Ideal Boilers Classic FF 250 P Datasheet

Classic FF - Propane Installation 1
INSTALLATION
MANUAL
classic
the wall hung boiler
Wall hung, fanned flue,
gas fired boiler
Installers guide to central heating boilers
& SERVICING
Classic FF 250P-275P

2Classic FF - Propane Installation
Table 1 - General Data
To obtain the gas consumption:
a. For l/s divide heat input (kW) by C.V. of the gas (MJ/m3)
b. For ft3/h divide heat input (Btu/h) by C.V. of the gas (Btu/ft3)
GENERAL
Boiler Size FF 250 P FF 260 P FF 275 P
Gas supply connection Rc 1/2 (1/2)
Flow connection 22mm 28mm copper
copper (FEMALE)
Return connection 22mm 28mm copper
copper (FEMALE)
Maximum static water head m (ft.) 30.5 (100)
Minimum static water head m (ft.) 0.45 (1.5)
Electrical supply 230 V ~ 50 Hz Boiler power consumption; 100W
Fuse rating External; 3A Internal; F1A to BS.4265
Water content litre (gal.) 3.65 (0.8) 4.65 (1.0)
Dry Weight
kg (lb) 46.6 (102.8) 52.6 (116.0)
Maximum installation weight kg (lb) 37.4 (82.5) 43.1 (95.0)
Boiler size Height mm (in.) 700 (27.5)
Width mm (in.) 380 (15.0)
Depth mm (in.) 300 (11.8)
Flue duct diameter mm (in.) 100 (4.0)
Boiler Size FF 250 P FF 260 P FF 275 P
Boiler input kW 18.3 20.9 26.7
(Btu/h) (62 500) (71 250) (91 250)
Gas consumption l/s (ft3/h) 0.20 (25.0) 0.22 (28.5) 0.29 (36.5)
Boiler output kW 14.7 16.7 21.4
(Btu/h) (50 000) (57 000) (73 000)
Burner Setting mbar 35.3 35.0 35.0
pressure (HOT) (in.w.g.) (14.1) (14.0) (14.0)
Inlet pressure mbar (in.w.g.) 37.0 (14.8)
Seasonal efficiency (SEDBUK)* [80.0]% [76.8]% [75.7]%
Table 2 - Performance Data
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.
*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.

Classic FF - Propane Installation 3
GENERAL
Classic FF
B.G. Certified - P.I. No. 87 AP 107
Destination Countries: GB and IE
Propane Gas only Appliance type: C12 & C32
Data Badge: on top of the controls support
Key to symbols
IE = Ireland
GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
C12 & 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
up stream of the combustion chamber.
I3P = An appliance designed for use on 3rd Family gas,
Group P only.
Models G.C. Appliance No.
Classic FF 250 P 41 387 07
Classic FF 260 P 41 387 08
Classic FF 275 P 41 387 09
CONTENTS
Air Supply. ..................................................................... 7
Boiler Clearances ......................................................... 5
Boiler Exploded View ................................................ 11
Burner Exploded View .............................................. .35
Control Box Exploded View ..................................... .35
Electrical Connections .............................................. 22
Electrical Regulations ................................................. 7
Extension Ducts - Fitting ........................................... 21
External Control ......................................................... 22
Fault Finding .............................................................. 34
Flue Installation ............................................................ 6
Rear installation ...................................................... 14
Side installation ...................................................... 17
Gas Safety ..................................................................... 4
Gas Supply ................................................................... 6
Health & Safety Document .......................................... 4
Initial lighting . ............................................................ 25
Installation .................................................................. 11
Mandatory Requirements ............................................ 4
Pump ............................................................................. 8
Servicing ..................................................................... 27
Short List of Parts ...................................................... 36
Spares Replacement .................................................. 29
System Diagrams ....................................................... 23
Terminal Guards. .......................................................... 6
Water and Systems ...................................................... 8
Water Treatment ........................................................... 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.
BENCHMARK LOG BOOK DETAILS
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

4Classic FF - Propane Installation
INTRODUCTION
The Classic FF250-275 Propane is a range of automatically
fully controlled, wall mounted, balanced flue, fanned gas boilers.
The heat exchanger is cast iron. The boiler casing is of white
enamelled mild steel.
The boiler casing has a removable controls pod containing a
drop-down door. The boiler thermostat is located behind the
drop- down door.
Note.
These boilers cannot be used on systems which
include gravity circulation.
If gravity circulation is required the Classic RS range of boilers
is suitable.
See Frame 1 for details of the correct boiler tappings to use.
The boilers are supplied with a standard flue kit suitable for rear or
side outlet applications from 114 mm (4 1/2") to 600 mm (23 1/2").
The boilers are suitable for connection to the following
open vented or sealed systems:
zFully pumped CH and indirect DHW
zPumped heating only.
zPumped indirect DHW only.
OPTIONAL EXTRA KITS
Downward Piping Kit
Programmer Kit.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS.5482 Domestic butane and propane burning appliances
BS.6891 Low pressure installation pipes.
BS.6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS.5449 Forced circulation hot water systems.
BS.5546 Installation of gas hot water supplies for domestic
purposes (2nd and 3rd Family Gases).
BS.5440.1 Flues for gas appliances of rated input not
exceeding 60 kW.
BS.5440.2 Ventilation for gas appliances of rated input not
exceeding 60 kW.
BS.7593 Treatment of water in domestic hot water central
heating systems.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
Manufacturer’s notes must NOT be taken in any way as
overriding statutory obligations.
IMPORTANT. These appliances are certificated by the British
Standards Institution for safety and performance. It is, therefore,
important that no external control devices, e.g. flue dampers,
economisers etc., are directly connected to these appliances -unless
covered by these ‘Installation and Servicing’ instructions or otherwise
recommended by Caradon 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.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation panels
which can cause irritation to the skin. No asbestos, mercury or CFCs
are included in any part of this boiler.
GENERAL
Vertex Flue Kit. For vertical flue connection
Roof Flue Kit.
90° Flue Elbow
Turret Kit
Sealed System Unit. Fits on top of the appliance.
Extension ducts. Up to 3 m (118").
Current Gas Safety (Installation and Use)
Regulations or rules in force.
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.
LOCATION OF BOILER
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment.
The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary - unless
required by the local authority. The boiler must not be fitted
outside.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should be
fitted in accordance with the Institute of Gas Engineering
document IG/UP/7:1998.
Bathrooms
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,

Classic FF - Propane Installation 5
1 BOILER WATER CONNECTIONS
GENERAL
This appliance in NOT suitable for use in a direct
hot water system or for gravity circulation.
FF 275P boiler ONLY
must be fitted with the 22mm x 28mm copper sockets,
provided in the Hardware Pack (or equivalent 22mm x
28mm compression fittings), and the pumped flow and
return pipes run in 28mm pipe.
2 BOILER CLEARANCES
The following minimum clearances
must be maintained for operation and
servicing
Additional space will be required for
installation, depending upon site
conditions.
Side and Rear Flue
a. Provided that the flue hole is cut
accurately, e.g. with a core drill, the
flue can be installed from inside the
building.
Installation from inside ONLY
b. If a core boring tool is to be used
inside the building; the space in
which the boiler is to be installed
must be at least wide enough to
accommodate the tool.
c. If using the Complete Sealed
System Unit then refer to the
instructions packed with the unit for
the necessary clearances.
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.
Front clearance: 533mm (17 3/4")
from the front of the boiler casing.
Minimum front clearance when
built in to cupboard is 75 mm (3").

6Classic FF - Propane Installation
GENERAL
Terminal Position Minimum Spacing
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")
Table 3 - Balanced flue terminal position
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 (Model K1)
Telephone No. 01732 351 555
Ensure that the guard is fitted centrally.
5. Where the terminal is fitted within 1000mm (39 1/2") of a
plastic 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.
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.
Where installation will be in an unusual location, special
procedures may be necessary and BS.6798 gives detailed
guidance on this aspect.
Compartment Installations
A compartment used to enclose the boiler should be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided it is
modified for the purpose.
In both cases details of essential features of cupboards/
compartment design, including airing cupboard installation, are to
conform to the following :
zBS. 6798.
zThe position selected for installation MUST allow adequate
space for servicing in front of the boiler and for air circulation
around the boiler, see section on 'Air Supply'.
zFor the minimum clearances required for safety and
subsequent service, see the Wall mounting diagram, Frame
2. In addition, sufficient space may be required to allow lifting
access to the wall mounting plate.
GAS SUPPLY
A local propane supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas.
Installation pipes, cylinders and pressure regulators MUST be fitted
in accordance with BS. 5482.1.
Pipework from the supply to the boiler MUST be of an adequate
size.
Bulk tank installations must comply with the Home Office code of
practice for the storage of liquefied petroleum gas at fixed
installations.
The complete installation MUST be tested for gas soundness and
purged as described in the above code.
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.
7. Where it is essential that the terminal wall plate is fitted, i.e.
wall thicknesses over 600mm (23 1/2") or with an inaccurately
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.
TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses, refer to Frame 10 'Unpacking'.

Classic FF - Propane Installation 7
GENERAL
AIR SUPPLY
Detailed recommendations for air supply are given in BS.5440:2.
The following notes are for general guidance:
1. It is NOT necessary to have a purpose provided air vent in the
room or internal space in which the boiler is installed.
2. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for cooling purposes) in the
cupboard/compartment, at both high and low levels. The air vents
must either communicate with room/internal space, or be direct
to outside air. The minimum effective areas of the permanent
air vents, required in the cupboard/compartment, are specified
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.
Refer to Table 4 for details of air vent position and sizing.
Table 4 - High and low vent areas
Boiler Air from room/internal Air direct
space cm2(in2) outside cm2(in2)
FF 250 P 170 (26) 83 (13)
FF 260 P 198 (31) 102 (16)
FF 275 P 264 (41) 132 (21)
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 [phone] or
Betz Dearborn Ltd, Widnes, Cheshire, tel. [phone]
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
WARNING. The 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.
WATER CIRCULATION SYSTEM
The boiler must NOT be used for direct hot water supply. For the
types of system and correct piping procedure refer to 'Introduction'
and Frame 1.
The central heating system should be in accordance with BS. 6798
and, in addition, for Smallbore and Microbore systems, BS. 5449.
The domestic hot water system, if applicable, should be in
accordance with the relevant recommendations of BS. 5546. Copper
tubing to BS. 2871:1 is recommended for water carrying pipework.
The hot water storage cylinder MUST be of the indirect type and
should preferably be manufactured of copper.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating, nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated under floor spaces.
The boiler must be vented (not on sealed system).
IMPORTANT
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler and
hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879.
The boiler is fitted with a special drain plug which is provided to
drain the BOILER ONLY in the event of the system drain plug
being unable to do so. The hydraulic resistances of the boilers, at
MAXIMUM OUTPUT with an 11oC (20OF) temperature differential,
are shown in Table 5.
Maximum boiler operating temperature should be 82 oC (180 oF).
Table 5 - Water flow rate and pressure loss
Boiler Size FF 250 P FF 260 P FF 275 P
Boiler kW 14.7 16.7 21.4
Output Btu/h 50 000 57 000 73 000
Water Flow l/min 19.0 22.8 30.3
Rate gal/h 250 300 400
Pressure mbar 31.5 41.7 77.0
Loss in w.g. 12.6 16.7 30.9

8Classic FF - Propane Installation
GENERAL
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.
Note.
A cold water feed must be available back to the boiler,
when all automatic valves are in the closed position (Refer
BS. 6798) and when close coupled the feed must not be in
a vertical leg.
Minimum Requirements
3 OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED.
System
return
Connections
to boiler Inverted cold
feed entry
System
flow to
pump
150 (6")
Max
15mm
Cold
feed
450 (18")
Mimimum
450 (18")
Mimimum
22mm
Open vent
Feed / expansion
cistern
Water
level
(cold)
Surge
arrester
75 (3)
Min.
450
(18)
Min. 200
(8)
Min.
Highest
point of
flow or
return
150
(6)
Max
Max. practical
length
To pump
Cold
water
level
Feed / expansion
cistern
75 (3) Min.
Flow
Return 22 (3/4)
Open vent
The Classic range of boilers can be installed in
low head situations by fitting a 'surge arrester'
in the expansion pipe as shown.
The following conditions MUST be observed:
1. The surge arrester must be at least 42mm
in diameter x 150mm long, thus ensuring a
MINIMUM air gap and a MINIMUM depth of
water below the static water level (cold) of
75mm.
2. The static water level (cold) must be at least
200mm above the top of the horizontal flow
pipe, fitted as shown. The vent connection
MUST NOT be made immediately off the
top of the boiler, as venting is made less
efficient.
3. The maximum practical length of 15mm
cold feed pipe should be used in order to
reduce the effective volume of system water
expanding into the feed/expansion cistern to
a minimum.
Note. The pump manufacturers minimum
requirements must be complied with. All dimensions in mm (in.). NB. Imperial dimensions are approximate.
4 LOW HEAD INSTALLATIONS

Classic FF - Propane Installation 9
Note.
The method of filling, refilling, topping up or flushing sealed
primary hot water circuits from the mains via a temporary hose
connection is only allowed if acceptable to the local water
authority.
1. General
a. The installation must comply with the requirements of
BS.6798 and BS.5449.
b. The installation should be designed to work with flow
temperatures of up to 82oC.
c. All components of the system, including the heat
exchanger of the indirect cylinder, must be suitable for a
working pressure of 3 bar (45 lb/in2) and temperature of
110oC. Care should be taken in making all connections
so that the risk of leakage is minimised.
2. Safety Valve
A spring loaded safety valve complying with the relevant
requirements of BS.6759 must be fitted in the flow pipe, as
close to the boiler as possible and with no intervening valve
or restriction. The valve should have the following features:
a. A non-adjustable pre-set lift pressure not exceeding 3 bar
(45 lb./in2)
b. A manual testing device.
c. Provision for connection of a discharge pipe. The valve or
discharge pipe should be positioned so that the discharge
of water or steam cannot create a hazard to the
occupants of the premises or cause damage to electrical
components and wiring.
3. Pressure Gauge
A pressure gauge covering at least the range 0-4 bar (0-60
lb./in2) must be fitted to the system. The gauge should be
easily seen from the filling point and should preferably be
connected at the same point as the expansion vessel.
4. Expansion Vessel
a. A diaphragm type expansion vessel must be connected at
a point close to the inlet side of the pump, the connecting
pipe being not less than 15mm (1/2" nominal) size and not
incorporating valves of any sort.
b. The vessel capacity must be adequate to accept the
expansion of the system water when heated to 110oC
(230oF)
c. The charge pressure must not be less than the static
water head above the vessel The pressure attained in the
system when heated to 110oC (230oF) should be at least
0.35 bar (5lb/in2) less than the lift pressure of the safety
valve.
For guidance on vessel sizing refer to the table in Frame 6.
For further details refer to BS.5449 and the British Gas
Corporation publication : Material and Installation
Specifications for Domestic Central Heating & Hot Water.
5. Cylinder
The cylinder must be either of the indirect coil type or a direct
cylinder fitted with an immersion calorifier which is suitable
for operating on a gauge pressure of 0.35 bar (5lb./in2) in
excess of the safety valve setting. Single feed indirect
cylinders are not suitable for sealed systems.
6. Make-up Water
Provision must be made for replacing water loss from the
system, either:
a. From a manually fitted make-up vessel with a readily
visible water level. The vessel should be mounted at least
150mm (6") above the highest point of the system and be
connected through a non-return valve to the system, fitted
at least 300mm (12") below the make-up vessel on the
return side of the domestic hot water cylinder or radiators.
b. Where access to a make-up vessel would be difficult by
pre-pressurisation of the system. Refer to 'Filling.'
5 SEALED SYSTEM REQUIREMENTS
Make-up vessel
(max. capacity
3 litres)
Hose
union
bib
tap
Non-return
valve
Air vent
Water
supply
Pressure gauge Automatic
air vent
Safety valve
Drain cock
BOILER Expansion
vessel
Pump
Hose
connector
HEATING
CIRCUIT Hosepipe
(disconnect
after filling)
BS.1010:2
stop tap
Test cock
Double check valve
cla1787
GENERAL

10 Classic FF - Propane Installation
6 SEALED SYSTEM REQUIREMENTS - cont.
Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less
than that given by the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).
Safety valve setting 3.0 bar 2.5 bar 2.0 bar
Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0
system pressure bar bar bar bar bar bar bar bar
Total water content of system Expansion vessel volume
(litres) (litres)
25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0
50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0
75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0
100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0
125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0
150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0
175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0
200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0
225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0
250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0
275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0
300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0
Multiplying factors for
other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20
7. Mains Connection
There must be no direct connection to the mains water supply
or to the water storage tank supplying domestic water, even
through a non-return valve, without the approval of the local
water authority.
8. Filling
The system may be filled by one of the following methods:
a. Through a cistern, used for no other purposes, via a ball
valve permanently connected directly to a service pipe
and / or a cold water distributing pipe.
The static head available from the cistern should be
adequate to provide the desired initial system design
pressure. The cold feed pipe from the cistern should
include a non-return valve and a stop valve with an
automatic air vent connected between them, the stop
valve being located between the system and the
automatic air vent. The stop valve may remain open
during normal operation of the system if automatic water
make-up is required.
b. Through a self-contained unit comprising a cistern,
pressure booster pump (if required) and, if necessary, an
automatic pressure reducing valve and flow restrictor.
The cistern should be supplied through a temporary
connection from a service pipe or cold water distributing
pipe.
This unit may remain permanently connected to the
heating system to provide limited automatic water make-
up. Where the temporary connection is supplied from a
service pipe or distributing pipe which also supplies other
draw-off points at a lower level then a double check valve
shall be installed upstream of the draw-off point.
c. Through a temporary hose connection from a draw-off tap
supplied from a service pipe under mains pressure. Where
the mains pressure is excessive a pressure-reducing valve
shall be used to facilitate filling.
The following fittings shall form a permanent part of the
system and shall be fitted in the order stated:
A stop valve complying with the requirements of
BS. 1010, Part 2 (the hose from the draw-off tap shall be
connected to this fitting).
A test cock.
A double check valve of an approved type.
• Thoroughly flush out the whole of the system with cold
water, without the pump in position.
• With the pump fitted, fill and vent the system until the
pressure gauge registers 1.5 bar (21.5lb/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 the system.
GENERAL

Classic FF - Propane Installation 11
INSTALLATION
7
BOILER ASSEMBLY - Exploded view
Classic FF 30 shown
LEGEND
1A. Heat exchanger.
2. Flue baffles.
3. Tie rods.
4A. Pumped flow pipe.
5A. Pumped return pipe.
6. Collector hood assembly.
7. Combustion chamber.
12. Main burner.
19. Control box .
24. Pressure switch.
30. Fan.
40. Wall mounting plate.
44B. Programmer (optional).
52. Back panel.
INSTALLATION

12 Classic FF - Propane Installation
INSTALLATION
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.
Pack B Contents
zDuct cutting support, 1 off
(cardboard )
zTerminal wall plate, 1 off.
zTerminal grille assy, 1 off.
zPolyurethane foam seal 400 lg., 1 off.
zNo. 8 x 8 lg. Pozi pan hd. screws, 3 off.
8 UNPACKING
Pack A Contents
zThe complete boiler
zInstallation & Servicing Instructions
zUser's Instructions
zHardware Pack (listed below)
zWall mounting template
zWall mounting plate
zSide outlet terminal mounting plate
zFlue extension tube, 1 off
zBoiler sealing ring, 1 off
Wall mounting plate
Hardware Pack Contents
z50mm x No. 14 wood screw, 4 off
z50mm x No. 10 wood screw, 8 off
zWall plug , 12 off
zData badge indicator arrow, 1 off
zM8 washer, 1 off
z22mm x 28mm copper reducing socket
(FF 275 P ONLY), 2 off
zM5 wing nut, 3 off
zSealing plate, 1 off
zM8 x 12 lg. screw, 1 off
INSTALLATION

Classic FF - Propane Installation 13
INSTALLATION
9 PACKAGING AND CASING REMOVAL
SIDE FLUE
INSTALLATION
REAR FLUE
INSTALLATION
Flue length
for rear
Flue length for side
Jacking screw for
boiler alignment
It is MOST important that the boiler is installed in a
vertical position. 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 3 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.
(a) Casing retaining
screws, 2 off
Packing base
Controls pod casing
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
support protection frame to ease handling and
installation.
4. Unpack the boiler terminal box and, if applicable,
the extension flue box(es)
10 DETERMINING THE FLUE LENGTH
Flue length mm Accessories Product No.
Up to 600 B Pack 1 off 150308
600 to 1550 B Pack 1 off + D Pack, 1 off 150308+153883
1550 to 2500 B Pack 1 off + D Pack, 2 off 150308+
153883, 2 off
2500 to 3000 B Pack 1 off + D Pack, 3 off 150308+
153883, 3 off
Note.
Vertex and roof flue kits are available as optional
extras for vertical flue installation, supplied with
separate fitting instructions.
INSTALLATION

14 Classic FF - Propane Installation
INSTALLATION
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.
12 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
5. Remove the templates from the wall.
Note. Check all of the hole
positions BEFORE drilling
11 FLUE ASSEMBLY - Exploded View
2. When cutting the
ducts, always use
the cardboard
support rings
provided.
1. An optional flue
duct extension kit
is required for
wall thicknesses
greater than
600mm (23 1/2")
Refer to Frame
10.
LEGEND
1. Terminal.
2. Weather seal.
3. Flue assembly.
4. Boiler sealing ring.
5. Flue extension tube.
13 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 (5/16")
masonry drill. If the stand-off brackets are used ensure the
correct holes are chosen.
3. Insert the plastic plugs provided.
REAR FLUE OUTLET

Classic FF - Propane Installation 15
INSTALLATION
14 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.
1. Fit the boiler sealing ring inside the outer flue duct. Ensure
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.
15 FITTING BOILER SEALING RING TO THE FLUE
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.
1. Insert the flue extension tube into the flue assembly.
2. Insert the flue assembly through the hole sufficiently far
enough to allow the rubber seal to unfold completely
and form an adequate seal on the outside wall.
3. Ensure the notch is at the top. This will aid the location
of the studs into the boiler back panel.
1. Fix the mounting plate to the wall with the No.14 x 50mm
wood screws.
2. If the down ward 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.
3. Check with a spirit level that the plate is vertical.
16 FITTING THE FLUE ASSEMBLY
17 WALL MOUNTING PLATE
REAR FLUE OUTLET

16 Classic FF - Propane Installation
INSTALLATION
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.
19 CONNECTING THE FLUE TO THE BOILER
20 TERMINAL WALL PLATE
18 MOUNTING 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
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.
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 (9/32") masonry
drill.
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 3.
REAR FLUE OUTLET

Classic FF - Propane Installation 17
INSTALLATION
21 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 10.
2. When cutting the ducts
always use the cardboard
support provided.
3. Flue assembly.
4. Boiler sealing plate.
5. Flue extension tube.
LEGEND
1. Terminal.
2. Weather seal.
22 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 in 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.
Extended centre
line
Terminal
mounting
plate screw
and flue
duct hole
positions
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.
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.
23 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
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 (5/16") masonry drill and insert the plastic
plugs provided, for the wall mounting plate.
3. Drill 4 holes with an 7mm (9/32") masonry drill and insert the plastic
plugs provided, for the side mounting plate .
3. Ensure squareness by hanging a plumb line as shown.
4. Mark onto the wall (if required) the following:
a. The four 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.
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).
SIDE FLUE OUTLET

18 Classic FF - Propane Installation
INSTALLATION
For flue lengths greater than 600mm refer
to Frames 34 & 35 - Flue extension ducts.
Flue assembly
1. Insert the flue assembly through the hole sufficiently 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.
26 FITTING BOILER SEALING RING
TO THE FLUE
1. Fit the boiler sealing ring inside the outer flue duct.
Ensure 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 (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.
25 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.
24 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 11.
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 support , and cut to length.
5. Remove cardboard support and remove any burrs.
27 FITTING THE FLUE ASSEMBLY
SIDE FLUE OUTLET

Classic FF - Propane Installation 19
INSTALLATION
28 FITTING THE SIDE OUTLET PLATES
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. 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.
29 WALL MOUNTING PLATE
1. Fix the mounting plate to the wall with the No.14 x 50mm
wood screws.
2. If the 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.
30 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.
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.
SIDE FLUE OUTLET

20 Classic FF - Propane Installation
INSTALLATION
33 FLUE EXTENSION DUCTS - For flue lengths greater than 600mm
PACK D Flue extension duct kit contents
31 CONNECTING THE FLUE TO THE BOILER
32 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 (9/32") masonry drill.
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 3.
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.
REAR & SIDE FLUE OUTLET