Ideal Boilers Classic LXFF 230 Installation And Servicing Manual
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Ideal Boilers Classic LXFF 230 Installation And Servicing Manual

Wall hung, fanned flued, gas fired boiler
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Summary of Contents for Ideal Boilers Classic LXFF 230

  • Page 2 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...

  • Page 3: Table Of Contents

    GENERAL Classic FF CONTENTS Air Supply..............6 B.G. Certified - P.I. No. 87 AP 107 94 Boiler Clearances ............5 Boiler Exploded View ........... 9 Data Badge: on top of the controls support Burner Exploded View ..........34 Destination Countries: GB and IE Control Box Exploded View ........

  • Page 4: Location Of Boiler

    GENERAL INTRODUCTION BS.6891 Low pressure installation pipes. The Classic FF230-2 100 is a range of automatically fully controlled, BS.6798 Installation of gas fired hot water boilers of rated input wall mounted, balanced flue, fanned gas boilers. not exceeding 60 kW. BS.5449 Forced circulation hot water systems.

  • Page 5: Boiler Clearances

    GENERAL 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.

  • Page 6: Gas Supply

    GENERAL people have access then the terminal MUST be protected by Where a room-sealed appliance is installed in a room containing a a purpose designed guard. The minimum spacing in Table 3, bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated Table 3 - Balanced flue terminal position that it cannot be touched by a person using the bath or shower.

  • Page 7: Water Treatment

    GENERAL Table 5 - Water flow rate and pressure loss 1. It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed. Boiler Size 280 2 100 2. If the boiler is to be installed in a cupboard or compartment, permanent air vents are required (for cooling purposes) in Boiler 8.8 11.7 14.6 17.6 20.5 23.4 29.3...

  • Page 8: Low Head Installations

    GENERAL 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 Feed / expansion should be inverted and MUST be positioned between the 450 (18") cistern Mimimum...
  • Page 9 INSTALLATION BOILER ASSEMBLY - Exploded view Classic FF 230 shown LEGEND 1A. Heat exchanger. Fan. Collector hood assembly. Flue baffles. Wall mounting plate. Combustion chamber. Tie rods. 44B. Programmer (optional). Main burner. 4A. Pumped flow pipe. Back panel. Control box . 5A.
  • Page 10 INSTALLATION UNPACKING Pack A Contents The boiler is supplied fully assembled in Pack A, together with The complete boiler a standard flue assembly for lengths up to 600mm (23 "), Installation & Servicing Instructions rear or side flue outlet, in Pack B. User's Instructions Optional extras, if ordered (Downward Piping Kit, Programmer Hardware Pack (listed below)

  • Page 11: Determining The Flue Length

    INSTALLATION PACKAGING AND CASING REMOVAL 1. Unpack the boiler. (a) Casing retaining 2. Remove the casing as follows and place to one side to screws, 2 off avoid damage. a. Undo the 2 casing retaining screws (a) retaining the casing to the back panel. b.

  • Page 12: Wall Mounting Template

    INSTALLATION FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 600mm (23 ") Refer to Frame 8. 2. When cutting the ducts, always use the cardboard support rings provided. LEGEND 1.

  • Page 13: Fitting The Flue Assembly

    INSTALLATION 12 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.

  • Page 14: Mounting The Boiler

    INSTALLATION 16 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.
  • Page 15 INSTALLATION 19 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 ") Refer to Frame 8.
  • Page 16 INSTALLATION 23 FITTING THE FOAM SEAL 22 CUTTING THE FLUE For flue lengths 114 to 600mm ONLY 1. To determine the position for the foam seal measure the wall thickness and mark it onto the flue, measuring from 1. Measure the flue length required (i.e. the distance from the groove near the terminal.

  • Page 17: Fitting The Side Outlet Plates

    INSTALLATION 26 FITTING THE SIDE OUTLET PLATES 27 WALL MOUNTING PLATE Note. If the boiler is fitted closer than 25mm to the side wall 1. Fix the mounting plate to the wall with the No.14 x 50mm the side outlet plate must be fitted now. wood screws.
  • Page 18 INSTALLATION 29 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.
  • Page 19 INSTALLATION 32 FLUE EXTENSION DUCTS - continued Flue length General arrangement Extension Note. Side flue shown. Extension duct tube 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.

  • Page 20: Electrical Connections

    INSTALLATION 34 GAS CONNECTION 35 WATER CONNECTIONS Refer to 'Gas Supply ', page 6. 1. Remove the plastic plugs from the flow and Refer to Frame 2 for gas inlet service dimensions. return pipes. A minimum pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating.
  • Page 21 INSTALLATION 38 PICTORIAL WIRING LEGEND blue bk black brown yellow white orange violet pink gy grey y/g yellow/green 39 MID POSITION 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.

  • Page 22: Frost Protection

    INSTALLATION 40 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.

  • Page 23: Initial Lighting

    INSTALLATION Gas Installation 42 COMMISSIONING AND TESTING (a) Electrical 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. 1. Checks to ensure electrical safety should be carried out by a competent person.

  • Page 24: Pump

    INSTALLATION 44 INITIAL LIGHTING - continued 19. Swing the control box back into its working position and secure. 20. Remove the boiler casing. 21. Refit the controls support to the boiler casing and tighten the 2 front fixing screws. 22. Refit the complete casing to the boiler.

  • Page 25: Boiler Casing Removal

    SERVICING 47 SCHEDULE d. Clean the heat exchanger. Refer to Frame 50. To ensure the continued safe and efficient operation of the appliance, it is recommended that it is checked at regular e. Clean the main and pilot injectors. Refer to Frame 51. intervals and serviced as necessary.

  • Page 26: Cleaning The Fan Assembly / The Flueways

    SERVICING 50 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.

  • Page 27: Gas Pressure Adjustment

    SERVICING 53 GAS PRESSURE ADJUSTMENT PILOT MAIN BURNER The pilot is factory set to maximum and no further After any servicing, reference should be made to Table 2 adjustment is possible. If, after removing and checking the which quotes details of the rated output with the related injector (as detailed in Frame 58) and ensuring that there is burner setting pressure and the heat input.

  • Page 28: Pilot Burner Replacement

    SERVICING 57 THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and ON/OFF SWITCH REPLACEMENT Refer also to Frame 54. A. Remove the fixing screws B. Swing the control box down into the servicing position. Thermostat control 1. Pull the knob off the shaft. 2.

  • Page 29: Ignition Electrode And Lead Replacement

    SERVICING 59 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.
  • Page 30 SERVICING 62 FAN REPLACEMENT 1. Refer to Frame 54 2. Remove the 2 silicon rubber tubes from the fan sensing points. 3. Disconnect the fan leads. 4a. Rear flue. Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue. 4b.

  • Page 31: Heat Exchanger Replacement

    SERVICING 66 HEAT EXCHANGER REPLACEMENT 7. Remove the thermostat sensors from the pockets on the heat exchanger by removing the M3 screws and plates. Note. Refer to Frame 5 (Boiler assembly - Exploded view) for 8. Slacken 3 turns only the 4 heat exchanger / inter-panel illustration of the procedure detailed below.

  • Page 32: Fault Finding

    FAULT FINDING Check mains supply and fuses. Reset the overheat 'stat. Set control START Check programmer and system 'stat to maximum. Allow the boiler to Check that the mains on neon thermostats are all ON. Check that reach temperature - if the overheat 'I3' is illuminated.

  • Page 33: Short List Of Parts

    When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Key No.

  • Page 34: Burner Assembly - Exploded View

    SHORT LIST OF PARTS 69 BURNER ASSEMBLY - Exploded View 12. Main burner. LEGEND 17. Gas control valve. 10. Burner manifold 13. Main burner injector. 42. Gas service cock. 11. Air box and pilot assembly. 16. Pilot shield. 70 CONTROL BOX - Exploded View LEGEND 19.
  • Page 35 SHORT LIST OF PARTS 71 BOILER CASING ASSEMBLY 72 SHORT PARTS LIST Classic Installation & Servicing...
  • Page 36 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 The code of practice for the installation, system specifiers. commissioning & servicing of central heating systems For details of courses please ring: ....

This manual is also suitable for:

Classic lxff 260Classic lxff 240Classic lxff 270Classic lxff 280Classic lxff 250Classic ff 2 100

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