IDEAL Response FF80 Installation And Servicing
2
Response FF80 - Installation
Response: The combi boiler
The Ideal Response is a wall mounted, fanned flue combination boiler
which serves a home's central heating system and delivers instant hot
water on demand. It has been designed to be 'friendly' to the user, installer
and service engineer.
Response: The fit anywhere combi
Simple fanned 'go anywhere' flue
The Response's flue turret simply rotates through 360° to allow horizontal
outlet in any direction. Options include horizontal flue length extensions
or simple vertical flue kits - and the flue is self-sealing, eliminating the
need for outside assembly - an important benefit in high-rise applications.
Downward or upward connections...
Water and gas connections have been designed to be as simple and fast
as possible. The Ideal Response comes complete with a rugged mounting
frame which can accommodate downward or upward routed gas, water
and electrical connections before the boiler is fitted.
...and it fits inside a cupboard
Its compact size - up to half that of other combis - makes the Response
ideal for any kitchen. It can be installed inside a standard size kitchen wall
unit without insulation and with minimal ventilation or it can be mounted to
sit flush with the front face of adjacent kitchen units.
Response: The combi you can rely on
The Response has been designed and developed with reliability as the
number one priority. But even the finest engineered product may develop
a fault at some stage in its lifetime. To support the Response we've created
the Ideal Care Guarantee which sets out our target to repair any fault
next day.
Free Guarantee: 1st Year Ideal Care
The home owner is entitled to 12 months free Ideal Care, which includes
both parts and labour, to restore the boiler to full function. Please encourage
the home owner to complete and return the registration form in their
Householder's pack within 30 days of installation.
Optional Extra Year Cover with Ideal Care
You may wish to offer your own annual service plan or you may wish to
advise the home owner to complete their application form for the
appropriate level of extended Ideal Care - Silver, Gold or Platinum. Full
details are available in the Ideal Care brochure.
3
Response FF80 - Installation
PERFORMANCE DATA
Boiler Response FF80
Gas supply type & connection 2H-G20-20mbar, Rc1/2
Inlet connection Domestic Hot Water 15mm copper
Outlet connection Domestic Hot Water 15mm copper
Flow connection & Central heating
Return connection 22 mm copper
Flue terminal diameter mm (in.) 100 (4)
Max. working pressure (sealed systems) bar (lb/in
2
) 2.65 (38.5)
Max. DHW water inlet pressure bar (lb/in2) 10.0 (145.0)
Min.
DHW water inlet pressure bar (lb/in2) 0.5 (7)
Electrical supply & loading 230 V ~ 50 Hz, 160W max
External fuse rating 3A
Internal fuse rating PCB 38 F1: T2A PCB 38 F2: H2A PCB 37 F1: H2A
Water content Central Heating litre (gal.) 2.3 (0.50)
Domestic Hot Water litre (gal.) 0.48 (0.11)
Dry Weight kg (lb.) 50 (110)
Boiler size Height mm (in.) 640 (25
3/16)
Width mm (in.) 436 (17 1/8)
Depth mm (in.) 278 (10
15/16)
Table 1 - General Data
Table 2 - Performance Data - CENTRAL HEATING
Response FF80
Max Min
Burner pressure (HOT) mbar (in.w.g.) 8.3 (3.4) 3.7 (1.5)
Input based on nett CV kW (Btu/h) 19.8 (67 500) 12.6 (43 000)
Input based on gross CV kW (Btu/h) 22 (75 000) 13.9 (47 500)
Output kW (Btu/h) 17.6 (60 000) 11.7 (40 000)
Gas consumption (Hot) l/s (ft
3
/h) 0.568 (220) 0.359 (139)
Table 3 - Performance Data - DOMESTIC HOT WATER
Response FF80 (Maximum)
Burner pressure (HOT) mbar (in.w.g.) 14.8 (5.9)
Input based on nett CV kW (Btu/h) 26.4 (90 000)
Input based on gross CV kW (Btu/h) 29.3 (100 000)
Output kW (Btu/h) 23.4 (80 000)
Gas consumption (Hot) l/s (ft
3
/h) 0.757 (293)
Flow 35 0C. temp. rise l/m (gpm) 9.6 (2.1)
Domestic hot water specific rate l/m (gpm) 11.2 (2.4)
Key to symbols
IE = Ireland (Countries of
GB = United Kingdom destination)
PMS = Maximum operating pressure of water
C13 = A room sealed appliance designed for connection via ducts to a
horizontal terminal, which admits fresh air to the burner and
discharges the products of combustion to the outside through
orifices which, in this case, are concentric. The fan is up stream
of the combustion chamber.
I
2H
= An appliance designed for use on 2nd Family gas, Group H only.
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:-
a. FOR L/S - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m
3
)
b. FOR FT
3
/H - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
CAUTION.
To avoid the possibility of injury during the installation, servicing or cleaning of
this appliance care should be taken when handling edges of sheet steel components.
4
Response FF80 - Installation
NOTE TO THE INSTALLER:
LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER
Response FF80 Natural gas only G.C. Appliance No. 47 415 09
B.G. Certified P.I. No. 87AR183 Destination Countries: GB, IE.
5
Response FF80 - Installation
GENERAL
CONTENTS
Air Supply ...................................................................... 6
Boiler Dimensions/Clearances.................................... 5
Boiler Exploded Diagram ........................................... 11
Commissioning and Testing...................................... 29
Electrical Connections ............................................... 27
Electrical Diagrams .................................................... 28
Electrical Supply Reqirements ................................... 8
Extension Ducts - Fitting ........................................... 24
Fault Finding ............................................................... 47
Flow Wiring Diagram .................................................. 28
Flue Fitting
Rear outlet .............................................................. 14
Side outlet .............................................................. 19
Flue Installation Reqirements ...................................... 7
Gas Safety (Installation & Use)
Regulations, 1994 ......................................................... 6
Gas Supply Reqirements ............................................. 7
Health & Safety Document No 635 .............................. 6
Initial Lighting ............................................................. 30
Installation ................................................................... 12
Mandatory Requirements ............................................. 6
Sealed System Requirements ...................................... 8
Servicing ...................................................................... 32
Short List of Parts ....................................................... 58
Terminal Guards............................................................ 7
Thermostatic Radiator valves ...................................... 8
Water and Systems ....................................................... 7
Water Connections ....................................................... 5
Wiring Diagrams.......................................................... 28
INTRODUCTION
Response FF80 are wall mounted, low water content, balanced
flue combination gas boilers of type C13 intended for use with
gas group I2
H.
Central heating (CH) output modulates between 11.7 kW
(40,000 Btu/h) minimum and 17.6 kW (60,000 Btu/h) maximum.
Instantaneous domestic hot water (DHW) output is also fully
modulating, with a maximum of 23.4kW (80,000 Btu/h).
The boiler is suitable for connection to fully pumped, pressurised
sealed water systems ONLY.
A system bypass is only required when TRV's are fitted to all
radiators (see Frame 5).
Boilers are supplied fully assembled and, being a 'tube-withintube' design, require no diverter valve or domestic hot water
calorifier.
A circulating pump, pressure gauge, safety valve and expansion
vessels for both central heating (CH) and domestic hot water
(DHW) are provided.
The CH flow temperature is controlled by an electronic
thermostat. In DHW mode the boiler modulates to sustain a
nominal adjustable water flow temperature of 60 oC.
The boiler casing is of white painted mild steel with a drop-down
controls access door.
The boiler temperature control is located behind the controls
access door.
The heat exchanger is made of copper and cast iron.
The system pipework must include drain cocks in appropriate
places. Pipework may be taken downwards or upwards behind
the boiler (using the stand-off channels).
OPTIONAL EXTRA KITS
Programmer Kit - fits neatly within the casing. Separate fitting
instructions are included with the kit. Note. If using an alternative
programmer read Frame 42 first.
Extension Ducts - up to 3m (120")
90o Elbow kit (Max. of 2 / installation).
Roof Flue Kit - for vertical flue connection
Vertex flue kit.
OPERATION
With no call for CH the boiler fires only when DHW is drawn off.
When there is a call for CH, the heating system is supplied at
the selected temperature until DHW is drawn off. The full output
of the boiler is then directed by the automatic switching off of the
circulation pump to heat the inner coils and supply a maximum
draw-off of :
Response FF80 9.6 l/min(2.1 gpm) at 35 degree rise.
The nominal DHW temperature is 60
o
C, but water drawn off
when the boiler has been on for central heating may be hotter
than this, for a short period of time.
6
Response FF80 - Installation
GENERAL
1
BOILER WATER CIRCUIT DIAGRAMS
7
Response FF80 - Installation
GENERAL
2
BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in.)
Front clearance
The minimum front clearance when built in to a
cupboard is 5mm (1/4") from the cupboard door but
450mm (17 3/4") overall clearance is still required,
with the cupboard door open, to allow for servicing.
See Table 4.
Note. For the FF80 central heating circuit 22mm
(3/4") pipes may be used.
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 where wall
thicknesses do not exceed 600mm (24").
Where the space into which the boiler is
going to be installed is less than the length of
flue required the flue must be fitted from the
outside.
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.
Boiler connections are made on the mounting frame. Refer to Frame 17.
Distance X is 20mm for DHW pipes & safety valve outlet.
Distance X is 23.5mm for CH pipes & gas inlet.
Per side 5 mm
Top 160 mm (depth of elbow and lift
Front 450 mm clear of spigot space,
Bottom 150 mm internal wall ring plate)
CLEARANCES
* Bottom clearance
Bottom clearance after installation can be reduced to
10mm in an adequately ventilated enclosed cupboard.
However, 150 mm must be available for servicing.
8
Response FF80 - Installation
GENERAL
GAS SAFETY (INSTALLATION AND USE)
REGULATIONS, 1994
It is law that all gas appliances are installed and serviced by a
CORGI registered installer (identified by
) 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, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 60 kW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 60 kW).
BS. 5449 Forced circulation hot water systems.
BS. 5546 Installation of gas hot water supplies for domestic
purposes (2nd Family Gases)
BS 6700 Design, installation testing and maintenance of
services supplying hot water for domestic use.
BS. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 6891 Low pressure installation pipes.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certificated 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 as otherwise
recommended by Caradon Ideal Limited in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Ltd. could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
LOCATION OF BOILER AND FLUE OUTLET
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 British Gas publication 'Guide for
Gas Installations in Timber Frame Housing', reference DM2.
Bathroom Installations
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.
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.
Note. It is not permissible to install a mains socket in a
bathroom.
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 or cupboard, including airing cupboards, must
conform to the following:
z BS. 6798.
z For the minimum clearances required for safety and
subsequent service see the wall mounting template and
Frame 2. In addition, sufficient space will be required to
allow lifting access to the wall mounting plate.
z Ventilation of the compartment ,e.g. permanent high and low
level air vents, must be provided in accord with the current
issue of BS 5440, Part 2. See Table 4 and 'Air Supply' below.
Table 4 - Minimum air vent free area for compartments /
cupboards (high and low levels)
Boiler Air from room or Air direct
internal space from outside
- cm
2
(in.2 ) - cm2 (in.2 )
FF80 265 (41) 135 (21)
AIR SUPPLY
Detailed recommendations for air supply are given in BS.5440:2.
The following notes are for general guidance:
1. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for cooling purposes) in
the cupboard/compartment at both high and low levels. The
air vents must either communicate with room/internal space
or be direct to outside air. The minimum effective areas of
the permanent air vents required in the cupboard/
compartment are specified in Table 4 and are related to
maximum rated heat input.
2. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.
3. In siting the air vents, care must be taken to avoid the
freezing of pipework.
4. If the boiler is NOT installed in a cupboard or compartment
no air vent is necessary.
9
Response FF80 - Installation
GENERAL
4. Where the lowest part of the terminal is fitted less than 2m
(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard. The minimum
spacing in Table 3, Nos. 2, 3, 4, 5 and 6 would be 75mm, in
order to allow a terminal guard to be fitted.
Terminals guards are available from boiler suppliers - ask for
Tower Flue Guard, Model K1 . In case of difficulty seek
advice from:
Tower Flue Components Ltd.,
Vale Rise, Tonbridge, Kent TN9 1TB
Telephone No. 01732 351 555
Ensure that the guard is fitted centrally.
5. Where the terminal is fitted within 850mm (34") of a plastic
or painted gutter or 450mm (18") of painted eaves then an
aluminium shield at least 750mm (30") 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 610mm (24") or with an inaccurately
cut hole, the minimum spacing in Table 3, Nos. 2, 3, 4, 5 and
6 would be 60mm (2.4") 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
as 'unsafe' and corrective action taken.
FLUE LENGTHS
The flue assembly can be adapted to accommodate flue lengths
up to 3 metres. Refer to Frame 10.
WATER CIRCULATION SYSTEM
The boilers are designed for connection to pressurised, fully
pumped, sealed water central heating systems ONLY. The
domestic hot water (DHW) calorifier is incorporated within the
heat exchanger and only requires connection to the mains water
supply.
IMPORTANT. Ensure that the mains water supply pressure is
adequate to provide the required DHW flow rate. Refer to Table
1 on page 3.
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 should be in accordance with
BS. 5546 and BS. 6700.
Copper tubing to BS 2871:1 is recommended for water carrying
pipework and MUST be used for pipework carrying potable
water.
Any soldered joints on potable water pipework MUST NOT be
made with solder containing lead.
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.
A gas meter can only be connected by the local gas supplier or
by a registered CORGI engineer.
Check that the appliance is suitable for the proposed gas supply.
A working gas pressure of 20 mbar MUST be available at the
boiler inlet.
Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to FF80 boilers MUST be of an
adequate size, i.e. not less than 22mm O.D. copper or
3/4" BSP iron.
Do not use pipes of smaller size than the boiler inlet gas
connection.
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: Part 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 5.
Note (Positions 2-6) : Due to the terminal design, installation is
possible with clearances less than those specified in BS 5440,
Part 1.
Table 5 - Balanced flue terminal position
Terminal Position
Minimum Spacing
1. Directly below or alongside an
openable 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")
10
Response FF80 - Installation
GENERAL
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 or ventilated
underfloor spaces.
Draining taps should be at least
1/2" BSP nominal size and be in
accordance with BS 2879.
Maximum recommended system hydraulic losses are given in
Table 7, within Frame 5.
WATER TREATMENT
Antifreeze fluid, corrosion and scale inhibitor fluids suitable for
use with boilers having copper heat exchangers may be used in
the central heating system.
For further information contact either:
Fernox Manufacturing Co. Ltd.
Britannic Works
Clavering
Essex
CB11 4QZ
Tel.01799 550811
or
Grace Service Chemicals
Grace Dearborn Ltd.,
Widnes
Cheshire
Tel. 0151 424 5351
THERMOSTATIC RADIATOR VALVES (TRV)
Caradon Ideal Ltd. 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 area 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.
For further information refer to the 'Good Practice Guide 143' , a
publication of the Energy Efficiency Office, available from the
Building Research Establishment, Garston, Watford WD2 7JR.
Tel: 01923 664258.
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 for bathroom
installations where 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.
REQUIREMENTS
1. General
Any 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 it complies with Water
Bye-law 14, which states:
" (1) No closed circuit shall be connected to a supply pipe.
(2) Paragraph (1) shall not apply to a temporary connection
provided that:
a. The connection is made through a double check valve
assembly or some other no less effective device which is
permanently connected to that circuit;
and
b. The temporary connection is removed after use. "
The method described in this instruction complies with that
Byelaw.
2. BS. Requirements
The installation must comply with the requirements of
BS. 6891:1988 and BS. 5449.
3. Flow Temperature
The installation should be designed to work with flow
temperatures of up to 90° C.
4. Working Pressure
All components of the system must be suitable for a
working pressure of 3 bar (45 lb/in
2
) and temperature of
110°C. Extra care should be taken in making all
connections so that the risk of leakage is minimised.
The following components are incorporated within the
appliance:
a. Circulating pump.
b. Safety valve; with a non-adjustable pre-set lift pressure
of 3 bar (45lb/in
2
).
c. Pressure gauge; covering a range of 0-6 bar.
d. 8-litre expansion vessel; with an initial charge pressure
of 1 bar (15 lb/in
2
).
e. Domestic hot water (DHW) mini expansion vessel.
For further details refer to BS.5449:1 and the British Gas
Corporation publication 'Specifications for Domestic Central
Heating and Hot Water'.
3
SEALED SYSTEM REQUIREMENTS - Central Heating
N.B. Ideal Response FF80 combination boilers are suitable for
fully pumped pressurised sealed systems only.
11
Response FF80 - Installation
GENERAL
5. Filling the system
Fill the system 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
filling system:
A double non-return valve with at least 1 isolation valve,
which is used as a temporary connection to fill the system
from the mains, after which it should be disconnected and
left with the installation.
4
SEALED SYSTEM REQUIREMENTS - Central Heating - continued
Proceed with the following:
• Thoroughly flush out the whole of the system with
cold water before fitting the boiler.
• Fill and vent the system until the pressure gauge
registers 1.5 bar (22 lb/in
2
). Examine for leaks.
• Release water from the system until a pressure of 1
bar (15 lb/in
2
) is reached. To avoid getting debris on
the valve seat, do not use the safety valve to do
this.
• Light the boiler and heat the system to the
maximum working temperature. Examine for leaks.
• Turn off the boiler and drain the system while still
hot.
• Refill and vent the system.
• Re-pressurise the system to the desired charge
pressure (see Table 6).
6. Size of expansion vessel
For the system water expansion to be contained by the 8litre expansion vessel fitted to the boiler the cold system
volume must not exceed:
119 litres when pressurised to 0.5 bar (cold)
107 litres when pressurised to 0.7 bar (cold)
91 litres when pressurised to 1.0 bar (cold)
If the pressure exceeds 2.65 bar when the boiler is up to
temperature with all radiators in use then an additional
expansion vessel MUST be installed on the return
pipework.
For expansion volumes see Table 6.
Guidance on vessel sizing is given below and also in BS
7074:1 and BS 5449.
Table 6 - Vessel sizing / Expansion volumes
System charge pressure (bar) 0.5 0.7 1.0
Safety valve setting (bar) 3.0
Vessel pre-charge pressure (bar) 0.5 0.7 1.0
System volume litres Volume of expansion vessel in
addition to 8-litre unit fitted to boiler
75 None None None
100 None None 0.8
125 0.4 1.3 3.0
150 2.1 3.1 5.1
175 3.8 4.1 7.3
200 5.4 6.8 9.5
225 7.1 8.7 11.7
250 8.8 10.5 13.9
275 10.6 12.4 16.1
300 12.2 14.2 18.4
Multiply this factor by system volume and
deduct 8 litres to obtain size of additional 0.067 0.074 0.088
vessel for other system volumes.
12
Response FF80 - Installation
Boiler FF80
Max CH Output kW 17.6
(Btu/h) (60 000)
Water flow rate l/sec 0.382
(gal/min) (5.04)
Temperature
o
C11
differential (oF) (20)
Head available for m.w.g. 2.75
system pump, pos.3 (ft.w.g.) 9.0
GENERAL
7. Thermostatic radiator valves.
Caradon Ideal Limited support the recommendations
made by leading manufacturers of domestic heating
controls 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. Such an arrangement will provide for a more
efficient control of the environment and will also avoid the
continuous running of the circulation pump during
programmed heating ON periods, saving electrical energy.
It is therefore strongly recommended that, when
thermostatic radiator valves are used, the space heating
temperature control over a living/dining area or a hallway,
having a heat requirement of at least 10% of the boiler
output, is achieved using a room thermostat whilst other
rooms are individually controlled by thermostatic radiator
valves.
However, if thermostatic radiator valves are fitted to all
radiators then a bypass MUST be fitted. This should
consist of 22mm (3/4") pipe for the FF 80 positioned as far
from the boiler as possible and incorporating a balancing
valve which cannot be adjusted by the householder.
For adjustment refer to Frame 45
a. The total length of pipework A, B, C & D MUST NOT
be less than 3m (10') and must not include any other
valves.
b. The balancing valve MUST be at least one turn open.
8. Hydraulic resistance
Having subtracted the hydraulic resistance of the boiler the
head available to overcome system resistance at
MAXIMUM CENTRAL HEATING OUTPUT, with an 11
0
C
(200F) temperature differential, is shown in Table 7.
9. Draining the system
Draining taps MUST be located in accessible positions to
permit the draining of the whole central heating system,
including the central heating side of the boiler. The taps
should be at least
1/2" BSP nominal size and be in
5
SEALED SYSTEM REQUIREMENTS - Central Heating - continued
1. The domestic hot water service must be in accordance
with BS 5546 and BS 6700.
2. For the minimum and maximum working pressures of the
FF80 domestic hot water circuit refer to Table 1, page 3.
3. The cold water supply pipe should be flushed before fitting
the boiler.
4. The boilers are suitable for connection to most types of
washing machine and dishwashing appliances.
6
DOMESTIC HOT WATER REQUIREMENTS
Table 7 - Water Flow Rate and Pressure Loss
5. When connecting to suitable showers, i.e. those designed
for modulating domestic hot water, ensure that:
a. The cold inlet to the boiler is fitted with an approved
anti-vacuum or syphon non-return valve.
b. Hot and cold supplies are of equal pressure.
6. Hard water areas
In areas where the water is 'hard' it is recommended that a
proprietary scale-reducing device is fitted into the boiler
cold supply - within the requirements of the local water
company.
accordance with BS 2879. The boiler flow and return
service valves (fitted to the piping frame) have drain
plugs to drain the BOILER ONLY, in the event of the
system drain tap being unable to do so.
13
Response FF80 - Installation
7
BOILER ASSEMBLY - Exploded View
INSTALLATION
30. EMC filter.
39. Boiler front panel.
40. Sealing panel
43. Tank cover assy.
59. Turret clamp.
64. Controls panel assy.
66. Transformer.
22. Pump.
24. DHW Flow switch.
25. Automatic air vent.
26. Heat exchanger.
27. Burner sensing pipe.
28. Fan sensing pipe.
29. Sensing pipe clamp.
9. Boiler overheat 'stat.
10. Water pressure switch.
15. Pressure gauge.
17. Fan assembly.
19. Safety valve.
20. DHW expansion vessel
21. CH expansion vessel
LEGEND
1. Main burner.
2. Main burner injector.
2A. Gas valve.
3. Flame sensing electrode.
4. Ignition electrode.
5. Air pressure switch.
6. PCB 37.
7. PCB 38.
14
Response FF80 - Installation
INSTALLATION
8
UNPACKING
INSTALLATION
9
PACKAGING AND FRONT PANEL REMOVAL
Pack B Contents
z Terminal grille assembly
z No.8 x 8mm self tapping screw - 3 off
z Flue support cutting aid - 1 off
z Terminal wall plate - 1 off
z 90
0
Elbow Kit
z Powered Vertical
flue Kit
Optional extras, if ordered, are available in separate boxes.
z Programmer Kit
z Roof Flue Kit
z Extension Duct Kit D
Pack A Contents
z The boiler
z These Installation & Servicing Instructions
z The User's Instructions
z Wall mounting template
z Wall mounting frame
z 1 pair stand-off channels (optional use)
z Flue turret
z Clamping and sealing ring
z Mains connector assy.
z Hardware Pack
The boiler is supplied fully assembled in one Pack A, together
with a standard flue assembly for lengths up to 600mm, rear or
side flue outlet, in Pack B.
Unpack and check the contents.
Hardware Pack
z M6 x 10 Pp. Hd. screw - 4 off
z 1/2" x 15mm copper connector - 1 off
z No.14 x 2" slotted Rd. Hd. screw - 6 off
z No.10 x 2" slotted Rd. Hd. screw - 4 off
z Wall plug (brown) - 10 off
z Press. relief valve drain pipe - 1 off
z Pressure relief valve nut - 1 off
z 22mm pipe connector - 2 off
z 15mm pipe connector - 3 off
z 22mm x 15mm reducing coupling - 1 off
z DHW filter - 1 off
z 22mm compression nut - 2 off
z 15mm compression nut - 2 off
z 22mm olive - 2 off
z 15mm olive - 3 off
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
z 22mm 'O' ring - 2 off (spare items for CH/
z 15mm 'O' ring - 1 off DHW connectors)
1. Remove the lid.
2. The top tray contains:
z Flue turret
zMounting frame
zHardware pack
zStand-off channels
zWall mounting template
zInstallation instructions
These contents can be removed, leaving the boiler in its protective package.
15
Response FF80 - Installation
Total Length of Flue Extra Packs Required
* 600mm (23 5/8") None
*1800mm (70 7/8") One Pack D
3000mm (118
1/8") Two Pack D
INSTALLATION
Flue Kit Requirements
INSTALLATION
Pack B - supplied as standard.
Pack D - optional extra kit, to extend the flue.
* N.B.
If the measured flue length is only just above these sizes,
it may be necessary to shorten the standard flue before
adding extension duct(s), in order to prevent interference
between flue duct connectors and the boiler flue elbow.
For side flue option
PROCEED TO FRAME 20
.
10
DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
Use a maximum of two extension ducts only. When using 90o elbow
kits, each elbow is equivalent to 1 metre flue length.
Calculate the total length of flue by the following:
Rear flue length = Dim. W + 79mm (3 1/8")
Rear flue length with stand-off channels = Dim. W + 109mm (4
3/8")
RHS flue length = Dim. R + 220mm (8
5/8")
LHS flue length = Dim. L + 96mm (3
3/4
")
Note.
These figures include the length of flue entering the
flue turret socket
16
Response FF80 - Installation
13
DRILLING THE WALL (Rear Flue)
IMPORTANT. Ensure that, during the cutting operation,
masonry falling outside the building does not cause damage or
personal injury.
1. Cut the flue hole (preferably with a 5" core boring tool),
ensuring that the hole is square to the wall.
2. Measure and note the wall thickness 'W'.
3. Drill the 6 fixing holes with an 8mm (
5/16") masonry drill.
Note. If the terminal is to be sited within 25-40mm of a
corner or vertical pipe (refer to Table 4) then the hole MUST
be accurately cut and the rubber weather seal trimmed
around the groove provided.
(The terminal wall plate cannot be fitted close to a corner).
INSTALLATION
11
REAR FLUE ASSEMBLY
- Exploded View
REAR FLUE OUTLET
12
WALL MOUNTING TEMPLATE (Rear Flue)
IMPORTANT.
For direct mounting (wall mounting frame on wall) choose one
black dot in each group.
If using the stand-off channels choose one dotted circle in each
group. Care MUST be taken to ensure the correct holes are
drilled.
1. Tape the template into the selected position.
2. Ensure squareness by hanging a plumbline as shown.
3. Mark onto the wall the following:
a. The 6 wall mounting plate screw positions.
b. The position of the flue duct.
Mark the centre of the hole as well as the circumference.
4. Remove the template from the wall.
LEGEND
1. Terminal.
2. Weather seal.
3. Duct assembly.
4. Sealing ring.
5. Clamping ring.
6. No.8 x 8 self tapping screw.
7. Flue turret.
8. M5 x 10 pozi Hex screw.
9. Turret clamp.
Note. For boiler to be flush with 300mm deep units use stand-off channels
17
Response FF80 - Installation
REAR FLUE OUTLET
INSTALLATION
14
FITTING THE WALL MOUNTING FRAME
Refer to Frame 34 for service connections.
Fit the wall mounting frame either:
a. Directly to the wall
zz
zz
z Insert wall plugs.
zz
zz
z Put the screws into the wall plugs and leave
10mm proud
zz
zz
z Hang the frame onto the screws and tighten
up.
or
b. Use stand-off channels
(To allow pipework to be taken upwards).
zz
zz
z Insert wall plugs.
zz
zz
z Put the screws into the wall plugs and leave
10mm proud.
zz
zz
z Fasten each channel to the frame with the
6mm screws provided.
zz
zz
z Hang the channels and frame onto the screws
and tighten up.
Note. If the clearances above and below the
boiler are less than the length of the pipes it
will be necessary to position the pipes behind
the wall mounting plate BEFORE the plate is
screwed to the wall.
Showing the use of 'stand-off' channels,
to enable upward pipework.
18
Response FF80 - Installation
INSTALLATION
REAR FLUE OUTLET
15
CUTTING THE FLUE - Wall thicknesses up to 600mm (23 5/8")
1. The flue cut length is
calculated as detailed in Frame
10.
2. Measure from the groove and
mark the tube.
3. To ensure the tube is cut
square, mark the flue all the
way round. using (e.g). a long
straight strip of paper with its
ends overlapped.
4. Cut to length, using the
cardboard support aid.
5. Remove the cardboard support
and any burrs.
For flue lengths greater than 600mm (23 5/8") refer to Frames 30 to 32 Flue Extension Ducts
16
FITTING THE FLUE
1. Attach the clamping/sealing rings to the flue (this prevents the
assembly being pushed right through the hole and causing an
accident).
2. Pass the cut flue through the prepared hole, ensuring that the
groove is uppermost.
3. Pull the flue back to compress the rubber seal and fix in place with
the clamping/sealing rings.
Note.
To facilitate turret fixing or removal do NOT make good the wall.
19
Response FF80 - Installation
INSTALLATION
REAR FLUE OUTLET
18
CONNECTING THE TURRET TO THE BOILER
1. Mate the turret to the flue.
2. Secure the flue turret on top of the
boiler by inserting the open ends of
the turret clamp under the 2 studs
and fixing it in the middle with the
single M5 x 10mm pozi-hex screw
provided.
3. Drill a 3.2mm hole through the flue
via the hole already present in the
turret. Secure the turret to the flue,
using the self tapping screw
provided.
4. Flues over 1 metre long.
Fix the flue support bracket to the
wall, using the wall plug and wood
screw.
• For standard installations use
the short wood screw.
• If the 'stand-off' option is used
secure the support bracket,
using the spacer bracket and
long wood screw.
17
MOUNTING THE BOILER
IMPORTANT. This must not be
omitted.
6. Engage and tighten the 5 pipe
unions.
7. Fix the pressure relief valve
drain pipe to the pressure
relief valve, using the nut and
olive supplied in the hardware
pack.
1. The boiler may be prewired to the loose electrical
connector and secured with the cable clamps. Refer
to Frame 39.
2. Lift the boiler onto the wall mounting frame, locating
it over the tabs at the top of the frame.
3. Lower the boiler into position.
4. Remove plastic plugs and check that 'O' rings are in
position (spare 'O' rings in the hardware pack).
5. Fit the filter to the DHW inlet valve as shown.
20
Response FF80 - Installation
INSTALLATION
19
TERMINAL WALL PLATE
REAR FLUE OUTLET
This plate allows neat concealment and full compression
of the rubber seal. It should be used, where practicable::
a. When the wall is more than 24" thick (to support the
flue weight and prevent movement).
or
b. When the hole has not broken through neatly.
or
c. When the wall face is rough and the rubber seal on its
own would be ineffective.
1. Position the terminal wall plate over the terminal.
2. Drill 4 fixing holes with a 7mm (
1/4") masonry drill.
3. Insert the 4 plastic plugs provided in boiler h/ware pack.
4. Secure the plate with 4 of the No.10 x 2" screws provided
in boiler h/ware pack.
Note. If the terminal is less than 2m (6' 6") above ground level,
an approved terminal guard should be fitted.
Refer to 'Flue Installation', Page 7.
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