ideal Classic Slimline FF 230 User guide
INSTALLATION
& SERVICING
MANUAL
Classic Slimline
the wall hung boiler
Wall hung, fanned flue,
gas fired boiler
FF 230 - 260
BOILERS
Installers guide to central heating boilers
GENERAL
Classic Slimline FF
Natural Gas only
Data Badge: on top of the controls support
B.G. Certified - P.I. No. 87 BL 43
Destination Countries: GB & IE Appliance type: C
Slimline models G.C. Appliance No.
Classic FF 230 41 387 74
Classic FF 240 41 387 75
Classic FF 250 41 387 76
Classic FF 260 41 387 77
Key to symbols
IE = Ireland
GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
= A room sealed appliance designed for connection
C
12
via ducts to a horizontal terminal, which admits fresh
air to the burner and discharges the products of
combustion to the outside through orifices which, in
this case, are concentric. The fan is down stream of
the combustion chamber.
= An appliance designed for use on 2nd Family gas,
I
2H
Group H only.
CONTENTS
Air Supply. ..................................................................... 6
12
Boiler Clearances ......................................................... 5
Boiler Exploded View ................................................ 11
Burner Exploded View .............................................. .36
Control Box Exploded View ..................................... .36
Electrical Connections .............................................. 21
Electrical Regulations ................................................. 7
Extension Ducts - Fitting ........................................... 19
External Control ......................................................... 21
Fault Finding .............................................................. 33
Flue Installation ............................................................ 6
Rear installation ...................................................... 13
Side installation ...................................................... 16
Gas Safety ..................................................................... 4
Gas Supply ................................................................... 6
Initial Lighting . .......................................................... 24
Installation .................................................................. 10
Mandatory Requirements ............................................4
BENCHMARK LOG BOOK DETAILS
Pump ............................................................................. 8
Boiler Page
Make and model ........................................................3
Appliance Serial No. on Data Badge ....................... 11
Controls ....................................................... as applicable
For all boilers
Flushing to BS.7593 ..................................................7
Inhibitor ......................................................................7
Gas inlet working pressure ........................................ 6
Burner operating pressure ......................................... 2
Heat input .......................................... to be calculated
Temperature differential .............. measure and record
For combination boilers only ................... Not applicable
For domestic hot water mode .................. Not applicable
For condensing boilers ............................. Not applicable
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
CAUTION.
this appliance, care should be taken when handling edges of sheet steel components.
To avoid the possibility of injury during the installation, servicing or cleaning of
2
Servicing ..................................................................... 26
Short List of Parts ...................................................... 34
Spares Replacement .................................................. 28
System Diagrams ....................................................... 22
Terminal Guards. .......................................................... 6
Water and Systems ...................................................... 7
Water Treatment ........................................................... 7
Classic Slimline FF - Installation & Servicing
GENERAL
Table 1 - General Data
Boiler Size FF 230 FF 240 FF 250 FF 260
Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female)
Flow connection 22mm copper
Return connection 22mm copper
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)
Dry Weight kg (lb) 40.9 (90.3) 46.6 (102.8)
Maximum installation weight kg (lb) 31.4 (69.3) 37.4 (82.5)
Boiler size Height mm (in.) 700 (27.5)
Width mm (in.) 380 (15.0)
Depth mm (in.) 280 (11.0)
Flue duct diameter mm (in.) 100 (4.0)
Flue duct length (max) m (ft) 1.0 (3.3)
Table 2 - Performance Data
Boiler Size FF 230 FF 240 FF 250 FF 260
Boiler input MINIMUM kW 5.6 11.3 15.0 18.5
(Gross) Btu/h x 1000 19.1 38.5 51.2 63.3
Gas consumption l/s 0.15 0.29 0.38 0.49
3
ft
/h 19.4 37.1 48.7 62.9
MID kW 8.3 13.0 16.7 20.3
Btu/h x 1000 28.5 44.3 56.85 69.2
Gas consumption l/s 0.22 0.34 0.43 0.53
3
ft
/h 28.1 42.7 54.5 67.6
MAXIMUM kW 11.0 14.7 18.3 22.0
Btu/h x 1000 37.5 50.0 62.5 75.0
Gas consumption l/s 0.28 0.38 0.47 0.57
3
ft
/h 36.1 48.2 60.2 72.3
Boiler output MINIMUM kW 4.4 8.8 11.7 14.7
Btu/h x 1000 15 30 40 50
MID kW 6.6 10.3 13.2 16.1
Btu/h x 1000 22.5 35 45 55
MAXIMUM kW 8.8 11.7 14.7 17.6
Btu/h x 1000 30 40 50 60
Burner Setting
pressure (HOT) MINIMUM mbar (in.w.g.) 3.3 (1.3) 6.6 (2.6) 8.8(3.5) 10.0 (4.0)
MID mbar (in.w.g.) 7.4 (2.9) 9.2 (3.7) 11.5 (4.6) 12.3 (4.9)
MAXIMUM mbar (in.w.g.) 13.1 (5.2) 11.7 (4.7) 13.8 (5.5) 14.4 (5.8)
Seasonal Efficiency (SEDBUK) * [ ] % Band E 76.2 Band E 75.8 Band E 76.2 Band E 76.7
* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been certified by BG plc 0087.
Note. Gas consumption is calculated using a calorific value of
38.7 MJ/m
3
(1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different calorific value:-
a. FOR L/S - divide the gross heat input (kW) by the gross C.V.
of the gas (MJ/m
3
)
b. FOR FT3/H - divide the gross heat input (Btu/h) by the gross
C.V. of the gas (Btu/ft3)
Classic Slimline FF - Installation & Servicing
3
GENERAL
INTRODUCTION
The Classic Slimline FF230-260 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 dropdown 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
(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
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
70 kW.
BS.5440.2 Ventilation for gas appliances of rated input not
exceeding 70 kW.
Health & Safety Document No. 635
The Electricity at Work Regulations, 1989.
Manufacturer’s notes must NOT be taken in any way as overriding
statutory obligations.
IMPORTANT. These appliances are certificated by the BG
Technology Certification Services 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 certification and
the normal appliance warranty. It could also infringe the Gas
Safety Regulations and the above regulations.
OPTIONAL EXTRA KITS
Extension duct - up to 1m (39").
Cupboard installation - multi-pack Product No.156663
CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS OR RULES IN FORCE.
It is law that all gas appliances are installed by a CORGI
registered installer in accordance with the above regulations.
Failure to install appliances correctly could lead to prosecution.
It is in your own interest, and that of safety, to ensure the law is
complied with.
The installation of the boiler MUST also be in accordance with
the latest I.E.E (BS.7671) Wiring Regulations, local building
regulations, bylaws of the local water authority, the Building
Regulations and Building Standards (Scotland) and any relevant
requirements of the local authority.
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.
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 the 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 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 6.
NOTE TO THE INSTALLER:
LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
4
Classic Slimline FF - Installation & Servicing
1
BOILER WATER CONNECTIONS
This appliance in NOT suitable for use in a direct
hot water system or for gravity circulation.
2
BOILER CLEARANCES
The following minimum
clearances must be maintained
for operation and servicing.
Additional space will be required
for installation, depending upon
site conditions.
Side and Rear Flue
a. Provided that the flue hole is
cut accurately, e.g. with a
core drill, the flue can be
installed from inside the
building.
Installation from inside
ONLY
b. If a core boring tool is to be
used inside the building; the
space in which the boiler is
to be installed must be at
least wide enough to
accommodate the tool.
GENERAL
Front clearance: 533mm (21")
from the front of the boiler casing.
Minimum front clearance when
built behind a concealing panel is
5mm (1/4") provided that the top
and bottom of the casing are
NOT enclosed.
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 Slimline FF - Installation & Servicing
5
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'.
z For the minimum clearances required for safety and
subsequent service refer to
Frame 2. In addition, sufficient space may be required to allow
lifting access to the wall mounting plate.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
The boiler is to be installed only on gas supply with a governed
meter.
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.
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.
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 75 mm ( 3")
3. Below eaves 200 mm ( 8")
4. Below balconies or a car port roof 200 mm ( 8")
5. From vertical drain pipes or soil pipes 75 mm ( 8")
6. From internal or external corners 300 mm ( 12")
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
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.
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.
Minimum Spacing
1/2") of a plastic
TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 10.
AIR SUPPLY
Detailed recommendations for air supply are given in
BS.5440:2. The following notes are for general guidance:
6
Classic Slimline FF - Installation & Servicing
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
FF 230 102 (16) 51 (8)
FF 240 135 (21) 68 (11)
FF 250 170 (26) 83 (13)
FF 260 198 (31) 102 (16)
2
) 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.
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
Table 5.
Maximum boiler operating temperature should be 82
O
C (20OF) temperature differential, are shown in
O
C (180OF).
Table 5 - Water flow rate and pressure loss
Boiler Size FF 230 240 250 260
Boiler kW 8.8 11.7 14.6 17.6
Output Btu/h x 1000 30 40 50 60
Water Flow l/min 11.4 15.2 19.0 22.8
Rate gal/h 150 200 250 300
Pressure mbar 22.0 20.4 31.5 41.7
Loss in wg 8.9 8.3 12.6 16.7
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 Limited recommend the use of Fernox or Betz
Dearborn water treatment products which must be used in
accordance with the manufacturers instructions. For further
information contact :Fernox Manufacturing. Co. Ltd, Tandem House, Marlowe Way,
Croydon, Surrey CRO 4XS, tel. 0870 5601 5000 or
Betz Dearborn Ltd, Widnes, Cheshire, tel. 0151 424 5351
IMPORTANT. Any other treatment for this product will render the
guarantee of Caradon Plumbing Ltd INVALID.
Notes.
1. If an inhibitor is used, and in hard water areas where treatment
to prevent lime deposits is necessary, it is most important that
the water treatment MUST be maintained at the correct
concentrations recommended by the treatment manufacturer.
2. Artificially softened water must not be used in the system, under
any circumstances
THERMOSTATIC RADIATOR VALVES
Caradon Plumbing Limited recommend that heating systems
utilising full thermostatic radiator valve control of temperature in
individual rooms should also be fitted with a room thermostat
controlling the temperature in a space served by radiators not fitted
with such a valve as stated in BS. 5449.
When thermostatic radiator valves are used, the space heating
temperature control over a living / dining area or hallway having a
heating requirement of at least 10% of the boiler heat output should
be achieved using a room thermostat, whilst other rooms are
individually controlled by thermostatic radiator valves. However, if
the system employs thermostatic radiator valves on all radiators, or
two port valves without end switches, then a bypass must be fitted
to ensure a flow of water should all valves be in the closed position.
ELECTRICAL SUPPLY
This appliance must be efficiently earthed.
Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply.
The point of connection to the mains should be readily accessible
and adjacent to the boiler, except that for bathroom installations;
the point of connection to the mains MUST be situated outside of
the bathroom.
Note. Where a room sealed appliance is installed in a room
containing a bath or shower then the appliance and any electrical
switch or appliance control utilising mains electricity should be so
situated that it cannot be touched by a person using the bath or
shower. See Frame 38 for details.
.
Classic Slimline FF - Installation & Servicing
7
GENERAL
3
OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED.
The system should be vented directly off the boiler flow
pipe, as close to the boiler as possible. The cold feed entry
should be inverted and MUST be positioned between the
pump and the vent, and not more than 150mm (6") away
from the vent connection.
There should be a minimum height - 450mm (18") - of open
vent above cistern water level. If this is impossible refer
below.
The vertical distance between the highest point of the
system and the feed/expansion cistern water level MUST
not be less than 450mm (18").
The pump MUST be fitted on the flow side of the boiler.
A suitable pump is a domestic circulator capable of
providing an 11°C (20°F) temperature differential (e.g.
Grundfos UPS 15/50 or equivalent). The vertical distance
between the pump and feed/expansion cistern MUST
comply with the pump manufacturers minimum
requirements to avoid cavitation. Should these conditions
not apply, either lower the pump position or raise the
cistern above the minimum requirement specified by
Caradon Plumbing Limited.
Feed / expansion
cistern
Water
level
(cold)
System
return
22mm
Open vent
Connections
to boiler
15mm
Cold
feed
Inverted cold
feed entry
450 (18")
Mimimum
450 (18")
Mimimum
150 (6")
Max
System
flow to
pump
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.
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.
Return
450
(18)
Min.
200
(8)
Min.
75 (3)
Min.
75 (3) Min.
Highest
point of
flow or
return
Minimum Requirements
Feed / expansion
Surge
arrester
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
8
All dimensions in mm (in.). N.B. Imperial dimensions are approximate
Classic Slimline FF - Installation & Servicing
5
SEALED SYSTEM REQUIREMENTS
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.
GENERAL
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°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 (45lb/in2 ) and temperature of 110°C. Care should be taken in
making all connections so that the risk of leakage is minimised.
2. 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 (5 Ib/in2) in excess of the
safety valve setting. Single feed indirect cylinders are not suitable for
sealed systems.
3. 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 150 mm (6") above
the highest point of the system and be connected through a nonreturn valve to the system, fitted at least 300 mm (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'.
4. 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.
5. 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 supplies other draw-off points at a lower level, then a doublecheck 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 both system and pump until the
pressure gauge registers 1.5 bar (21.5lb/in2). 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 both system and pump.
• Adjust the initial pressure to the required value.
Classic Slimline FF - Installation & Servicing
9
6
SEALED SYSTEM REQUIREMENTScontinued
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 opposite, multiplied by a
factor of 0.8 (for flow temperature of less than
88°C).
INSTALLATION
If the system volume exceeds the figure given
in the opposite table for an 8-litre expansion
vessel then an additional vessel may be fitted,
provided that it is as close to the appliance on
the return to the boiler as is practically
possible.
Refer to BS 5449 and BS 7074:1 for detail of
expansion vessel application, selection and
installation.
INSTALLATION
Safety valve setting 3.0 bar
Vessel charge and 0.5 1.0 1.5
initial system pressure bar bar bar
Total water content of system
25 litres 2.1 2.7 3.9
50 4.2 5.4 7.8
75 6.3 8.2 11.7
100 8.3 10.9 15.6
125 10.4 13.6 19.5
150 12.5 16.3 23.4
175 14.6 19.1 27.3
200 16.7 21.8 31.2
225 18.7 24.5 35.1
250 20.8 27.2 39.0
275 22.9 30.0 42.9
300 25.0 32.7 46.8
Multiplying factors for
other system volumes 0.0833 0.109 0.156
Expansion vessel volume (litres)
7
UNPACKING
The boiler is supplied fully assembled in Pack A, together with a
standard flue assembly for lengths up to 600mm (23
side flue outlet, in Pack B.
1/2"), rear or
Optional extra, if ordered (Extension Duct Kit D) is available in a
separate box.
Unpack and check the contents.
Pack A 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
Cl 1724
z Side outlet terminal mounting
plate
z Flue extension tube - 1 off
z Boiler sealing ring - 1 off
z Flue elbow (for side outlet only)
Hardware Pack Contents
z 50mm x No. 14 wood screw, 4 off
z 50mm x No. 10 wood screw, 8 off
z Wall plug, 12 off
z Data badge indicator arrow, 1 off
z M8 washer, 1 off
z M5 wing nut, 3 off
z Sealing plate, 1 off
z M8 x 12 Hx. Hd. screw, 1 off
10
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.
Classic Slimline FF - Installation & Servicing
8
BOILER ASSEMBLY - Exploded view
Classic FF 230 shown
INSTALLATION
INSTALLATION
LEGEND
1. Heat exchanger.
2. Flue baffles.
3. Hook bolts
4. Flow pipe assy.
5. Return pipe assy.
Classic Slimline FF - Installation & Servicing
6. Collector hood assembly.
7. Combustion chamber.
12. Main burner.
19. Control box .
24. Pressure switch.
30. Fan.
40. Wall mounting plate.
52. Back panel.
56. Baffle plate (250/260 only).
11
9
PACKAGING AND CASING REMOVAL
1. Unpack the boiler.
2. Remove the casing as follows and place to one side
to avoid damage.
a. Undo the 2 casing retaining screws (a) retaining
the casing to the back panel.
b. Swing the bottom of the boiler casing up until the
controls pod casing has cleared the controls then
unhook the top from the back panel.
3. Remove the boiler from its packaging base. The
boiler may now be stood upright on its controls
INSTALLATION
support protection frame to ease handling and
installation.
INSTALLATION
(a) Casing retaining
screws, 2 off
Packing base
4. Unpack the boiler terminal box and, if applicable, the
extension flue box(es).
10
DETERMINING THE FLUE LENGTH
It is MOST IMPORTANT that the boiler is installed
in a vertical position.
REAR FLUE
INSTALLATION
SIDE FLUE
INSTALLATION
Flue length
for rear
Controls pod casing
FLUE KITS
Pack B: supplied as standard.
Pack D: optional extension kit for side flue or rear
flue outlet. Refer to 'Flue Extension Ducts'
A maximum of 1 extension duct (plus the standard
flue duct) may be used together.
12
Note: The total length must not exceed 1 metre.
Flue length for side
Jacking screw for
boiler alignment
Flue length mm Accessories Product No.
Up to 600 B Pack 1 off 150308
600 to 1000 B Pack 1 off + D Pack 1 off 150308 + 153883
Classic Slimline FF - Installation & Servicing
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