Halstead BFF40, BFF50, BFF60 Instructions For Use Installation And Servicing

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2000225095B.10.02

Balanced Fanned Flue Boiler

This is a Cat I2H Appliance

Reference in these instructions to British Standards and Statutory

Regulations/Requirements apply only to the United Kingdom.

For Ireland the rules in force must be used.

The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration

Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety

(Installation and Use) Regulations, be handed to the user on completion of the installation.

To be left with the user

Instructions for Use

Installation and Servicing

9706

Model: BFF40

G.C. No. 41-333-88

Model: BFF50

G.C. No. 41-333-89

Model: BFF60

G.C. No. 41-333-90

Halstead Boilers Limited, 20/22 First Avenue, Bluebridge Industrial Estate, Halstead, Essex CO9 2EX

Tel: 01787 272800. Sales Direct Line: 01787 475557. Fax: 01787 474588. Service Helpline: 01926 834834.

e-mail: sales@halsteadboilers.co.uk or service@halsteadboilers.co.uk Website: www.halsteadboilers.co.uk

2000225095B

TESTING AND CERTIFICATION

This boiler is tested and certificated for for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Halstead Boilers Ltd.

Any alteration not approved by Halstead Boilers Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.3.

CE MARK

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels.

Type test for purposes of Regulation 5 certified by: Notified body 0086. Product/production certified by: Notified body 0086. The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health.

Ceramic fibre/Insulation Pads, Glassyarn

These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe irritation to the skin seek medical attention.

SPARE PARTS

REMEMBER, when replacing a 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 Halstead Boilers Ltd.

MANUAL HANDLING GUIDANCE

During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance whilst lifting as the appliance or component exceeds the recommended weight for a one man lift.

In certain situations it may be required to use a mechanical handling aid. Take care to avoid trip hazards, slippery or wet surfaces.

Important Information

Introduction 3 Lighting the Boiler 4

General Data 1 5 Water Systems 2 8 Flue and Ventilation 3 9 Installation 4 10 Electrical Wiring 5 17 Commissioning 6 18 Instructions to User 7 20

Servicing 8 20 Fault Finding 9 23 Replacement Parts 10 26 Spare Parts 11 28

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

SERVICING

INSTRUCTIONS

2000225095B

Instructions for Use

Introduction

Please read these instructions and follow them carefully for the safe and economical use of your boiler.

The Halstead Buckingham 4 BFF series are balanced fanned flue boilers. They provide heating and if required, an indirect domestic hot water supply.

The boiler is automatic in operation, having only one user control, the boiler temperature control.

Gas Safety (Installation and Use) Regulations

In your own interests and that of safety, it is the law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations.

WARNINGS

Gas Leak or Fault

If a gas leak fault exists or is suspected the boiler must be turned off, including the electrical supply and must not be used until the fault has been put right. Advice/help should be obtained from the local gas undertaking or your installation/ servicing company.

Clearances

Make sure that nothing obstructs the ventilation grills or clearances.

Minimum clearances must be left around the boiler as shown in diagrams 1.6, 1.7 & 1.8.

Sheet Metal Parts

This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.

Cleaning

Keep the casing clean by wiping it occasionally with a damp soapy cloth and dry with a polishing cloth.

Do not use abrasive cleaners.

Boilers Installed in a Compartment

If the boiler is fitted in a compartment, cupboard etc., do not obstruct the purpose built compartment vents or the grill on the boiler.

Do not use the compartment for storage purposes.

Maintenance

To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough.

It is the law that servicing must be carried out by a competent person.

If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section

35. To obtain service please call your installer or Halstead Boilers

Ltd. using the telephone number given on the inside of the front panel.

Please be advised that the ‘Benchmark’ logbook should be completed by the installation engineer on completion of commissioning and servicing.

All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Logbook. You can check your installer is CORGI registered by calling CORGI direct on :- 01256 372300.

Boiler Electrical Supply

THIS BOILER MUST BE EARTHED. The boiler must only be connected to a 230V~50Hz supply

protected by a 3A fuse, maximum. All wiring must be in accordance with the current issue of

BS7671. Heat resistant flexible cable having a conductor size of 0.75mm

to the current issue of BS6500 Table 16 must be used.

To Connect an Electrical Plug

The standard colours of three core flexible cable are, Brown - live, Blue - neutral, Green and Yellow - earth. As the markings on your plug may not correspond with these

colours, continue as follows: The Blue cable must be connected to the terminal marked “N”

or “Black”. The Brown cable must be connected to the terminal marked “L”

or “Red”. The Green and yellow cable must be connected to the terminal

marked “E” or “Green” or the earth symbol

Protection Against Freezing

If the boiler is to be out of use for any period of time during severe weather conditions we recommend the whole system, including the boiler, be drained off to avoid the risk of freezing up. If an immersion heater is fitted to the hot water cylinder make sure it is switched off.

2000225095B

To Turn the Appliance On

Turn the electrical supply on to the boiler and check that all remote controls are calling for heat.

Turn the boiler temperature control clockwise to any position between “0” and "Max", see diagram 1.

"Max" is approximately 82°C (180°F). The boiler lighting operation is now automatic as follows: The fan operates and after a short period of time, the spark

ignition operates, the solenoid opens, then the burner will light shown by the burner ON neon (green) on the control panel lighting up.

The burner will remain alight until switched off by the control thermostat or any remote control.

Note: If the boiler is turned OFF at the boiler temperature control, wait at least 30 seconds before switching on again.

When the boiler switches off, the burner will go out. The automatic lighting sequence will operate again when heat

is required. It should be noted that this is a fanned flue appliance and fan

operation may be heard. If the reset neon lights, turn the boiler temperature control to "0"

(off), wait 30 seconds, then repeat the lighting instructions.

To Turn the Appliance Off

For short periods, turn the boiler temperature control fully anticlockwise to “0” (off).

To relight, turn the boiler temperature control to any position between “0” and “Max”.

For longer periods, turn the boiler temperature control fully anticlockwise to “0” (off) and switch off the electrical supply to the boiler.

To relight follow the lighting sequence given above.

Instructions for Use

Diagram 1

BOILER TEMPERATURE CONTROL

10169

"BURNER ON" NEON

RESET NEON

"OFF" POSITION

2000225095B

1 General Data

Important Notice

This boiler is for use only on G20 gas. The boiler is delivered in one pack and the flue pack is supplied

separately. Wherever possible, all materials, appliances and components to

be used shall comply with the requirements of applicable British Standards.

Where no British Standard exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship.

Refer to Manual Handling Operations, 1992 Regulations.

Sheet Metal Parts

WARNING. When installing or servicing this boiler, care should

be taken to avoid any possibility of personal injury when handling the edges of sheet metal parts.

1.1 Technical Data

See diagrams 1.1, 1.2, 1.3 & 1.4 All dimensions are given in millimetres (except as noted)

Approximate weight of complete boiler : 84kg (185lb) Water content : 5.76 litre (1.27gallons) Gas connection : Rc

/2 (1/2in BSPT)

Water connection : Rc1 (1in BSPT) Electrical supply : 230V~50Hz, fused 3A Burner : Aeromatic

A B C D E F G H J K L M

300 700 558 294 384 555 442 3 Max 900/ 300 108 32

Min 860

GENERAL DIMENSIONS - given in millimetres

Diagram 1.1

9707

WATER CONNECTIONS

Rc1 (1in. B.S.P.T.)

WATER CONNECTIONS Rc1 reduced with DISTRIBUTOR TUBE to Rc

(

in. B.S.P.T.) (pumped return)

GAS CONNECTION

(

in. B.S.P.T.)

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is 'D' BFF40 = 78.3%, BFF50 = 78.2% & BFF60 = 78.5%.

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 B.S.I.

1.2 Range Rating

See diagrams 1.2, 1.3 & 1.4 for boiler ratings.

NOTE: The boiler casing can be

set at two heights, MAX. and MIN.

Diagram 1.2

10166

2000225095B

1.3 Statutory Requirements

The installation of this appliance must be carried out by a competent person and must be in accordance with the relevant requirements of the current issue of:

Manufacturer’s instructions supplied. The Gas Safety (Installation and Use) Regulations, Building

Regulations, Local Water Company Bye-laws, The Building Standards (Scotland) Regulations, (applicable in Scotland), Health and Safety at Work Act, Control of Substances Hazardous to Health, Electricity at Work Regulations and any applicable local regulations.

Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice,

BS6891, BS5440 Part 1 and 2, BS6798, BS5449, BS5546, BS6700, BS7478, BS7593, BS7671.

Manufacturer’s instructions must not be taken as overriding statutory requirements.

1.4 B.S.I Certification

This boiler is certificated by B.S.I., for safety and performance. It is, therefore, important that no alteration is made to the boiler unless agreed, in writing, by Halstead Boilers Ltd.

Any alteration not approved by Halstead Boilers Ltd., could invalidate the B.S.I. certification, boiler warranty and could infringe the current issue of the Statutory Requirements.

1.5 Gas Supply

The gas installation should be fitted in accordance with the current issue of BS6891.

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

On completion test the gas installation using the pressure drop method and suitable leak detection fluid, purge in accordance with the current issue of BS6891.

1.6 Electrical

WARNING. This boiler must be earthed.

The electrical installation must be carried out by a competent person. All external components shall be of the approved type and shall be connected in accordance with the current issue of BS7671 and any local regulations which apply.

Connection of the boiler and any system controls to the mains supply through an unswitched shuttered socket outlet and 3A fused 3 pin plug, both to the current issue of BS1363. Alternatively, a 3A fused double pole isolating switch may be used, having a minimum double pole contact separation of 3mm, serving only the boiler and system controls.

Heat resistant cable of at least 0.75mm

(24/0.20mm), to the current issue of BS6500 Table 16, must be used for all connections within the boiler casing, to the control box, pump etc.

BOILER CASING HEIGHT(S)

Diagram 1.5

BOILER CASING ALTERNATIVE HEIGHT POSITIONS

MIN.

MAX.

To floor level

FLOOR LEVEL

9710

1 General Data

MAX.900 MIN. 860

Diagram 1.3

Diagram 1.4

10168

10167

2000225095B

1 General Data

1.7 Boiler Location

This boiler is not suitable for outside installation. The boiler casing can be fitted at two heights. Refer to

diagram 1.5. The boiler is assembled at the factory with the control box and

heat shield fitted in the lower position. The boiler must stand on a level floor, conforming with local

authority requirements and building regulations. The base temperature is within the requirements of the current issue of BS5258. The boiler may stand on a wooden floor but a metal base plate is required to protect plastic tiles and similar floor coverings.

Suitable installation clearance needs to be available at the sides of the boiler to facilitate direct connection of pipework and making good around the flue assembly. The actual clearance required will vary with site conditions.

When the boiler is to be installed level with work surfaces and the like, minimum clearances should be provided as shown in diagram 1.6. Work tops which overhang the cupboard sides, almost in contact with the casing top, require a larger minimum air gap. Flush sided fixtures require the same overall minimum space but can have a reduced air gap on one side.

Boilers to be installed under work tops or fixtures, should be positioned to provide minimum clearances as shown in diagram

1.7. To facilitate minimum clearances it may be necessary to modify kitchen units and fixtures.

A front access clearance for servicing of 700mm, should be provided from a permanent wall or fixture.

The boiler may be installed in a cupboard, refer to minimum ventilation and clearances as shown in diagram 1.8.

If the boiler is to be installed in a cupboard or compartment, make sure that nothing will obstruct the openings/vents in the compartment.

A compartment used to enclose the boiler must be designed and constructed specifically for this purpose. An existing cupboard or compartment modified for the purpose may be used. Details of essential features of cupboard or compartment design are given in the current issue of BS6798.

The boiler may be installed in any room, although particular attention is drawn to the requirements of BS7671 with respect to the installation of a boiler in a room containing a bath or shower. Any electrical switch should be so positioned that it cannot be touched by a person using the bath or shower. The electrical provisions of the Building Standards (Scotland) Regulations apply to such installations in Scotland.

Where the installation of the boiler will be in an unusual location, special procedures are necessary the current issue of BS6798 gives detailed guidance on this aspect.

1.8 Heating System Controls

The heating system should have installed: a programmer and room thermostat controlling the boiler.

Thermostatic radiator valves may be installed, however they must not be fitted in a room where the room thermostat is located.

Note: For further information, see the current issue of the Building Regulations, approved document L1, and the references:

1) GIL 59, 2000: Central heating system specification (CheSS) and

2) GPG 302, 2001: Controls for domestic central heating system and hot water. BRECSU.

Diagram 1.6

Diagram 1.7

MINIMUM CLEARANCES LEVEL WITH WORKTOP

MINIMUM CLEARANCES UNDER WORKTOP, FIXTURES

9711

320 MIN.

CUPBOARDS

WORKTOP

9712

CUPBOARD

WORKTOP OR FIXTURE

BOILER

CUPBOARD MINIMUM VENTILATION & CLEARANCE

Diagram 1.8

11626

DOOR

205cm2 FREE AREA FOR VENTILATION

NOTE : A clearance of 10mm is required between the front of the boiler and fitted door.

Ventillation slots in the front of the boiler must be kept clear.

The free area for ventilation must not be reduced if a grille is fitted.

2000225095B

Diagram 2.2

FULLY PUMPED SYSTEM (DIAGRAMMATIC)

2 Water Systems

0870

1 metre MIN. 27metres MAX.

PUMP

Heating Circuit

TO INDIRECT CYLINDER

22mm VENT

15mm COLD FEED

Distributor tube in pumped return connection

BOILER C

DRAIN OFF COCK

2.1 Water Pressure Head

The boiler shall only be connected to a cistern water supply with a minimum head of 1metre (3ft3in) and a maximum head of 27metres (90ft) which has an open vent in the system.

The working pressure must be within the range 0.1bar to 2.7bar (1.3 to 39lbftin

The boiler MUST NOT be connected to a sealed water system.

2.2 Inhibitor

Attention is drawn to the current issue of BS5449 and BS7593 on the use of inhibitors in central heating systems.

If an inhibitor is to be used in the system, contact should be made with the inhibitor manufacturers so that they can recommend their most suitable product.

When using in an existing system take special care to drain the entire system, including the radiators, then thoroughly clean out before fitting the boiler whether or not adding an inhibitor.

2.3 Gravity Domestic and Pumped Heating

It is recommended that a cylinder thermostat is used to prevent the stored water temperature becoming unnecessarily high when the central heating pump is off.

The domestic primary flow and return must be 28mm o.d. The installation must comply with the current issue of BS5546 and BS6700, see diagram 2.1.

If the above conditions cannot be met, it is suggested that a fully pumped system be used.

2.4 Pumped Heating and Hot Water

Where a single flow and return is taken from the boiler, a minimum static head of 1metre (3ft3in) must be provided between the water line of the feed tank and the centre of the waterway, see diagram 2.2.

2.5 Circulation Pump

Normally the pump should be set to give a temperature difference of 11

C (20oF) across the boiler. At the appropriate pumped flow rate the pressure loss through the boiler can be found from the graph, diagram 2.3.

Use a pump with integral valves or fit isolating valves as close to the pump as possible.

2.6. Cylinder

For all systems supplying domestic hot water the cylinder must be indirect.

2.7 Safety Valve

A safety valve need not be fitted to an open vented system.

2.8 Draining Tap

A draining tap must be provided at the lowest points of the system which will allow the draining of the entire system, including the boiler and hot water cylinder.

Draining taps should be to the current issue of BS2879.

2.9 Thermostatic Radiator Valves

If thermostatic radiator valves are fitted care must be taken to ensure that there is an adequate flow rate through the boiler when they close, refer to the current issue of BS7478 for guidance. If fitted to all radiators ensure a bypass is fitted and adjust to achieve a temperature difference no greater than 20oC between flow and return with the thermostatic valves closed.

Diagram 2.1

0869

27metres Max.

PUMP

Heating Circuit

INDIRECT CYLINDER (Shown with recommended thermostat and valve).

22mm VENT

15mm COLD FEED

REFER TO BS 5546

28mm

Distributor tube in pumped return connection

BOILER C

DRAIN OFF COCK

Diagram 2.3

0872

600 500 400 300 200 100

8 4 0

812

16 20 24 28

FLOW RATE (LITRES/MINUTE)

WATER PRESSURE LOSS

(mm HEAD OF WATER)

WATER PRESSURE LOSS

(INCHES HEAD OF WATER)

800

32 28

700

0123456

FLOW RATE (GALLON/MINUTE)

2000225095B

3 Flue and Ventilation

FROM OUTSIDE

COMPARTMENT AIR VENT TABLE

COMPARTMENT VENTILATION REQUIREMENTS

VENTILATION FROM ROOM OR SPACE

BFF40 130cm2 20in2 130cm2 20in

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

The flue must be installed in accordance with the rules in force in the countries of destination.

3.1 Terminal Position

The minimum acceptable siting dimensions for the terminal from obstruction, other terminals and ventilation openings are shown in diagram 3.1.

The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

BFF50 162cm2 26in2 162cm2 26in

BFF60 188cm2 29in2 188cm2 29in

BFF40 65cm2 10in2 65cm2 10in

BFF50 81cm2 13in2 81cm2 13in

BFF60 94cm2 15in2 94cm2 15in

Car ports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if it is made of plastic sheeting. If the car port consists of a roof and two or more walls, seek advice from the local gas company before installing the boiler.

If the terminal is fitted within 600mm below plastic guttering or painted soffit an aluminium shield 1500mm long should be fitted immediately beneath the guttering or eaves. If the terminal is fitted within 450mm below painted eaves or a painted gutter, an aluminium shield 750mm long should be fitted immediately beneath the guttering or eaves.

3.2 Timber Frame Buildings

If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from the local gas undertaking or Halstead Boilers Ltd.

3.3 Terminal Guard

A terminal guard is required if persons come into contact with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal.

A suitable guard, reference Type “K3”, can be obtained from:

Tower Flue Components Ltd., Morley Road, Tonbridge, Kent. TN9 1RA

3.4 Room Ventilation

The boiler is room sealed and does not require the room or space containing it to have permanent air vents.

3.5 Ventilation for Boilers Installed in a Cupboard

For minimum ventilation and clearances for cupboard installation refer to section 1.7 and diagram 1.8.

3.6 Compartment Ventilation

Where the boiler is fitted in a compartment, the high and low level permanent air vents must have effective areas, see “Compartment Air Vent Table” .

Both the high and level air vents must communicate with the same room or must both be on the same wall to outside air.

MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION MM

HORIZONTAL FLUES

A DIRECTLY BELOW, ABOVE OR

HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOW, AIR VENT, OR ANY

OTHER VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 25 C BELOW EAVES 25 D BELOW A BALCONY OR CAR PORT 25 E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 25 F FROM INTERNAL/EXTERNAL CORNERS

OR TO A BOUNDARY ALONGSIDE THE

TERMINAL 25 G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300 H FROM SURFACE OR A BOUNDARY

FACING THE TERMINAL 600 I FACING TERMINALS 1200 J FROM OPENING (DOOR/WINDOW)

IN CAR PORT INTO DWELLING 1200 K VERTICAL FROM A TERMINAL 1500 L HORIZONTALLY FROM A TERMINAL 300

Diagram 3.1

B,C

UNDER CAR PORT etc.

H,I

11508

2000225095B

Diagram 4.2

General Installation Notes

The appliance pack contains :-

Boiler. Fan connector. Casing panels, packed seperately.

Loose items fittings pack, see list in pack. The flue is supplied seperately. NOTE: The rear flue option kit Part. No. 425861 is available,

which consists of wall cover plates, for replacement Buckingham balanced flue appliances.

Before installation of the boiler make sure that the location selected is in accordance with the requirements of Section 1.7.

4.1 Unpacking

The boiler casing panels are packed separately within the main carton and are designed to enable gas and water connections to be made before fitting the casing panels.

The casing brackets, flue restrictor, distributor tube and other loose items, are in the fittings pack.

NOTE:

To make a neat finish to the flue outlet a flue collar kit, part No. 900850, with instructions, is available, see diagram 4.4.

If required an optional wall liner kit, part no. 900862, is available complete with instructions.

All flue assemblies are designed for internal installation. Make sure that the ductings do not slope down towards the

boiler.

Diagram 4.1

9867

9868

4.2 Flue Position and Length

Select the boiler location, with due regard to the flue length and terminal position, see diagrams 3.1 and 4.1.

For a wall thickness up to 300mm, provided that the optional wall liner kit is used, the flue can be fully installed from the inside.

For a wall thickness of over 300mm the external flue hole will need to be made good from the outside, this also applies if you use the flue kit without the optional wall liner kit, irrespective of wall thickness.

4 Installation

REAR STD.

REAR 75 95 510

MINIMUM

WALL

THICKNESS

MINIMUM

FLUE

LENGTH

MAXIMUM

FLUE

LENGTH

FLUE

PACKS

NOTE :

IF IT IS NECESSARY TO CUT THE DUCTS TO ACHIEVE THE "FLUE LENGTH" MAKE SURE THAT THE OVERLAPS ARE AS FOLLOWS :THE OVERLAP FOR AIR DUCT = 25mm THE OVERLAP FOR FLUE DUCT = 50mm

FLUE & AIR DUCT LENGTH = A + 15 + 3

10062

300

700

Ø115

FRONT VIEW

BOILER OUTLINE

* INCREASE TO 30mm IF A FLUE COLLAR IS ADDED

2000225095B

4.3 Flue Hole Cutting

Mark out the flue centre, see diagram 4.2, then cut a hole for the flue using, preferably, a 115mm minimum core drill.

4.4 Rear Flue Option Kit -

425861 (if applicable)

Fit the wall cover plates as descibed in the instructions supplied with the kit.

4.5 Flue Preparation

Note: If the flue collar kit, see diagram 4.4, is to be used

increase the 15mm projection to 30mm. Extend the telescopic flue to the required length, making sure

that the minimum overlap is no less than 25mm, and that the flue terminal projects 15mm minimum beyond wall face, see diagram

4.1. If it is necessary to cut the flue ensure that the overlap is as

stated in diagram 4.1. Carefully drill though air duct pilot hole and secure with self

tapping screw provided in fittings pack, see diagram 4.3. Seal the joint with the tape provided. Note: Should any one of the flue sections require cutting to

obtain desired flue system length make sure that the overlaps are as follows:-

The overlap for air duct = 25mm The overlap for flue duct = 50mm. Take the terminal restrictor and position the clamping bracket

making sure the clamping bracket nib protrudes in the slot of the terminal restrictor and secure with locking screw, but do not tighten, see diagram 4.5.

Engage the terminal restrictor on the flue terminal by hooking it over the terminal end and engaging the clamping bracket behind the inner ring of the terminal securing it by tightening the locking screw, see diagram 4.5.

9869

SCREW (4)

SPIGOT

GASKET

FLUE

BAYONET CONNECTION

Diagram 4.4

7148

OPTIONAL FLUE COLLAR

4 Installation

Diagram 4.3

Diagram 4.5

7323

RESTRICTOR

CLAMPING BRACKET

CLAMPING BRACKET NIB

FLUE TERMINAL

LOCKING SCREW

TERMINAL RESTRICTOR SHOWN FITTED

STANDARD 510mm REAR

7332

SCREW AND TAPE

Fit the self adhesive foam seal provided in the flue pack around the air duct at the position shown in diagram 4.1.

Make sure that the ductings do not slope down towards the boiler.

Make good around the flue outside after installation of the boiler. Important: If the wall liner kit is used, the self adhesive foam seal

included in the wall liner kit must be used in place of the one supplied with the flue pack, see diagram 4.6 for position of self adhesive seal.

Push the flue assembly into and through the hole such that it is within the wall, and does not stick out into the room. Do not push the flue assembly too far into the hole as it has to be pulled back into the boiler and secured.

If the boiler is not to be fitted for some time cover the hole in the wall.

2000225095B

Diagram 4.7

WATER CONNECTIONS - GRAVITY DOMESTIC, PUMPED HEATING

ALTERNATIVE HEATING RETURN With distributor tube (not shown)

ALTERNATIVE HEATING OR DOMESTIC HOT WATER FLOW

GRAVITY DOMESTIC RETURN TO ANY OF THE 3 REMAINING LOWER CONNECTIONS

9859

4.6 Water Connections - Gravity Domestic and Pumped Heating

Fit suitable fittings into the boiler tappings, see diagram 4.7. Make sure that all pipes are taken backwards and will clear the

casings, see diagram 1.1. Heating flow: Any one of the four upper connections may be

used. Domestic flow: Any one of the three remaining upper connections

may be used. Heating return: The water distributor tube must be fitted into

either of the front lower connections on all installations, see diagram 4.8. This tube is in the fittings pack.

Domestic return: Any one of the three remaining lower connections may be used for the gravity domestic hot water return.

Fit plugs into any unused boiler tappings.

4.7 Water Connections - Fully Pumped Systems

Fit suitable fittings into the boiler tappings as required, see diagram 4.9. Make sure that all pipes are taken backwards and will clear the casings.

It is important that all connections are made as shown in diagram 4.9.

Fit the water distributor tube into the return connection, see diagram 4.8. This tube is in the fittings pack.

Fit plugs into any unused boiler tappings.

4 Installation

Diagram 4.6

FOAM SEAL

WALL THICKNESSOVER 300mm

15mm

WALL THICKNESSUP TO 300mm

Q-35mm

7331

WITH WALL LINER KIT ONLY

DISTRIBUTOR TUBE

Diagram 4.8

0871

MARKERS

DISTRIBUTOR TUBE MUST BE IN PUMPED RETURN CONNECTION

Notch on DISTRIBUTOR must lie within the shaded area, BETWEEN TWO MARKERS

Diagram 4.9

WATER CONNECTIONS FULLY PUMPED SYSTEMS

9859

ALTERNATIVE FLOW POSITIONS

ALTERNATIVE RETURN POSITIONS With distributor tube (not shown)

2000225095B

CASING BRACKETS FITTING

Diagram 4.13

9858

FRONT CASING BRACKET

No.8 SCREW (4)

CAPTIVE NUT

UPPER CASING BRACKET

CAPTIVE NUT

4.8 Pipework

When the front tappings are used, it is essential that any pipework or fittings do not project more than shown in diagram

4.10. When using a rear tapping with Rc (1in BSP) fitting for 28mm od

pipework, it is recommended that a short nipple and an Rc thread (BSP) to copper elbow is used. If the pipework is required to run back to the wall, make sure that it will clear the boiler air duct and, if working to minimum clearance, does not project too far from the boiler, see diagram 4.11.

Do not route any pipework, water or gas, across the front of the combustion chamber cover.

The gas pipework must be along the left hand side of the boiler.

4 Installation

No.8 SCREW (4)

4.9 Casing Brackets

Loosen the side insulation blankets by removing the securing bracket, see diagram 4.12 and fit the two upper and two front casing brackets shown in diagram 4.13, using the No.8 screws provided.

NOTE: The screws will already be fitted. Ensure insulation blankets are replaced as before and secure

as diagram 4.12. Push the captive nuts, supplied loose, on to the casing brackets

as shown in diagram 4.13.

Diagram 4.10

PIPEWORK CASING CLEARANCES

Diagram 4.11

REAR CONNECTION PIPEWORK (28mm)

9861

FOR MINIMUM CLEARANCE

9860

Diagram 4.12

SCREW (2)

SECURING BRACKET

INSULATION BLANKET

2000225095B

4.10 Side In-fill Panel (If required)

A side in-fill panel is supplied with the boiler, which can be fitted at the rear of the left or right hand side casing but can be discarded if the water connections are made on both sides of the boiler or if the boiler is screened by fixtures. The in-fill panel will usually be fitted on the side where there are no pipework connections.

Insert the push fit plastic location peg, supplied, through the infill panel and side casing holes and secure with the spring clips, see diagram 4.14.

NOTE

The boiler is assembled at the factory with the control box and heat shield fitted in the lower casing height position.

Diagram 4.14

Diagram 4.16

SCREW

SIDE CASING (R.H. SHOWN)

9863

SIDE CASINGS FITTING

Diagram 4.15

MAX.

SIDE CASING (R.H.)

MIN.

BOILER PLINTH

FRONT CASING BRACKET

No. 8 SCREW (4)

LOCATING SLOTS

4 Installation

UPPER CASING BRACKET

4.11 Side Casings

Fit the side casings by locating their lugs into the appropriate slot in the boiler plinth, see diagram 4.15, depending on the required height, there are two options, see section 1.7.

Secure the casing sides to the front and rear upper casing brackets with self-tapping screws supplied, see diagrams 4.15 and 4.16.

PLASTIC PEG

SPRING CLIP

SIDE CASING (R.H.SHOWN)

UPPER VIEW

LOWER VIEW

SPRING CLIP

SIDE CASING (R.H. SHOWN)

IN-FILL PANEL

2000225095B

4 Installation

Diagram 4.17

0886

WING NUT

SELF TAPPING SCREWS (3)

Diagram 4.18

TOGGLE LATCHES

FAN ACCESS DOOR

4.12 Flue / Boiler Connection

Remove the three self-tapping screws from the lower part of the control box support bracket, see diagram 4.17.

Undo the wing nut that secures the top of the heat shield and carefully hinge down control box and heat shield, see diagram

4.17. Release the two toggle latches that secure the fan access door

and remove, see diagram 4.18. Remove the electrical connections from the fan by pulling the

insulation boots only and disconnect the two silicone tubes from the fan and air pressure switch taking note of their positions, see diagram 4.19.

Remove the fan assembly from the flue hood by removing the securing screw, pull forward and lift up to release the 3 hooked securing lugs underneath the fan, see diagram 4.20.

From the flue pack take the flue spigot,the gasket is supplied in the fittings pack.

Connect the flue spigot and gasket to the rear flue outlet of the boiler using the self tapping screws provided, see diagram 4.3.

IMPORTANT. With regards to the Manual Handling Operations, 1992 Regulations, the following operation, exceeds the recommended weight for one man lift.

Place the boiler in position taking care not to damage the casing panels.

With access to the flue system through the boiler, pull the flue on to the spigot bayonet connection, twist anti-clockwise to lock into position.

Take the flue duct extension from the boiler and slide on to the fan duct until it will go no further, see diagram 4.21.

Fit fan and engage the flue duct extension into the flue duct, secure fan, replace electrical connections and silicone tubes.

The polarity of the electrical connections is not important. Make sure that the air pressure tubes are fitted as before, see

diagram 4.19 and that the fan duct engages fully into the flue duct extension piece.

(3) SELF TAPPING SCREWS (for height adjustment only)

"LOW" position

"HIGH" position

"LOW" position

"HIGH" position

Diagram 4.19

AIR PRESSURE TUBE (RED)

AIR PRESSURE SWITCH

ELECTRICAL CONNECTORS

AIR PRESSURE TUBE (CLEAR)

FAN SECURING SCREW

11340

2000225095B

4.13 Water & Gas connections

Replace fan access door, heat shield and control box. Note: When replacing the fan access door make sure the lip at

the top of door fits into and behind the slotted bracket located at the top of the boiler.

As there are two casing height options, the control box height and the heat shield may have to be adjusted to suit your requirements.

Complete the water connections to the boiler. Fill, vent and flush the system. Check for any water leaks and put right. Make the gas connection to the service cock, at the lower left

hand side of the boiler, see diagram 1.1. The whole of the gas installation, including the meter, should be

inspected, tested for soundness and purged in accordance with the current issue of BS6891.

4.14 Top Casing

Refer to diagram 4.22 Fit two plastic pegs, one on each side, in the holes on the top

casing. The plastic pegs are a tight fit and are best pushed home with a flat faced tool.

Secure fron of top casing with screws provided.

4 Installation

Diagram 4.22

TOP CASING

9865

SCREW (2)

PLASTIC PEG (2)

Diagram 4.21

10069

Diagram 4.20

FLUE DUCT EXTENSION PIECE

FAN

SECURING LUGS

2000225095B

5 Electrical Wiring

MAINS INLET CONNECTOR

Diagram 5.2

CABLE CLAMP SCREW

5.1 Control Box Access

Remove control box cover by undoing the four securing screws (two on control box, two on the heat shield) and lift off, see diagram 5.1.

5.2 Electrical Connections

WARNING. This boiler must be earthed.

Take care not to damage any internal wiring. Using heat resistant (85oC) cable of at least 0.75mm2 (24/

0.2mm) and of a suitable length, route as shown in diagram 5.3. Thread through the grommet at the bottom rear of the control box, through the cable clamp and connect to appropriate terminals. Tighten cable clamp screws, see diagram 5.2.

Standard colours are, brown - live (L), blue - neutral (N) and green/yellow - earth

The mains cable outer insulation must not be cut back external to the cable clamp.

Make sure the cable is suitably secured. When making connections make sure that the earth conductor

is made of a greater length than the current carrying conductors, so that if the cable is strained the earth conductor would be the last to become disconnected.

5.3 Pump Connection

The pump must be connected to the external controls.

5.4 Testing - Electrical

Checks to ensure electrical safety must be carried out by a competent person.

After installation of the system, preliminary electrical system checks as below should be carried out.

1. Test insulation resistance to earth.

2. Test earth continuity and short circuit of all cables.

3. Test the polarity of the mains. The installer is requested to advise and give guidance to the

user of the controls scheme used with the boiler. Replace the control box cover.

Diagram 5.3

CABLE CLAMP

CONTROL BOX COVER

CONTROL BOX

SECURING SCREWS

BOILER TEMPERATURE CONTROL

Diagram 5.1

9905

CABLE CLIPS

HEAT RESISTANT CABLE

TERMINAL BLOCK CONNECTIONS

TERMINAL BLOCK

2000225095B

6 Commissioning

IMPORTANT NOTE

The WARNING NOTICE attached to the front casing

must only

be removed by the user Please ensure the “Benchmark” logbook is completed and left

with the user, and the magnetic lighting instruction label is placed on the surface of the boiler casing.

6.1 All Systems

Commissioning should be carried out by a competent person in accordance with the current issue of BS6798.

UNDER ALL CIRCUMTANCES the case must be correctly fitted and sealed, unless fault finding.

Make sure that the system has been thoroughly flushed out with cold water without the pump in place.

Refit the pump, fill the system with water, ensuring that all the air is properly vented from the system and pump.

6.2 Initial Lighting and Testing

CAUTION. This work must be carried out by a competent

person, in accordance with the current issue of BS6798. Make sure that all naked lights and cigarettes are extinguished. Refer to ‘Instructions for Use’ and identify the controls. Check that the boiler is isolated from the electrical supply. Turn the gas service cock “On” , see diagram 6.1. Purge in accordance with the current issue of BS6891. WARNING. The multifunctional control and fan operate on

mains voltage, terminals will become live. If programmer control is fitted, make sure it is in the ON mode. Make sure that any remote controls are calling for heat. Turn the boiler temperature control clockwise to “Max”.

Diagram 6.1

BOILER COMPONENTS

10052

A CONTROL BOX B PHIAL POCKET C GAS SERVICE COCK D "BURNER ON" NEON E RESET NEON F TEMPERATURE CONTROL G BURNER PRESSURE TEST POINT H GAS PRESSURE ADJUSTMENT SCREW J DATA LABEL

The ignition system will operate to light the boiler. After a pre- set time if ignition has not taken place the boiler will shutdown.

To re-start the lighting sequence, turn the boiler temperature control to “O”, then fully clockwise to “Max”.

"Max" is approximately 82°C (180°F). After the burner has lit, the “Burner on” neon on the control panel

will come on. Isolate the boiler from the electrical supply. Loosen the burner pressure test point screw and connect a

suitable pressure gauge, see diagram 6.1. Switch on the electrical supply to the boiler. WARNING. The multifunctional control and fan operate on

mains voltage, terminals will become live.

6.3 Testing - Electrical

Turn the boiler temperature control fully clockwise to the maximum setting.

The lighting sequence is automatic as follows: The fan operates and after a short period of time, the spark

ignition operates, the solenoid opens, then the burner will light shown by the “Burner On” neon on the control panel lighting up.

The burner will remain alight until switched off, either by the boiler temperature control, programmer (if fitted) or any remote system control.

To make sure that the flame supervision device is working correctly the following should be done.

With the burner alight, turn the gas service cock “Off”, see diagram 6.1.

After a short period the burner will go out. The correct working of the flame supervision is shown by the

“Burner On” neon going out and the ignition sequence starting up.

2000225095B

6 Commissioning

After a short period the boiler will shut down. If the lighting sequence descibed fails, refer to fault finding

section 9. To carry on turn the gas service cock “On”, see diagram 6.1. To re-start the lighting sequence, turn the burner temperature

control to “0” then fully clockwise to “Max.”. During normal operation when the boiler switches “Off”, the

burner will go out. The automatic lighting sequence will work again when heat is required.

If the reset neon lights, turn the boiler temperature control to "0" (off), wait 30 seconds, then repeat the lighting instructions.

6.4 Testing - Gas

With the boiler on proceed as follows: Test for gas soundness around the boiler gas components

using a suitable leak detection fluid, in accordance with the current issue of BS6891.

Check the burner gas pressure at least 10 minutes after boiler has lit, refer to Data Label, see diagrams 1.2, 1.3 & 1.4.

If necessary adjust the gas pressure to obtain the required setting turning screw clockwise, to decrease pressure, see diagram 6.1.

Should any doubt exist about the gas rate, check it using the gas meter test dial and stop watch at least 10 minutes after the burner has lit, making sure that all other gas burning appliances and pilot lights are off.

The gas rates: Buckingham 4 BFF40 : 1.7m

/h (49ft3/h)

Buckingham 4 BFF50 : 2.1m

/h (60ft3/h)

Buckingham 4 BFF60 : 2.5m

/h (70ft3/h)

are for guidance only, dependent on the heat setting. Turn the boiler temperature control fully anti-clockwise to “0”. Isolate from the electrical supply. Remove the pressure gauge from the test point and refit screw,

making sure a gas tight seal is made. When the boiler temperature control is turned to the “0” position,

by hand, wait at least 30 seconds before turning On again. There may be an initial smell given off from the boiler when new,

this is quite normal and it will disappear after a short period of time.

6.5 Testing - All Water Systems

Allow the system to reach maximum working temperature and examine for water leaks.

There should be no undue noise in the system. The boiler should then be turned off and the system drained off

as rapidly as possible,whilst still hot. Refill system.

6.6 Open Vented System

Ensure there is no pumping over of water or entry of air at the open vent above the feed and expansion cistern.

6.7 Adjustment - Fully Pumped Open Vented System

When commissioning the system the boiler should first be fired on full service, that is, central heating and domestic hot water. Adjust the pump to the system design setting, then balance the system, making adjustments as necessary.

Diagram 6.2

LOCATING STUDS

LOCATE UNDER LIP

FRONT PANEL

Diagram 6.3

FRONT PANEL SECURING SCREWS

BOTTOM PLINTH PANEL

SECURING SCREWS

6.8 Completion

Adjust the boiler temperature control and any system controls to their required settings.

Fit the bottom plinth panel and secure with two dog point screws, see diagram 6.2.

Finally fit the front panel by hooking under front of top panel locating on the two studs and securing at the bottom on to the bottom plinth panel with two screws, see diagram 6.3.

11621

2000225095B

7 Instructions to the User

Instruct and demonstrate the safe and efficient operation of the boiler, heating system and domestic hot water system. Advise the user, that to ensure the continued efficient and safe operation of the boiler, it is recommended that it is checked and

serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough.

Draw attention, if applicable to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance.

It is the Law that servicing is carried out by a competent person. Advise the user of the precautions necessary to prevent damage to the system and building in the event of the heating system being

out of use during frost and freezing conditions. Reminder - Leave these instructions and the “Benchmark” logbook with the user.

REMEMBER, When replacing a 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 Halstead Boilers Ltd.

Products of Combustion Check

Note: To obtain a products of combustion reading, remove the front panel and remove the control box as descibed in the relevant paragraphs of section 4.12. Next, remove the cap from the sampling point, located on the top of the left hand side of the inner casing, see diagram 8.1.

Connect the analyser tube on to the nipple. WARNING. The multifunctional control and fan operate on

mains voltage, terminals will become live. Switch on the electrical supply and gas supply then operate the

boiler. On completion of the test switch off the electrical supply and gas

supply, remove analyser tube and replace sampling point cap.

Servicing

Before servicing turn off the gas and isolate the electrical supply to the boiler.

After completing a service always test for gas soundness, make electrical checks and carry out functional check on controls.

Unless stated otherwise all parts are replaced in the reverse order to removal.

8.1 Access

Remove the boiler front casing panel, refer to paragraph 6.8 . Remove the bottom plinth panel by unscrewing the two dog

point screws securing the panel to the boiler plinth, see diagram

8.4. Disconnect gas valve from gas cock and unplug electrical plug

from gas valve, firstly removing electrical plug securing screw, see diagram 8.2.

Unclip electrical wires from control box support bracket, see diagram 8.3.

Undo the self-tapping screws that secure the insulation blanket bracket and combustion chamber front and carefully remove together with the burner and gas valve assembly, taking care not to strain the ignition and earth leads, see diagram 8.5.

Note: When replacing burner in combustion chamber make sure it fits correctly on the guides and the insulation blanket bracket are replaced as diagram 8.5.

Diagram 8.2

GAS SERVICE COCK UNION

ELECTRICAL PLUG

Diagram 8.1

SAMPLE POINT

SECURING SCREW

8 Servicing

Disconnect the ignition and earth leads from the burner and remove by drawing the leads though the grommet, see diagram

8.6. Remove the three self-tapping screws from the lower part of the

control box support bracket, see diagram 8.7. Undo the wing nut that secures the top of the heat shield and

carefully hinge down control box and heat shield, see diagram

8.7. Release the two toggle latches that secure the fan access door

and remove, see diagram 8.8.

2000225095B

Diagram 8.5

8 Servicing

Note: When replacing the fan access door make sure the lip at the top of door fits into and behind the slotted bracket located at the top of the boiler.

Remove the electrical connections from the fan by pulling the insulation boots only, see diagram 8.8.

Disconnect the silicone tubes from the fan and air pressure switch taking note of their positions.

Remove the fan and flue hood by sliding back to disengage the retaining lugs then lift up,see diagram 8.8.

When replacing the flue hood ensure that it rests on the guides and that the rear of flue hood is located under the pegs at the rear and pushed down and back fully.

IMPORTANT: When re-fitting fan check that it fits fully into the flue duct extension piece.

COMBUSTION CHAMBER COVER

IGNITION AND EARTH LEADS

GROMMET

Diagram 8.7

0886

WING NUT

SELF TAPPING SCREWS (3)

Diagram 8.3

ELECTRICAL WIRE RETAINING CLIPS

CONTROL BOX SUPPORT BRACKET

Diagram 8.4

BOTTOM PLINTH PANEL

SECURING SCREWS

Diagram 8.6

11621

11690

IGNITION AND EARTH LEADS

INSULATION BLANKET

BRACKET

SECURING SCREW

2000225095B

8.3 Burner and Injector

Remove the two screws and nuts securing the burner support bracket to the combustion chamber cover, see diagram 8.10.

Remove the graphite coated nuts on the supply feed pipe at the rear of the burner to release the burner, see diagram 8.11.

Clean the burner. Use a vacuum cleaner or suitable stiff brush (not wire) to clean the burner thoroughly, making sure that all the burner ports are clear and unobstructed.

Check the burner injector for blockage or damage and replace if necessary, see diagram 8.12.

With the burner removed the injector can be inspected and cleaned as necessary.

For cleaning do not use a wire or sharp instrument on the hole. If removed, use a little suitable sealant on the external thread

when refitting to make sure a gas tight seal is made.

8.4 Service Checks

Inspect the spark electrode and clean and replace as necessary, see diagram 8.13.

Check the condition of the side and rear insulation panels in the combustion chamber.

Check the condition of the seals on the boiler access door and the combustion chamber cover.

Examine the flue hood and terminal to make sure they are clean and clear of obstructions.

Refit all parts. Light the boiler and carry out functional tests as described in

section 6.

MAIN BURNER

GRAPHITE COATED NUT(2)

SUPPLY FEED PIPE

Diagram 8.11

Diagram 8.10

BURNER SUPPORT BRACKET

SCREWS & NUTS (2)

8.2 Boiler Flueways

Remove flueway baffles noting that there are 1 centre and 2 side flueway baffles, see diagram 8.8.

Place a sheet of paper in the combustion chamber to catch any flue debris.

Thoroughly clean boiler flueways and fins with a suitable stiff brush.

Replace in reverse order, after completing the relevant instructions in sections 8.3 and 8.4.

Diagram 8.9

CENTRE FLUEWAY BAFFLE

HEAT EXCHANGER

8 Servicing

SIDE FLUEWAY BAFFLE

HEAT EXCHANGER

TOGGLE LATCHES

FAN

Diagram 8.8

FLUE HOOD

SECURING SCREW

2000225095B

8 Servicing

Diagram 8.13

ELECTRODE

SECURING SCREW

SPARK GAP = 3.6 1.1

Diagram 8.12

BURNER INJECTOR

GRAPHITE COATED NUT(2)

0939

IMPORTANT. On completion of the Fault Finding task which has required the breaking and remaking of the electrical connections, the continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.

WARNING. The multifunctional control and fan operate on mains voltage, the terminal will be live.

9 Fault Finding

Diagram 9.1

ELECTRICAL FAULT FINDING

9917

Check for 230V ac between N and common contact on air pressure switch.

With electrical supply isolated remove the fan access door as described in the relevant parts of section 8.1, to gain access to the air pressure switch. Switch on electrical supply Check for 230V ac between N and normally closed contact of air pressure switch.

Is there 230V ac between Ls and N

Ensure that any external controls are calling for heat and circuit water is cold. If neon 6 is lit flame failure has occured. Reset boiler by turning temperature control to Off, waiting 30 seconds and then on.

If fault persists continue with fault finding below.

Before carrying out fault finding, ensure that gas, electricity and water are available at the boiler.

Is neon 1 lit?

Check power supply

Is neon 2 lit?

YES

Faulty thermistor. Replace.

With electrical supply isolated disconnect the 2 way thermistor plug from the PCB. Check that there is a resistance between 14k - 2.5kOhms.

Faulty PCB. Replace.

Is neon 3 lit?

Faulty PCB. Replace.

YES

Faulty air pressure switch. Replace.

Does sparking take place (Listen for spark discharge.)

Faulty PCB. Replace.

Check for 230V ac between N and brown and between N and black, 3 way connector on PCB.

Faulty PCB. Replace.

Check continuity of gas valve harness.

Faulty gas valve. Replace.

Faulty harness. Replace.

YES

Is the fan turning?

YES

Is there 230V ac on fan?

Faulty PCB.

Faulty fan.

Does burner light?

YES

Is neon 4 lit?

YES

Appliance working satisfactorily.

Is integrity of electrode and ignition lead good?

Replace as necessary

Faulty PCB.

YES

2000225095B

FUSE TYPE F4A

AIR PRESSURE SWITCH CONNECTIONS

FAN

EV1

EV2

SPARK ELECTRODE

AIR PRESSURE SWITCH

(N/O)

(C)

(N/C)

KEY

bk BLACK br BROWN b BLUE p PURLPLE

r RED y YELLOW gy GREY

MAIN TERMINAL STRIP CONNECTIONS

PRINTED CIRCUIT BOARD CONNECTIONS

MAINS SUPPLY 230v ~ 50Hz

Diagram 9.3

10084

9.1 Electrical

Gain access to the control box, refer to the relevant paragraph in section 8.1, then remove the control box cover, refer to section 5.1.

Refer to: Boiler Fault Finding, see diagram 9.1, Fault Finding Wiring Diagram, see diagram 9.3, Pictorial Wiring Diagram, see diagram 9.4.

9.2 Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out. Operation will normally resume on the restoration of the electrical supply.

If the burner does not relight after an electrical supply failure and the red neon on the control panel is lit, turn the burner temperature control to “0”, wait 30 seconds, then fully clockwise to “Max.” see diagram 9.2.

Diagram 9.2

BOILER TEMPERATURE CONTROL

0900

9 Fault Finding

2000225095B

9 Fault Finding

Diagram 9.4

BOILER PILOT FAULT FINDING

9866

MAINS SUPPLY 230V~50Hz

= MAINS ON

= DEMAND ON

= FAN RUNNING

= BURNER LIT

= SAFETY TEMPERATURE LIMITER

= FLAME FAILURE

NEON 1 =

NEON 2 =

NEON 3 =

NEON 4 =

NEON 5 =

NEON 6 =

NEON KEY (see P.C.B)

FAN

P. C .B (CONTROL BOARD)

GAS CONTROL VALV E

TERMINAL BLOCK

THERMISTOR

AIR PRESSURE SWITCH

NEON 1 NEON 5

NEON 4

NEON 6

NEON 2

NEON 3

F4A FUSE

bk b

= LIVE (Switched)

g/yg/y

g/y

br BROWN b BLUE g/y GREEN/YELLOW g GREY bk BLACK p PURPLE y YELLOW r RED

KEY

g/y

= NEUTRAL = EARTH MAIN

KEY TO TERMINAL BLOCK

2000225095B

10 Replacement of Parts

IMPORTANT NOTES

Replacement of parts must only be carried out by a competent person.

Before removing or replacing any parts, turn off the gas supply at the gas service cock, see diagram 8.2 and isolate the electrical supply to the appliance.

Unless stated otherwise, all parts are replaced in the reverse order to removal.

After replacing any parts always test for gas soundness and if necessary carry out functional check of controls.

10.1 Electrical Thermistor

Remove front panel to gain access, see section 6.8. Remove control box cover by undoing the four securing screws

(two on control box, two on the heat shield) and lift off, see diagram 10.1.

Remove thermistor lead from retaining clip, located on the control box support bracket, see diagram 8.3.

Release strain relief grommet securing thermistor lead at the side of control box.

Disconnect the thermistor electrical plug from the control board (P.C.B) slightly bending back the retaining latch to allow withdrawal, see diagram 10.2.

Remove the retaining wire and withdraw the electrical thermistor from its phial, see diagram 10.3.

Draw the thermistor lead followed by the thermistor out though the control box case.

Re-assembly note. When fitting the thermistor make sure it is fully inserted into the phial, see diagram 10.3. Take care when re-threading retaining wire so as not to damage thermistor.

10.2 Control Board (P.C.B)

Remove front panel to gain access, see section 6.8. Remove control box lid by undoing the four securing screws

(two on control box, two on the heat shield) and lift off, see diagram 10.1.

CONTROL BOX COVER

CONTROL BOX

SECURING SCREWS

TERMINAL BLOCK

Diagram 10.1

9905

ELECTRICAL PLUGS

Diagram 10.2

PCB

Diagram 10.3

PHIAL POCKET

THERMISTOR

BOILER TEMPERATURE CONTROL

Carefully pull the boiler temperature control knob away from the P.C.B.

Disconnect the electrical plugs from the control board (PCB) slightly bending back the retaining latches to allow withdrawal, see diagram 10.2.

Disconnect the ignition lead. Carefully pull the board away from its supports bending back

slightly the retaining latches. When refitting refer to wiring diagram 9.4. Take care when replacing the burner temperature control knob

by supporting the potentiometer on the P.C.B.

10.3 Electrode

Remove front panel to gain access, see section 6.8. Refer to the relevant paragraphs of the servicing section to

remove the burner from combustion chamber. To remove the electrode, unscrew from the retaining bracket,

see diagram 8.12. Take the electrode out from below and remove the ignition lead. When removing and replacing the electrode take care not to

damage it. When refitting, check spark gap, see diagram 8.12.

10.4 Multifunctional Control

Remove front panel to gain access, see section 6.8. Disconnect the electrical plug, see diagram 10.4. Disconnect the gas cock, on the left hand side. Support the multifunctional control, remove the four screws (2

long, 2 short) from the flanged connection at the right hand side. Remove and discard the original “O” ring from the flanged

connection and fit the new “O” ring supplied, into recess, before fitting the replacement multifunctional control.

After assembly test for gas soundness and purge in accordance with the current issue of BS6891.

2000225095B

10 Replacement of Parts

Diagram 10.6

REAR INSULATION PANEL

SECURING NIB

SIDE INSULATION

Diagram 10.4

GAS SERVICE COCK UNION

ELECTRICAL PLUG

SHORT SCREWS (2)

LONG SCREWS (2)

SOLENOID SECURING SCREW

SOLENOID ASSEMBLY

BURNER SUPPORT BRACKET

NUTS

10.5 Solenoid

Remove front panel to gain access, see section 6.8. Remove the electrical plug from the multifunctional control and

remove the securing screw and then the solenoid assembly, see diagram 10.4.

10.6 Burner

Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber.

10.7 Injector

Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber.

The injector can then be unscrewed from the manifold. When replacing use a little jointing compound on the external

thread only, to ensure a gas tight seal.

10.8 Air Pressure Switch

Remove front panel to gain access, see section 6.8. Refer to the relevant paragraphs of the servicing section to

remove the fan access door. Remove the air pressure tube and electrical connections from

the switch, release the securing screws and remove the switch, see diagram 10.5.

When fitting the replacement make sure that the air pressure tubes are fitted, as shown in diagram 10.5 and the electrical connections are made as shown in wiring diagram 9.4.

10.9 Fan

Remove front panel to gain access, see section 6.8. Refer to the relevant paragraphs of the servicing section to

remove the fan access door. Remove the electrical connections and air pressure tube from

the fan. Note: Remove the electrical connections by pulling insulation

boots only. Undo the screw securing the fan to the flue hood and disengage

fan from flue hood, see diagram 10.5. When re-assembling, make sure that the air pressure tubes are

fitted as before and that the fan duct engages fully into the flue duct extension piece.

The polarity of the electrical connections is not important.

SECURING SCREW

Diagram 10.5

AIR PRESSURE TUBE (RED)

AIR PRESSURE SWITCH

ELECTRICAL CONNECTORS

AIR PRESSURE TUBE (CLEAR)

10.10 Insulation

Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber.

Sides

Undo the burner support bracket nuts and remove support bracket and insulation, see diagram 10.6.

Refit support bracket with new side insulation.

Rear

Bend forward rear insulation securing nibs, one on each side, to release insulation.

Fit new insulation and bend back securing nibs.

SECURING SCREW

2000225095B

Diagram 11.1

11 Spare Parts

9912

11.1 Part Identification

The key number in diagram 11.1 and the first column of the list will help identify the spare part.

11.2 Ordering

When ordering any spare part please quote the part number and the description from the list together with the model name and serial number information from the data label.

The data label is positioned on the heat shield, see diagram 6.1.

1 2000461752 Multifunctional control ****** 2 227131 Fan ****** 3 227070 Air pressure switch BFF40-50 ****** 3 227097 Air pressure switch BFF60 ****** 4 2000461793 Electrical thermistor ****** 5 202635 Spark electrode ****** 6 2000461714 Boiler temperature control knob ****** 7 K7218 Injector - BFF40 ****** 7 205729 Injector - BFF50 ****** 7 2000461837 Injector - BFF60 ****** 8 227098 Fuse ****** 9 227030 Control board ******

10 205658 Burner - BFF40 ****** 10 205655 Burner - BFF50-60 ******

Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

Key No. Part No. Description GC Part No.

Halstead BFF40, BFF50, BFF60 Instructions For Use Installation And Servicing

Specifications and Main Features

Frequently Asked Questions

User Manual