........................................................5
Boiler Exploded View ................................................. 11
Burner Exploded View ................................................38
Control Box Exploded View ...................................... .38
Electrical Connections ............................................... 22
Electrical Regulations ..................................................7
Extension Ducts - Fitting ............................................21
External Controls ........................................................22
Fault Finding ................................................................35
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 ..................................................... 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
Boiler Page
Make and model .......................................................3
Appliance serial no. on data badge ........................ 11
SEDBUK No. % .........................................................2
Controls
Time and temperature control to heating ......... 23/24
Time and temperature control to hot water ...... 23/24
Heating zone valves .......................................... 23/24
TRV's .........................................................................7
Auto bypass ...............................................................7
Boiler interlock ..........................................................7
For all boilers
Flushing to BS.7593 .................................................7
Inhibitor......................................................................7
Central heating mode
Heat input ................................................. to be calculated
NOTE TO THE INSTALLER:
LEAVE THESE
Burner operating pressure ....... measure and record
Central heating flow temp. ........ measure and record
Central heating return temp. ..... measure and record
For combination boilers only
Scale reducer .........................................................n/a
Hot water mode
Heat input ...............................................................n/a
Max. operating burner pressure ............................n/a
Max. operating water pressure ..............................n/a
Cold water inlet temp .............................................n/a
Hot water outlet temp. ............................................n/a
Water flow rate at max. setting ............................... n/a
For condensing boilers only
Condensate drain ..................................................n/a
For all boilers:
For assistance see Technical Helpline on the back page
complete, sign & hand over to customer
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
Page
Classic FF -
Propane Installation & Servicing
3
GENERAL
INTRODUCTION
The Classic FF350, FF360 and FF380 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:
! Fully pumped CH and indirect DHW
! Pumped heating only.
! 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 on FF 360 and FF 380 only (to
a maximum primary flue length of 4m and a maximum
secondary flue length of 6m (FF360) and 7m (FF380)).
Roof Flue Kit.
For vertical flue connection (to a maximum of 3m).
90° Flue Elbow Turret Kit
Sealed System Unit. Fits on top of the appliance.
Extension ducts. Up to 3 m (118").
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:
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 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.
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
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.
4
Classic FF -
Propane Installation & Servicing
1
BOILER WATER CONNECTIONS
This appliance in NOT suitable for use in a direct
hot water system or for gravity circulation.
FF 380P 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 (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.
Classic FF -
Propane Installation & Servicing
5
GENERAL
If the appliance is to be installed in a room containing a bath or
shower then, providing waterjets 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.
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 :
! 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, see section on 'Air Supply'.
! 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. In IE refer to I.S. 813:2002.
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
Approved Manufacturer’s Clearances
Terminal Position Minimum 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
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 an internal or external corner or
to a boundary alongside the terminal 25 mm ( 1")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface or a boundary
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")
Terminals guards are available from boiler suppliers. Ask for
TFC Flue Guard, Model K1. In case of difficulty seek advice
from:
Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge,
Kent TN9 1TB.
Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445
www.tfc-group.co.uk
Ensure that the guard is fitted centrally.
5. The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of any building.
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.
6
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
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.
Classic FF -
Propane 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 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 350 P 170 (26) 83 (13)
FF 360 P 198 (31) 102 (16)
FF 380 P 264 (41) 132 (21)
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
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 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
differential, are shown in Table 5.
Maximum boiler operating temperature should be 82 oC (180oF).
2
(in2 ) outside cm2 (in2)
o
C (20OF) temperature
Table 5 - Water flow rate and pressure loss
Boiler Size FF 350 P FF 360 P FF 380 P
Boiler kW 14.7 17.6 23.5
Output Btu/h 50 000 60 000 80 000
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
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,
Sheerwater, Woking, Surrey. GU21 5RZ. Tel. +44 (0) 1799 521133
or
G E Betz Ltd, Sentinel Division, Foundry Lane, Widnes, Cheshire,
WA8 8UD. Tel. +44 (0) 151 424 5351
or
Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate,
Sutton Coldfield, West Midlands B75 7BU. Tel. +44 (0) 121 378 0952
Notes.
Benchmark
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 -
Propane 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.
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.
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.
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
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.
The pump manufacturers minimum
Note.
requirements must be complied with.
8
Minimum Requirements
75 (3)
Min.
450
(18)
Min.
Return
All dimensions in mm (in.). NB. Imperial dimensions are approximate.
200
(8)
Min.
Surge
arrester
75 (3) Min.
Flow
Highest
point of
flow or
return
Classic FF -
Feed / expansion
cistern
22 (3/4)
Open vent
150
(6)
Max
Max. practical
length
Propane Installation & Servicing
Cold
water
level
To pump
SEALED SYSTEM REQUIREMENTS
5
ecl6060
GENERAL
Hose unions
Temporary hose
(disconnect
after filling)
Non-return
valve
Automatic
air vent
Hosepipe
(disconnect
after filling)
Additional
stop valve
Double check valve
assembly
(note direction of flow)
Hose connector
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 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
(0-60lb./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 110
o
F)
(230
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
o
C (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. 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
2
) in excess of the safety valve setting.
(5lb./in
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.'
o
C
Classic FF -
Propane Installation & Servicing
9
GENERAL
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
make-up. Where the temporary connection is supplied
from a service pipe or distributing pipe which also
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).
supplies other 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
).
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 & Servicing
7
BOILER ASSEMBLY - Exploded view
Classic FF 330 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 & Servicing
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.
59. Limit thermostat.
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
rear or side flue outlet, in Pack B.
Unpack and check the contents.
INSTALLATION
1/2"),
! The complete boiler
! Installation & Servicing Instructions
! User's Instructions
! Hardware Pack (listed below)
! Wall mounting template
! Wall mounting plate
! Side outlet terminal mounting plate
! Flue extension tube, 1 off
! Boiler sealing ring, 1 off
Wall mounting plate
Hardware Pack Contents
! 50mm x No. 14 wood screw, 4 off
! 50mm x No. 10 wood screw, 8 off
! Wall plug , 12 off
! M8 washer, 1 off
Pack B Contents
! Duct cutting support, 1 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.
! 22mm x 28mm copper reducing socket
(FF 380 P ONLY), 2 off
! M5 wing nut, 3 off
! Sealing plate, 1 off
! M8 x 12 lg. screw, 1 off
12
Classic FF -
Propane Installation & Servicing
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