ideal Classic LXFF 230, Classic FF 230 User guide

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CAUTION.

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

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

Classic LXFF, FF - Installation

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GENERAL

Table 1 - General Data

Boiler Size FF 230 FF 240 FF 250 FF 260 FF 270 FF 280 FF 2 100

Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female)

Flow connection 22mm 28mm copper

copper (FEMALE)

Return connection 22mm 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.) 2.7 (0.6) 3.65 (0.8) 4.65 (1.0) 4.65(1.0)

Dry Weight Standard Model kg (lb) 40.9 (90.3) 46.6 (102.8) 52.6 (116.0) 52.6(116)

Deluxe (LX) Model kg (lb) 43.9 (96.8) 49.6 (109.4) 55.6 (122.6) N/A

Maximum installation weight kg (lb) 31.4 (69.3) 37.4 (82.5) 43.1 (95) 43.1(95)

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

Width mm (in.) 380 (15.0)

Depth mm (in.) Deluxe model (LX) 315 (12

Standard model 300 (11.8)

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

Flue duct length (max) m (ft) 3 (9.8) 0.6 (2)

3/8) N/A

Table 2 - Performance Data

Boiler Size FF 230 FF 240 FF 250 FF 260 FF 270 FF 280 FF 2 100

Boiler input MINIMUM kW 5.6 11.3 15.0 18.5 22.5 26.3 31.6

(Gross) Btu/h x 1000 19.1 38.5 51.2 63.3 76.9 89.7 107.8

Gas consumption l/s 0.15 0.29 0.38 0.49 0.58) 0.67 0.80

/h 19.4 37.1 48.7 62.9 73.1 86.3 101

MID kW 8.3 13.0 16.7 20.3 24.0 27.8 34.2

Btu/h x 1000 28.5 44.3 56.85 69.2 82.0 94.9 116.7

Gas consumption l/s 0.22 0.34 0.43 0.53 0.62 0.71 0.87

/h 28.1 42.7 54.5 67.6 78.8 91.3 110.0

MAXIMUM kW 11. 0 14.7 18.3 22.0 25.6 29.3 36.6

Btu/h x 1000 37.5 50.0 62.5 75.0 87.5 100.0 125.0

Gas consumption l/s 0.28 0.38 0.47 0.57 0.66 0.76 0.95

/h 36.1 48.2 60.2 72.3 84.3 96.3 121

Boiler output MINIMUM kW 4.4 8.8 11.7 14.7 17.6 20.5 24.9

Btu/h x 1000 1 5 30 40 50 60 70 85

MID kW 6.6 10.3 13.2 16.1 19.0 22.0 27.1

Btu/h x 1000 22.5 35 45 55 65 75 92.5

MAXIMUM kW 8.8 11. 7 14.7 17.6 20.5 23.4 29.3

Btu/h x 1000 3 0 40 50 60 70 80 100

Burner Setting pressure (HOT) MINIMUM mbar (in.w.g.) 3.5 (1.4) 8.5 (3.4) 9.5 (3.8) 12.0 (4.8) 12.5 (5.0) 12.1 (4.8) 10.4 (4.2)

MID mbar (in.w.g.) 7.5 (3.0) 11.5 (4.6) 11.5 (4.6) 14.1 (5.6) 14.9 (6.0) 13.9 (5.6) 12.3 (4.9)

MAXIMUM mbar (in.w.g.) 13.2 (5.3) 14.5 (5.6) 13.5 (5.4) 16.5 (6.6) 16.5 (6.6) 16.0 (6.4) 14.5 (5.8)

Seasonal Efficiency (SEDBUK) * [76.2]% [75.8]% [76.2]% [76.7]% [77.1]% [76.0]% [76.4]%

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

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

Note. Gas consumption is calculated using a calorific value of

38.7 MJ/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a different calorific value:-

Classic LXFF, FF - Installation

a. FOR L/S - divide the gross heat input (kW) by the gross

C.V. of the gas (MJ/m3)

b. FOR FT3/H - divide the gross heat input (Btu/h) by the gross

C.V. of the gas (Btu/ft3)

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GENERAL

Classic LX FF & FF

B.G. Certified - P.I. No. 87 AP 107 94

Destination Countries: GB and IE

Natural Gas only Appliance type: C12 & C

Data Badge: on top of the controls support

Deluxe models G.C. Appliance No.

Classic LXFF 230 41 387 24 Classic LXFF 240 41 387 25 Classic LXFF 250 41 387 26 Classic LXFF 260 41 387 27 Classic LXFF 270 41 387 28 Classic LXFF 280 41 387 29

Standard models G.C. Appliance No.

Classic FF 230 41 387 01 Classic FF 240 41 387 02 Classic FF 250 41 387 03 Classic FF 260 41 387 04 Classic FF 270 41 387 05 Classic FF 280 41 387 06 Classic FF 2 100 41 349 71 (Classic FF 2 100 is a type C12 appliance only)

CONTENTS

Air Supply. ..................................................................... 8

Boiler Clearances ......................................................... 6

Boiler Exploded View ................................................ 10

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

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

Electrical Connections .............................................. 21

Electrical Regulations ................................................. 8

Extension Ducts - Fitting ........................................... 19

External Control ......................................................... 21

Fault Finding .............................................................. 33

Flue Installation ............................................................ 7

Rear installation ...................................................... 13

Side installation ...................................................... 16

Deluxe Model (LX)

Key to symbols

IE = Ireland

GB = United Kingdom (Countries of destination)

PMS = Maximum operating pressure of water

& C32 =

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

Standard Model

Gas Safety ..................................................................... 5

Gas Supply ................................................................... 7

Initial Lighting ............................................................ 24

Installation .................................................................. 10

Mandatory Requirements ............................................ 5

Pump ............................................................................. 9

Servicing ..................................................................... 26

Short List of Parts ......................................................34

Spares Replacement .................................................. 28

System Diagrams .......................................................22

Terminal Guards. .......................................................... 7

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

WaterTreatment ............................................................ 8

= An appliance designed for use on 2nd Family gas,

Group H only.

Classic LXFF, FF - Installation

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GENERAL

INTRODUCTION

The Classic FF230-2 100 (standard) and the Classic LX FF 230280 (deluxe casing) 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.

FF 230-2 100 (Standard Model)

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

FF LX 230-280 (Deluxe Model LX)

The boiler casing is fitted with a glass fascia. The glass fascia can be lifted up to gain access to the boiler thermostat.

All details for the deluxe casing model are the same as the standard model unless otherwise stated.

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 (23 1/2").

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

z Fully pumped CH and indirect DHW z Pumped heating only. z Pumped indirect DHW only.

1/2") to 600 mm

OPTIONAL EXTRA KITS

Downward Piping Kit. Programmer Kit. Vertex Flue Kit* - for vertical flue connection Roof Flue Kit*

90° Flue Elbow Kit*

Sealed System Unit - this fits on top of the appliance.

Suitable for standard boiler only.

Extension ducts* - up to 3m (118"). Turret Outlet Kit.*

*not available for FF2 100

GAS SAFETY (INSTALLATION AND USE) Regulations 1994, amendments 1996 or rules in force.

It is law that all gas appliances are installed by a CORGI registered

installer (identified by Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with.

) in accordance with the above regulations.

The installation of the boiler MUST also be in accordance with the latest I.E.E (BS.7671) Wiring Regulations, local building regulations, bylaws of the local water authority, the Building Regulations and Building Standards (Scotland) and any relevant requirements of the local authority. Detailed recommendations are contained in the following British Standard Codes of Practice:

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 Family Gases).

BS.7593 Treatment of water in domestic hot water central

heating systems.

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.

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

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

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

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

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

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. continued on page 7

NOTE TO THE INSTALLER:

LEAVE THESE

INSTRUCTIONS ADJACENT TO THE GAS METER.

ALSO COMPLETE THE BENCHMARK LOG BOOK

AND GIVE THIS TO THE CUSTOMER.

Classic LXFF, FF - Installation

Page 6

BOILER WATER CONNECTIONS

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

FF 270, FF 280 & FF2 100 ONLY

must be fitted with the 22mm x 28mm copper sockets, provided in the Hardware Pack, (or equivalent 22mm x 28mm compression fittings ) and the pumped flow and return pipes run in 28mm pipe.

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: 450mm (17 from the front of the boiler casing.

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

3/4")

Pelmet restrictions.

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

a. Release the controls pod

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

b. Undo the 2 screws (b)

retaining casing to the back panel.

c. The casing can now be

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

Classic LXFF, FF - Installation

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GENERAL

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

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

Compartment Installations

A compartment used to enclose the boiler 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 :

z BS. 6798. z The position selected for installation MUST allow adequate

space for servicing in front of the boiler and for air circulation around the boiler. Refer to 'Air Supply' on page 8.

z 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.

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

Terminal Position

1. Directly below or alongside an

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

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

3. Below eaves 25 mm ( 1")

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

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

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

7. Above adjacent ground, roof or

balcony level 300 mm (12")

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

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

10. From an opening in a car port

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

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

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

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

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

Minimum Spacing

A gas meter can only be connected by the local gas supplier or by a local regional contractor.

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. Pipework from the meter to the boiler MUST be of an adequate size. FF2 100 models should be piped in 22mm minimum. The final 1metre may be run in 15mm if it is visible.

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

FLUE INSTALLATION

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

The following notes are intended for general guidance:-

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

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

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

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

Ensure that the guard is fitted centrally.

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

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

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.

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.

1/2") or with an inaccurately

1/2") of a plastic

TERMINAL

The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 8.

AIR SUPPLY

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

Classic LXFF, FF - Installation

Page 8

GENERAL

1. It is NOT necessary to have a purpose provided air vent in

the room or internal space in which the boiler is installed.

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

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

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

Table 4 - High and low vent areas

Boiler Air from room/internal Air direct from

space, cm (in

FF230 102 (16) 51 (8)

FF240 135 (21) 68 (11)

FF250 170 (26) 83 (13)

FF260 198 (31) 102 (16)

FF270 231 (36) 116 (18)

FF280 264 (41) 132 (21)

FF2 100 340 (52) 170 (26)

) outside, cm (in2)

WATER CIRCULATION SYSTEM

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

Table 5 - Water flow rate and pressure loss

Boiler Size FF 230 240 250 260 270 280 2 100

Boiler kW 8.8 11.7 14.6 17.6 20.5 23.4 29.3 Output

Water Flow l/min 11.4 15.2 19.0 22.8 26.5 30.3 38.0

Rate gal/h 150 200 250 300 350 400 500

Pressure mbar 22.0 20.4 31.5 41.7 54.8 77.0 106

Loss in wg 8.9 8.3 12.6 16.7 22.0 30.9 42.5

Btu/h x 1000

30 40 50 60 70 80 100

WATER TREATMENT

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

Caradon Plumbing Ltd recommend the use of Fernox or Betz Dearborn water treatment products which must be used in accordance with the manufacturers instructions. For further information contact :Fernox Manufacturing. Co. Ltd, Tandem House, Marlowe Way, Croydon, Surrey CRO 4XS, tel 0870 5601 5000 or

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

IMPORTANT. Any other treatment for this product will render the

guarantee of Caradon Plumbing Ltd INVALID.

Notes.

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

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

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

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 resistance of the boilers, at MAXIMUM OUTPUT with an 11 are shown in Table 5.

C (20OF) temperature differential,

THERMOSTATIC RADIATOR VALVES

Caradon Plumbing Limited recommend that heating systems

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

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

ELECTRICAL SUPPLY

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

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

Note. Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower. See Frame 36 for details.

Classic LXFF, FF - Installation

Page 9

GENERAL

System return

Connections to boiler

Inverted cold feed entry

System flow to pump

150 (6") Max

15mm Cold feed

450 (18") Mimimum

22mm Open vent

Feed / expansion cistern

Water level (cold)

OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED.

The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.

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

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

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. Grunfos UPS 15/50 or equivalent). The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturers minimum requirements to avoid cavitation. Should these conditions not apply, either lower the pump position or raise the cistern above the minimum requirement specified by

Caradon Plumbing Limited.

Note. A cold water feed must be available back to the

boiler, when all automatic valves are in the closed position (refer to BS. 6798) and when close coupled the feed must not be in a vertical leg.

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.

LOW HEAD INSTALLATIONS

Return

450 (18) Min.

200 (8) Min.

75 (3) Min.

Surge arrester

75 (3) Min.

Highest point of flow or return

Minimum Requirements

Feed / expansion

22 (3/4)

Flow

Open vent

150

(6)

Max

cistern

To pump

Max. practical

length

Cold

water

level

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

Note. The pump manufacturers minimum requirements must be complied with

Classic LXFF, FF - Installation

All dimensions in mm (in.). N.B. Imperial dimensions are approximate

Page 10

INSTALLATION

BOILER ASSEMBLY - Exploded view

Classic FF 230 shown

LEGEND

1. Fan /collector hood assembly.

2. Inter-panel.

3. Pumped return pipe.

4. Rubber sealing grommets.

5. Pumped flow pipe.

6. Wall mounting plate.

7. Sealing plates, 3 off

9. Back panel.

10. Controls support.

11. Control box .

12. Programmer (optional)

13. Heat exchanger.

14. Combustion chamber.

15. Main burner.

16. Boiler drain point.

17. Flue baffles.

18. Pressure switch

Classic LXFF, FF - Installation

Page 11

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 1/2"), rear or side flue outlet, in Pack B.

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

Unpack and check the contents.

z The complete boiler z Installation & Servicing Instructions z User's Instructions z Hardware Pack (listed below) z Wall mounting template z Wall mounting plate z Side outlet terminal mounting plate z Flue extension tube - 1 off z Boiler sealing ring - 1 off

INSTALLATION

Hardware Pack Contents

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

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

z Wall plug, 12 off

Pack B Contents

z Duct cutting support, 2 off

(cardboard )

z Terminal wall plate, 1 off.

z Terminal grille assy., 1 off.

z Polyurethane foam seal 400 lg., 1 off.

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

z Data badge indicator arrow, 1 off

z M8 washer, 1 off

z 22mm x 28mm copper reducing socket

(FF 270, FF 280 and FF 2 100 ONLY), 2 off

z M5 wing nut, 3 off

z Sealing plate, 1 off

z M8 x 12 Hx. Hd. screw, 1 off

Classic LXFF, FF - Installation

Page 12

PACKAGING AND CASING REMOVAL

INSTALLATION

STANDARD MODEL

1. Unpack the boiler.

2. Remove the casing as follows and place to one side to

avoid damage.

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

casing to the back panel.

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

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

3. Remove the boiler from its packaging base. The boiler may

INSTALLATION

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).

(a) Casing retaining screws, 2 off

DELUXE MODEL (LX)

1. Unpack the boiler.

2. Remove the casing as follows and place to one side to

avoid damage.

a. Slide the glass fascia upward (arrow b)

b. Undo the 2 casing retaining screws (c), retaining the

casing to the back panel.

c. 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).

Packing base

Controls pod casing

DETERMINING THE FLUE LENGTH

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

REAR FLUE INSTALLATION

SIDE FLUE INSTALLATION

Flue length for rear

Flue length for side

FLUE KITS

Pack B: supplied as standard.

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

flue outlet. Refer to 'Flue Extension Ducts'

1. A maximum of 2 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

Up to 600 B Pack 1 off 152 227

600 to 1550* B Pack 1 off + D Pack, 1 off 152227+152132

1550 to 2500* B Pack 1 off + D Pack, 2 off 152 227+

Accessories Product No.

152132, 2 off

Jacking screw for boiler alignment

2500 to 3000* B Pack 1 off + D Pack, 3 off 152 227+

152132, 3 off

* Not for FF 2 100 model

Classic LXFF, FF - Installation

Page 13

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 8.

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

INSTALLATION

LEGEND

IMPORTANT. On FF 2 100 models only: the flue extension

tube includes an air deflector ring.

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

b. The position of the flue duct hole.

c. Downward pipe routing bracket screw positions.

1. Terminal

2. Weather sea

3. Flue assembly

4. Boiler sealing ring

5. Flue extension tube

5. Remove the templates from the wall.

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting operation,

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

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

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

3. Insert the plastic plugs provided.

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

Classic LXFF, FF - Installation

Page 14

INSTALLATION

CUTTING THE FLUE - wall thicknesses of 114 to 600mm

Note. If the stand-off brackets are used it is essential that

30mm is added to the measured wall thickness when marking the flue (to allow for the thickness of the brackets).

1. Measure and note the wall thickness X.

2. Mark the wall thickness onto the flue.

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

way round.

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

5. Remove cardboard ring and remove any burrs.

FITTING 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.

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.

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

WALL MOUNTING PLATE

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

screws.

2. If 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

Classic LXFF, FF - Installation

Page 15

INSTALLATION

MOUNTING THE BOILER

Note. Have ready to hand the M8 screw, washer

and rectangular plate supplied in the hardware pack. For downward routing of pipes the M5 spacer (supplied in the Downward Piping Kit) should now be fitted to the back of the boiler.

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

Do not use the burner / controls for lifting

2. Fit the M8 screw, washer and rectangular plate to retain the boiler.

Note.

Before fully tightening the M8 screw, check the boiler alignment, using a spirit level, and adjust as necessary with the jacking screw.

CONNECTING THE FLUE TO THE BOILER

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.

IMPORTANT On FF 2 100 models only: the flue extension tube

includes an air deflector ring.

TERMINAL WALL PLATE

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

1. Position the terminal wall plate over the terminal.

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

drill.

3. Insert the 4 plastic plugs provided.

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

9/32") masonry

Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to the Contents List on Page 4.

Classic LXFF, FF - Installation

REAR FLUE OUTLET

Page 16

INSTALLATION

FLUE ASSEMBLY - Exploded view

For wall thickness 114mm to 600mm

1. An optional flue duct

extension kit is required for lengths (distance from the outside wall to the relevant side of the boiler casing) greater than 600mm (23 1/2") Refer to Frame 8.

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

IMPORTANT. On FF 2 100 models only; the flue extension tube includes an air deflector ring.

LEGEND

1. Terminal

2. Weather sea

3. Flue assembly

4. Boiler sealing plate

5. Flue extension tube

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).

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.

Note. If the terminal is to be sited within 25-40mm of a corner or vertical pipe (refer to Table 3) then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided. The terminal wall plate need not be fitted.

5/16") masonry drill and insert the plastic

Classic LXFF, FF - Installation

Page 17

INSTALLATION

CUTTING THE FLUE For flue lengths 114 to 600mm ONLY

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

the side of the boiler to the outside face of the wall). Refer to Frame 9.

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.

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 32 & 33 - Flue extension ducts.

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.

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

Classic LXFF, FF - Installation

Flue assembly

Page 18

FITTING THE SIDE OUTLET PLATES

INSTALLATION

WALL MOUNTING PLATE

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

the side outlet plate must be fitted now.

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

2. Fit the 2 halves of the side outlet plate to the wall,

ensuring they are behind the boiler sealing ring.

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.

MOUNTING THE BOILER

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

2. For downward routing of pipes the M5 spacer (supplied in the Downward Piping Kit) should now be fitted to the back of the boiler.

SIDE FLUE OUTLET

1. The boiler is supplied for

rear outlet installation. Remove the blanking plate from the direction required and use this to blank off the rear outlet.

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

Do not use the burner/ controls for lifting.

3. Fit the M8 screw, washer and rectangular plate to retain the boiler.

Note. Before fully tightening the M8 screw check the boiler alignment using a spirit level and adjust as necessary with the jacking screw.

Classic LXFF, FF - Installation

Page 19

INSTALLATION

CONNECTING THE FLUE TO THE BOILER

1. Pull the flue through the side outlet plate and locate

the 3 studs in the hole in the side of the boiler.

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

3. Insert the flue extension tube into the flue.

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

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

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

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

TERMINAL WALL PLATE

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

1. Position the terminal wall plate over the terminal.

2. Drill 4 fixing holes with a 7mm (

3. Insert the 4 plastic plugs provided.

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

provided.

Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to the contents list on Page 4.

FLUE EXTENSION DUCTS -

9/32") masonry drill.

For flue lengths greater than 600mm (Not for FF 2 100 model)

PACK D Flue extension duct kit contents.

SIDE FLUE OUTLET

Classic LXFF, FF - Installation

Page 20

INSTALLATION

FLUE EXTENSION DUCTS - continued

General arrangement

Note. Side flue shown.

1. A maximum of 2 extension ducts (plus the standard flue

duct) may be used together.

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

Flue length Accessories Product No.

Up to 600 B Pack 1 off see Frame 8

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

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

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

Extension

tube

Boiler

Extension duct

Flue connector

* Not for FF 2 100 model

Flue length

Standard flue

Terminal grille

FITTING THE KIT

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 3 - 3.2mm ( outer air duct. Do not drill the inner flue

duct.

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

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

1/8") dia. holes through the

REAR & SIDE FLUE OUTLET

Classic LXFF, FF - Installation

Page 21

INSTALLATION

GAS CONNECTION

Refer to 'Gas Supply ', page 7. 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.

ELECTRICAL CONNECTIONS

WARNING. The appliance must be efficiently earthed.

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

All external controls and wiring must be suitable for mains voltage. Wiring should be in 3-core PVC insulated & sheathed cable, not less than 0.75mm Regulations and local regulations.

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

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

WATER CONNECTIONS

1. Remove the plastic plugs from the flow and

return pipes.

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

INSTALLATION

LEGEND b blue bk black

Flow wiring diagram

br brown r red y yellow

w white gy grey or orange

v violet pk pink y/g yellow/green

Note. If the optional Programmer Kit is to be

fitted refer to the instructions provided with the kit and Frame 37.

1. Remove the control box securing screw (M4 pozi). Pull the box forward to disengage. Refer to Frame 56.

2. Route the mains cable through the grommet in the plate of the control box.

3. Remove the screw and release the mains connection plate. Unscrew the cable clamp screws and remove the clamp.

4. Connect the mains cable wires to the terminal strip.

5. Assemble in reverse order.

6. Replace the control box and fasten to the

controls support.

EXTERNAL CONTROLS

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

For wiring external controls to the Classic FF boiler, reference should be made to the system wiring diagrams supplied by the relevant manufacturer, in conjunction with the wiring diagrams shown in Frames 39-41.

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

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

2. Controls that override an on/off control, e.g. frost thermostat, must be wired into the mains lead, in parallel, with the control(s) to be overridden. Refer to Frame 41.

Classic LXFF, FF - Installation

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.

1. Connection between a frost thermostat and the time

control should be made without disturbing other wiring.

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

Page 22

PICTORIAL WIRING

INSTALLATION

LEGEND

b blue

bk black

br brown

r red

y yellow

w white

or orange

v violet

p pink

gy grey

y/g yellow/green

INSTALLATION

MID POSITION VALVE

Notes.

1. Some earth wires are omitted for

clarity. Ensure proper earth continuity when wiring.

2. Numbering of terminals on thermostats is specific to the manufacturer.

3. This is 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

b blue

bk black

br brown

r red

w white

y/g yellow/green

or orange

gy grey

Pumped only

Classic LXFF, FF - Installation

Page 23

TWO SPRING CLOSED VALVE

Pumped only

Notes.

1. Some earth wires are omitted for

clarity. Ensure proper earth continuity when wiring.

2. Numbering of terminals on thermostats is specific to the manufacturer.

3. This is a fully controlled system - set the boiler thermostat to maximum.

INSTALLATION

4. Switchmaster valve has grey and

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

LEGEND

b blue

bk black

br brown

r red

y yellow

FROST PROTECTION

w white

gy grey

y/g yellow/green

or orange

v violet

pk pink

INSTALLATION

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.

Classic LXFF, FF - Installation

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.

Page 24

INSTALLATION

COMMISSIONING AND TESTING

(a) Electrical Installation

1. Checks to ensure electrical safety should be carried out

by a competent person.

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

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

INSTALLATION

INITIAL LIGHTING

LEGEND

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

TO LIGHT THE BOILER

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

the flow and return are open.

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

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

4. Fitting the Boiler Casing

Deluxe Model (LX) - 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 until it is flush with the assembly. Lift the glass fascia and pull the sliding catch out to retain the glass in the upper position. Secure with the 2 captive screws. To improve access to the gas valve, remove the controls casing bottom panel by removing its 2 retaining screws. Refer to Frame 44.

Standard Model - The boiler casing must be refitted with the controls pod 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. To improve access to the gas valve, remove the controls pod casing. Release the controls pod front fixing screws 3 turns only. Remove the pod by pulling it forward to

D Thermostat knob E Main burner pressure adjuster. F Burner pressure test point. H Boiler mains on/off switch.

(b) Gas Installation

1. The whole of the gas installation, including the meter,

MUST be inspected and tested for soundness, and purged in accordance with the recommendations of BS. 6891.

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

3. Retighten the union and check for gas soundness.

disengage from the keyhole slots. Refer to Frame 44.

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

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.

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

6. Switch the electricity supply ON and check that all external controls are calling for heat.

7. 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.

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

9. Operate the boiler for 10 minutes to stabilise the burner temperature.

10. The boiler is pre-set at the factory to its highest nominal rating but can be range rated to suit the system design requirements. Refer to Table 2 (page 3). Remove the silver threaded protection cap on the top of the regulator. Adjust the main burner pressure adjuster (E) until the required main burner pressure is achieved.

11. Set the boiler mains on/off switch to OFF.

12. Remove the pressure gauge and tube. Retighten the sealing

screw in the pressure test point.

13. Turn ON and check for gas soundness at the pressure test point.

14. Deluxe Model (LX)

Refit the controls casing bottom panel and screws.

Standard Model

Refit the controls pod and tighten the 2 front fixing screws.

15. Deluxe Model (LX)

Lower the glass fascia to its closed position.

Standard Model. Close the pod door.

Classic LXFF, FF - Installation

Page 25

INSTALLATION

INITIAL LIGHTING - continued

Standard Model

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.

Deluxe Model (LX)

INSTALLATION

d. Balance the system.

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

The temperatures quoted below are approximate and vary between installations.

Knob Setting Flow Temperature

°C °F

1 54 130

2 60 140

3 66 150

4 71 160

5 77 170

6 82 180

WARNING. The boiler MUST NOT be operated with

the casing removed.

HANDING OVER

After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions:

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

his or her responsibilities under the Gas Safety (Installation and Use) Regulations 1994, amendments 1996 or rules in force.

2. Deluxe model (LX) - Draw attention to the Lighting Instruction label affixed to the controls casing bottom panel.

Standard Model - 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.

Classic LXFF, FF - Installation

Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions.

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

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

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

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

9. After installation, commissioning and customer hand-over

instructions please complete the book and leave this with the customer.

10.. Stress the importance of regular servicing by a CORGI

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

appliance log

Page 26

SCHEDULE

SERVICING

BOILER CASING REMOVAL

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 a CORGI registered installer.

a. Light the boiler and, using the flue sampling point

(provided on the top RH side of the back panel) carry out a pre-service check, noting any operational faults.

b. Clean the main burner.

c. Clean the heat exchanger.

d. Clean the main and pilot injectors.

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

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

flue system is sealed correctly.

g. 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 48 to 52 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.

The boiler must NOT be operated if the casing is not

SERVICING

fitted.

Note. In order to carry out either servicing or replacement of components, the boiler casing must be removed. Refer to Frame 48.

1. If the Classic Sealed System Unit is fitted (Standard boiler only), lift off the casing.

2. Deluxe model (LX) -Lift the glass fascia and pull the sliding catch out to retain the glass in the upper position. Release the 2 captive screws at the bottom of the casing. Swing the bottom of the boiler casing out until the controls pod casing has cleared the controls, then unhook the casing top from the back panel. Retain the casing in a safe place.

Standard model - 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 (page 6) should should be followed.

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

Standard model

Deluxe model (LX)

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.

Classic LXFF, FF - Installation

Page 27

SERVICING

CLEANING THE FAN ASSEMBLY / THE FLUEWAYS

1. Remove the 2 silicon rubber tubes from the fan sensing

points.

2. Disconnect the fan leads.

3a. Rear flue

Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue.

3b. Side or top flue

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

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

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

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

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

8. Remove the flue baffles.

9. Remove all loose deposits from the heat exchanger,

particularly between the fins, using a suitable brush.

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

CLEANING THE BURNER AND PILOT ASSEMBLY

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

burner head (ensuring 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.

RE-ASSEMBLY

Re-assemble 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.

Check that:

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

to Frame 58 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 58). Clean or renew as

necessary.

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

6. Reconnect the gas supply and the electrical wiring. Refer to Frames 34 & 36.

7. Check the sightglass in the boiler casing. Clean or renew as necessary. Refer to Frame 55.

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

9. Refit the boiler casing (Refer to Frame 43, item 4). Note that it is not necessary to disturb the controls casing pod.

SERVICING

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.

5. Refit the control box.

Classic LXFF, FF - Installation

10. Deluxe model (LX)

Push the sliding catch in and lower the glass fascia to the closed position.

Standard model

Close the controls pod door.

Page 28

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 58) and ensuring that there is an inlet pressure of 20 mbar available, the pilot does not light then contact Caradon Plumbing Limited.

Relight in accordance with 'Initial Lighting', Frame 43.

REPLACEMENT OF PARTS

GENERAL

When replacing any component:

1. Isolate the electricity supply.

2. Turn OFF the gas supply.

3. Remove the boiler casing. Refer to Frame 48.

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 43.

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.

SIGHTGLASS REPLACEMENT

1. Refer to Frame 54.

SERVICING

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 52.

Note. Standard model illustrated. For the deluxe model (LX) slide

the glass fascia out before removing the sightglass assembly. Refit the glass fascia after refitting the new sightglass assembly.

OVERHEAT THERMOSTAT REPLACEMENT

Refer to Frames 37, 54 & 70.

1. Remove the control box fixing screw.

2. Pull the box forward and

downward to disengage.

3. To remove the overheat thermostat pull off the electrical connections at the thermostat. Remove the backnut retaining the thermostat to the bracket. Remove the thermostat from the heat exchanger pocket.

4. Re-assemble in reverse order.

Classic LXFF, FF - Installation

Page 29

SERVICING

THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and ON/OFF SWITCH REPLACEMENT

Refer also to Frame 54.

Remove the control box fixing screw (A). Pull the box forward and downward to disengage.

Thermostat control

1. Pull the knob off the shaft.

2. 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 re-assemble in reverse order.

Thermistor sensor lead

5. Pull the sensor lead connector off the printed

circuit board.

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

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

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

9. Replace and re-assemble in reverse order.

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. Re-assemble in reverse order.

PILOT BURNER REPLACEMENT

SERVICING

1. Refer to Frame 54.

2. Remove the burner and air box assembly.

Refer to Frame 49.

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 that the

Classic LXFF, FF - Installation

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. Replace the box assembly.

8. Replace the burner.

9. Replace the boiler casing.

10. The pilot is factory set to maximum and no further

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

Page 30

SERVICING

IGNITION ELECTRODE AND LEAD REPLACEMENT

1. Refer to Frame 54.

2. Remove the burner and air box assembly. Refer to Frame 49.

3. Remove the electrode retaining nut.

4. Remove the pilot shield.

5. Remove the ignition electrode and integral lead.

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

Ensure that the pilot shield is replaced.

7. Check the spark gap. Refer to Frame 58.

8. Refit the burner.

9. Replace the boiler casing.

10. Check the pilot ignition.

MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT

1. Refer to Frame 54.

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

SERVICING

an approved jointing compound is used sparingly.

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

6. Refit the M5 retaining screw.

7. Refit the boiler casing.

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

GAS CONTROL VALVE REPLACEMENT

Note. Also refer to Frame 69 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 54.

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

Frame 49.

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

4. Remove the gas control valve electrical connection.

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 gas control valve. Ensure that the new control is fitted the correct way round (an arrow engraved on back indicates the direction of flow).

Note. Remove the gas cock stub and refit into the new gas control valve. Use an approved jointing compound on the pipe stub.

5. Disconnect and remove the gas union from the gas control valve.

6. Whilst supporting the gas control valve, remove the 2 screws retaining the manifold to the back panel.

9. Re-assemble in reverse order.

10. Replace the boiler casing.

11. Check the gas valve operation.

Classic LXFF, FF - Installation

Page 31

SERVICING

FAN REPLACEMENT

1. Remove the 2 silicon rubber tubes from the fan sensing points.

2. Disconnect the fan leads.

3a. Rear flue. Slacken the M4 screw securing the flue connector to the

fan. Disconnect the connector from the fan and slide into the flue.

3b. 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. Remove the three M4 screws retaining the fan to the collector hood.

8. Re-assemble in reverse order, ensuring the fan leads, and 3 sensing

tubes are reconnected.

AIR PRESSURE SWITCH (APS) REPLACEMENT

1. Refer to Frame 54.

9. Refit the boiler casing.

10. Check the boiler operation.

2. Remove the APS fixing screw.

3. Remove both sensing tubes from the APS.

4. Remove the 3 electrical connections from the APS.

5. Connect the new APS in reverse order.

6. Refit the APS with the fixing screw.

7. Refit the boiler casing.

8. Check the boiler operation.

PRINTED CIRCUIT BOARD (PCB) REPLACEMENT

Note. Refer to Frames 69 & 70 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 54.

2. Remove the control box fixing screw. Pull the box forward

and downward to disengage.

3. Remove the HT lead from the PCB

4. Remove the 6 push-in connectors from the PCB.

5. Remove the neutral wire on the PCB from its connection to

the back of the socket inside the control box.

SERVICING

6. Remove the earth wire on the PCB from its connection to the

earth stud inside the control box.

7. Remove the 2 connections from the on/off switch and remove the switch.

8. Compress the barbs on the PCB stand-offs to release the PCB from the box

9. Fit the new PCB and re-assemble in reverse order, ensuring the correct orientation of the switch.

10. Refit the boiler casing.

11. Check the operation of the boiler.

COMBUSTION CHAMBER INSULATION REPLACEMENT

1. Refer to Frame 54.

2. Remove the burner and air box assembly.

Refer to Frame 49.

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.

Classic LXFF, FF - Installation

7. Remove the front and rear insulation panels.

8. Fit the new front and rear insulation panels.

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

10. Re-assemble in reverse order.

Page 32

SERVICING

HEAT EXCHANGER REPLACEMENT

Note. Refer to Frame 5 (Boiler assembly - Exploded view) for

illustration of the procedure detailed below.

1. Refer to Frame 54.

2. Remove the burner / air box assembly. Refer to Frame 49.

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 50.

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

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. Re-assemble 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 54.

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.

SERVICING

Notes.

The standard model is illustrated. Use the same procedure for casing seal replacement on the deluxe model (LX).

Model FF 2 100 does not have air deflector baffles fitted to jacket bottom.

PROGRAMMER REPLACEMENT (IF FITTED)

1. Refer to Frame 54.

2. Remove the programmer box fixing

screw. Pull the box forward and downward to disengage.

3. Pull the programmer forward out of its box.

4. Pull off terminal connections from back of programmer.

5. Fit the new programmer in reverse order.

6. Refit the boiler casing.

7. Set the programmer to the desired

programme and check the operation of the boiler.

Classic LXFF, FF - Installation

Page 33

FAULT FINDING

START

Check that the mains on neon

'I3' is illuminated.

YES

Is there a live supply to both

terminals of overheat 'stat?

YES

Check that the boiler thermostat

is set at maximum and the mains

on/off switch is ON.

Is the fan turning ?

YES

Is there a supply on the fan

connector at PCB ('Molex '

marked 'FAN'?).

YES

Is there a

supply at the fan ?

Check mains supply and fuses.

Check programmer and system

thermostats are all ON. Check that

boiler plug and socket are OK and

Can the overheat 'stat

Remove the sensor

(NTC) from the PCB.

Has the fuse blown on PCB ?

Is there a live supply on the

violet lead to pressure switch?

Change fan

Rectify bad connection

fully connected.

be reset when the

system is cold ?

Is the fan turning ?

YES

Is there a live supply on the

red lead to

pressure switch?

YES

Reset the overheat 'stat. Set control

'stat to maximum. Allow the boiler to

reach temperature - if the overheat

'stat trips again, measure flow

temperature.

If above 90°C replace control 'stat.

If below 90°C replace overheat 'stat.

Replace the overheat thermostat

Replace the sensor

Replace fuse BUT, before

attempting to start boiler, check

for short between live and

neutral, also between live and

earth, on all items plugged into

PCB

Check all connections to PCB.

If no error found, replace PCB.

Check connections and leads to

pressure switch/boiler thermostat

and check that fan is operating.

Is the ignition electrode sparking?

YES

Does the pilot light ?

Is there a gas supply

to the boiler?

YES

Is the pilot injector

blocked?

Ensure pilot and

main gas valve

leads are not

crossed over.

Is there a supply

voltage at pilot

gas valve?

YES

Replace

gas valve

YES

Does the

spark stop

after pilot is

Check the polarity of

the mains supply.

Check the continuity of

the ignition lead from

connector to electrode.

Does the spark now

cease when gas is lit ?

Check all connections to PCB.

If no fault found, replace PCB

lit?

YES

Is there a regular

spark from tube 'SG1'

on the PCB?

Is the boiler casing

correctly fitted?

Does main burner

cross-light from pilot?

Is there a supply on

terminals of main gas valve?

Is the main burner

injector clear?

YES

Replace main gas

solenoid valve

YES

Check connections to pressure

switch. If no faults found, change

pressure switch.

Check gap at ignition electrode.

Check electrode and lead are undamaged, and not close to

earthed metalwork.

Check all connections to PCB.

If no fault found change PCB.

Check pressure switch sensing

pipes for blockages, bad

connections and reversed

connection.

Is pressure difference at switch

greater than 0.9 mbar?

YES

Change

pressure switch

Change fan

FAULT FINDING

Classic LXFF, FF - Installation

Page 34

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 lists is held by British Gas, Caradon Plumbing Limited distributors and merchants.

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

9 308 365 Sightglass assembly kit 1 079602

13 Main burner

379 917 AEROMATIC No.AC 19/123 294; FF 230 & FF 240 1 111707 379 918 AEROMATIC No.AC 19/123 293; FF 250 & FF 260 1 111708 379 919 AEROMATIC No.AC 19/123 292; FF 270, FF 280 & FF 2 100 1 111709

14 Main burner injector

Injector 044-323-344 256; FF 230 1 153884 Injector 044-323-344 290; FF 240 1 153885

Injector 044-323-344 330; FF 250 153886 389 587 BRAY Cat. 10 - size 1550; FF 260 1 111989 389 588 BRAY Cat. 10 - size 1850; FF 270 1 111990 398 065 BRAY Cat. 10 - size 2300; FF 280 1 004760

Aeromatic Pt. No. 939021, 4.6mm; FF 2 100 1 152320

14A Copper washer, Aeromatic 914176(for injector);

FF230, FF240, FF250, FF2 100 1 152426

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

15 397 943 Pilot burner injector: HONEYWELL 4580 1075002 ; FF 230-280 1 004982

Pilot burner injector: HONEYWELL 4580 1075001 ; FF 2 100 1

16 308 358 Pilot burner head Q359A with:

Honeywell 4580 1075002 injector FF 230-280 1 079599

Honeywell 4580 1075001 injector FF 2 100 1 079590

18 Gas valve kit VR 4601AA1036, 230 V 1 075698

19 308 549 Ignition electrode complete with lead and backnut 410 mm lg. 1 111881

20 E02-653 Control box assembly, including thermostat, knob, PCB,

potentiometer and on/off switch 1 151252

24 308 283 Thermostat knob 1 079601

25 386 149 Automatic ignition printed circuit board :

PACTROL PCB 25 B 1 079716

27 385 861 Pressure switch: HONEYWELL YAMATAKE C6065 A 1010 1 111379

28 E02-661 Fan assembly: SIFAN No.WFFB 0221-039 FF 230-280 1 151586

SIFAN No.WFFB 0226-028 FF 2 100 1

33 E04-503 Boiler casing assembly complete with sightglass assy, insulation

& M5 x 16 dogpoint pozi pan hd (Stan'd model only) FF 230-280 1 075391

FF 2 100 1 075523

36 308 541 Controls casing door with Lighting Instructions (

37 E04-504 Casing seal pack complete with screws 1 075392

Standard model only)

1 079941

51 386 144 Overheat thermostat, RANCO LM7 P 8508 1 113200

52 308 622 Glass fascia FF (Deluxe model only) 1 112734

53 308 624 Plastic fascia trim FF (Deluxe model only) - BEIGE 2 138249

54 308 623 Plastic fascia trim FF (Deluxe model only) - WHITE 2 138405

55 E04-509 Boiler casing assembly - white stove enamel with sightglass and foil

insulation (Deluxe model only) 1 075393

56 - Controls casing bottom panel 1 138267

Classic LXFF, FF - Installation

Page 35

SHORT LIST OF PARTS

BURNER ASSEMBLY - Exploded View

LEGEND

(Numbers up to 51 relate to the B.G. spares list)

11. Burner manifold

CONTROL BOX - Exploded View

12. Air box and pilot assembly.

13. Main burner.

14. Main burner injector.

17. Pilot shield.

18. Gas control valve.

42. Gas service cock.

LEGEND

(Numbers up to 51 relate to the B.G. spares list)

20. Control box.

21. Thermostat potentiometer.

24. Thermostat knob.

25. Printed circuit board.

26. Mains on/off switch.

Classic LXFF, FF - Installation

Page 36

BOILER CASING ASSEMBLY

SHORT LIST OF PARTS

Standard model

Deluxe model (LX)

SHORT PARTS LIST

Classic LXFF, FF - Installation

Page 37

Classic LXFF, FF - Installation

Page 38

The code of practice for the installation,

commissioning & servicing of central heating systems

Technical Training

The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers.

For details of courses please ring: ............... 01270 413624

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.

Caradon Plumbing Limited, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Registered Office: National Avenue, Kingston upon Hull, HU5 4JN. A subsidiary

of Caradon p.l.c

LXFF.87/AQ/220 LXRS.87/AQ/221

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

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

Caradon Plumbing 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.

November 1999 UIN 111 497 A13

Natural Gas

appliances are

service listed by

British Gas

Ideal Installer/Technical Helpline: 01482 498663

Classic LXFF, FF - Installation

Page 39

YOUR FEEDBACK

and your chance to win a free boiler

At Ideal we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service. We will be giving away a free boiler for the five best ideas every year (to be selected by our Technical Director). Please complete this form, using extra sheets if required, and post it or fax it to us on 01482 498699.

Boiler details

Model / Size (e.g. Classic RS 230, Mexico CF 3/60 etc. Details on control panel door)

Date of Installation

Installer details

Name

Address

Post Code Telephone (Please include STD code)

How I would improve this boiler:

My general comments for Ideal:

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Ideal Installer/Technical Helpline: 01482 498663

Classic LXFF, FF - Installation

Page 40

Further information

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

Installer details

Name

Address

Post Code Telephone (Please include STD code)

General information required

Please send me details of Ideal Training Courses.

Please arrange for a technical representative to contact me.

Please arrange for me to join an Ideal factory tour.

Range guides required

The Ideal Guide: a specifier's and installer's introduction to the Ideal domestic boiler range.

The Ideal Householders Guide: to assist the installer when presenting to his/her customers.

Technical manuals required

The Ideal C class combi boiler

The Ideal Classic System wall hung boiler

The Ideal Classic LX Deluxe wall hung boiler

The Ideal Mexico floor standing boiler

The Ideal Minimiser heat-saving boiler

The Ideal Response combi. boiler

The Ideal Response SE super efficiency combi boiler

The Ideal Systemiser SE super efficiency system boiler

The Ideal Concord high output boiler

The Ideal Buccaneer oil fired boiler

Caradon Plumbing Limited, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Telephone: 01482 492251 Fax: 01482 448858.

Ideal Installer/Technical Helpline: 01482 498663

U.I.N. 111 497 A0



ideal Classic LXFF 230, Classic FF 230 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual