Halstead CFF80, Buckingham 4 CFF80 Instructions For Use Installation And Servicing

2000225008D.10.02

Chimney 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

9919

Model: CFF80

G.C. No. 41-333-97

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

Tel: [phone]. Sales Direct Line: 01787 475557. Fax: [phone]. Service Helpline: 01926 834834.

e-mail: [e-mail] or [e-mail] Website: www.halsteadboilers.co.uk

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2000225008D

TESTING AND CERTIFICATION

This boiler is tested and certificated 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 & 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

3

2000225008D

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 CFF series are fanned flue boilers
with a chimney flue adapter. 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 1.4, 1.5 & 1.6.

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.

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.

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

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

2

,

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

.

4

2000225008D

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

10191

"BURNER ON"
NEON

RESET
NEON

"OFF"
POSITION

5

2000225008D

1 General Data

Important Notice

This boiler is for use only on G20 gas.
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

Refer to diagrams 1.1, 1.2, 1.3 and 1.4.
All dimensions are given in millimetres (except as noted)

.

Approximate weight of complete boiler : 131.5kg (290lb)
Water content : 5.76 litre (1.27gallons)
Gas connection : Rc

1

/2 (1/2in BSPT)

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

GENERAL DIMENSIONS - given in millimetres

Diagram 1.1

10125

WATER CONNECTIONS

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

WATER CONNECTIONS
Rc1 reduced with
DISTRIBUTOR TUBE to
Rc

3

/

4

(

3

/

4

in. B.S.P.T.)

(pumped return)

GAS CONNECTION

Rc

1

/

2

(

1

/

2

in. B.S.P.T.)

The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is "D" 78.4%.

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, for boiler ratings.

A

C

D

H

B

F

G

E

J

K

L

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

387 145 558 294 364 555 442 3 Max 900/ 300 80 32

Min 860

M

NOTE:
The boiler casing can be set at
two heights, MAX. and MIN.

Diagram 1.2

10188

INSIDE DIAMETER OF
ADAPTER FOR 125mm (5in)
NOMINAL DIAMETER FLUE
TO BS567

*

C

L

*

6

2000225008D

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

2

(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.

1.7 Condensate Drain

A plastic drain pipe may need to be fitted to allow discharge of
condensate to a drain.

Condensate should, if possible, be discharged into the internal
household draining system. If this is not practical, discharge can
be made externally into the household drainage system or a
purpose designed soak away, see section 4.10 for more details.

BOILER CASING HEIGHT(S)

Diagram 1.3

BOILER
CASING
ALTERNATIVE
HEIGHT
POSITIONS

MIN.

MAX.

To
floor
level

FLOOR LEVEL

9922

1 General Data

Diagram 1.4

Diagram 1.5

MINIMUM CLEARANCES
LEVEL WITH WORKTOP

MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES

9923

407 MIN.

407 MIN.

CUPBOARDS

WORKTOP

9924

10

10

10

10

CUPBOARD

CUPBOARD

10

WORKTOP
OR FIXTURE

BOILER

BOILER

5

MAX.900
MIN. 860

25

7

2000225008D

1 General Data

1.8 Boiler Location

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

diagram 1.3.
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 1.4. 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

1.5. 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.

The boiler can be installed within a cupboard, refer to minimum
ventilation and clearances as shown in diagram 1.6.

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.

1.9 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.

CUPBOARD MINIMUM
VENTILATION & CLEARANCE

Diagram 1.6

DOOR

272cm2 FREE AREA
FOR VENTILATION

10mm

10mm

10mm

CUPBOARD CUPBOARD

272cm2 FREE AREA
FOR VENTILATION

IMPORTANT

A CLEARANCE OF 10mm IS REQUIRED BETWEEN THE
FRONT OF THE APPLIANCE AND THE FITTED DOOR.

THE VENTILATION SLOTS ON THE FRONT
OF THE APPLIANCE MUST BE KEPT CLEAR.

THE FREE AREA FOR VENTILATION MUST
NOT BE REDUCED IF A GRILLE IS FITTED.

8

2000225008D

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

L

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

2

).

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

o

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 2.3

1.50

1.25

1.00

0.75

0.50

0.25
0

30

20
10
0

0

6

12 18

24 30 36 42

FLOW RATE (LITRES/MINUTE)

WATER PRESSURE LOSS

(metre HEAD OF WATER)

WATER PRESSURE LOSS

(INCHES HEAD OF WATER)

60

40

2.00

70

50

1.75

0123456789

FLOW RATE (GALLON/MINUTE)

1074

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

L

DRAIN OFF
COCK

9

2000225008D

3 Flue and Ventilation

Important Notes

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

The flue must be in accordance with the current issue of
BS5440 Part 1.

The Chimney Flue Adapter Kit (Pt. No. 2000461993) socket is
designed to take flue pipes to the current issue of BS567. If a
flue pipe to BS715 is to be used, an adapter must be fitted to the
boiler flue socket.

The flue must be at least equivalent to 1m vertical.
The maximum flue length must not exceed 15m vertical.
Due to the Sedbuk D efficiency of the Halstead Buckingham 4

CFF, if the flue length exceeds the following ;

CFF80 - 9m

then provision must be made to ensure that the condensate
products are drained away and that the flue liner is of the
appropriate specification. We would recommend that one of the
following flue liners should be used or an equivalent specification:

Ritevent - Chimflex LW or SB
Selkirk - Selflex TS or TSE
An existing liner must be changed if there is any doubt that it will

not operate safely throughout the life of any new appliance.
A drain point is incorporated on the chimney flue adapter to

which a drain pipe can be connected, refer to section 4.10.

3.1 Flue Guidelines

The flue should be kept as short as possible. Horizontal or very
shallow runs of the flue should be avoided as they encourage
local cooling.

Always choose a flue route which will cause the least cooling of
the flue.

90º elbows should not be used.
The existing flue may not be completely sound. Therefore, to

prevent the possibility of leakage, additional sealing MUST be
carried out between the base of the chimney and the flue liner.

The end of the flue liner at the chimney top must be adequately
sealed and clamped, using proprietary fittings suitable for the
flue liner used, see diagram 3.1.

The flue should, preferably, end above ridge height but at the
least above the eaves of a pitched roof. Use a certificated
terminal.

If the flue is passed through or near any combustible material it
should be installed in accordance with the current issue of
BS5440 Part 1.3. If in doubt seek advice from the local gas
undertaking or Halstead Boilers Ltd.

3.2 Existing Chimney

An existing brick chimney must be thoroughly swept and all
debris cleared away before lining.

Remove any damper or register plate. Alternatively it may be
locked in the fully open position.

A flexible flue liner is preferred but a rigid liner may be used, with
connection to the boiler flue socket made with a short vertical
piece of flexible liner, see diagram 3.2.

The sealing plate also prevents debris falling and gives the flue
better insulation, reducing the possibility of condensation, see
diagram 3.1.

Check the system efficiency before installing the boiler.

Diagram 3.1

3.3 New Chimney

A newly built chimney can be lined with a moisture resistant
lining, such as salt glazed pipe, of an appropriate diameter as
specified in the Building Regulations.

In the case of a salt glazed lined flue, it is recommended that a
short vertical length of flue pipe, preferably flexible metallic be
used. Fix and seal it to the boiler flue socket and make good with
an approved seal.

If a flue and false chimney breast are to be constructed all
openings for pipework to upper floors etc. must be sealed.

If a specially built compartment is constructed for the boiler, it
must conform to the requirements of the current issue of
BS5440 Part 1 and BS5871.

Diagram 3.2

9915

APPROVED
SEAL

FLEXIBLE
LINER

BOILER

RIGID
FLUE
LINER

9914

SEALING AND
CLAMPING
PLATE

AIR
SPACE

150mm (6in) plug of Mineral Wool or similar

SEALING
PLATE

CHIMNEY
FLUE
ADAPTER

CHIMNEY
FLUE
ADAPTER

10

2000225008D

3.4 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.

3.5 Ventilation for Boiler Installed in a Room
or Space

If the boiler is to be installed in a room or space a purpose
designed permanent ventilation opening, to supply air for
combustion, must be provided on an outside wall to external air,
refer to the current issue of BS5440 Part 2 for details.

The opening may be directly into the room or the space
containing the boiler, or an outside wall of an adjacent room or
space which has an internal permanent air vent, of the same
size, into the room or space containing the boiler.

Do not ventilate through a bedroom, bedsitting room, private
garage or a room containing a bath or shower.

When the boiler is installed in a room or internal space already
containing other fuel burning appliances then the air supply of
such appliances must be taken into account.

The ventilation opening areas are given in “Air Vent Table ”. The
figures quoted refer to the minimum acceptable effective area.

3.6 Ventilation for Boilers Installed in a
Compartment

When the boiler is fitted in a compartment, high and low level
purpose designed, permanent openings must be provided to
supply air for combustion and compartment ventilation.

The cupboard containing the boiler must have the door removed
for ventilation reasons.

The air vents must have minimum areas, see “Compartment Air
Vent table". The figures quoted refer to the minimum acceptable
effective area.

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

If air vent grilles are fitted to a cavity wall, the opening through
the wall must be ducted.

Where ventilation air to a compartment is taken from a room or
space, then the room or space must be fitted with a ventilation
opening as specified in “Air Vent Table”.

For information regarding compartment requirements refer to
the appropriate section of the current issue of BS6798.

3.7 Ventilation for Boilers installed in a
Cupboard

For minimum ventilation and clearances for cupboard installation
refer to section 1.8 and diagram 1.6.

3.8 Extract Fans

If an extract fan is fitted in the premises, there is a possibility that
if adequate inlet openings are not provided, spillage of the
products from the boiler could occur.

When openings are fitted in accordance with the current issue
of BS5440 Part 2 and this section, extract fans should not cause
down draught, but where such fan installations are found, a
spillage test must be carried out in accordance with the current
issue of BS5440 Part 1 and any corrective work done.

3 Flue and Installation

FROM
OUTSIDE

COMPARTMENT AIR VENT TABLE

COMPARTMENT
VENTILATION
REQUIREMENTS

VENTILATION
FROM ROOM
OR SPACE

HIGH LEVEL LOW LEVEL

VENT AREA VENT AREA

205cm2 32in2 409cm2 64in

2

103cm

2

16in2 205cm2 32in

2

AIR VENT TABLE

FOR ROOM SPACE INSTALLATIONS

104cm

2

EFFECTIVE AREA OF VENT

16in

2

11

2000225008D

4 Installation

General Installation Notes

The appliance pack contains :-

Boiler.
Casing panels, packed seperately.
Loose items fittings pack, see list in pack.

The chimney flue adapter with flue extension is supplied
seperately.

Before installation of the boiler make sure that the location
selected is in accordance with the requirements of Section 1.8.

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.

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

4.2 Water Connections - Gravity Domestic and
Pumped Heating

Fit suitable fittings into the boiler tappings, see diagram 4.1.
Make sure that all pipes are taken backwards and will clear the

casings.
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 4.2. 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.

4.3 Water Connections - Fully Pumped
Systems

Fit suitable fittings into the boiler tappings as required, see
diagram 4.3. 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 4.3.

Fit the water distributor tube into the return connection, see
diagram 4.2. This tube is packed in the fittings pack.

Fit plugs into any unused boiler tappings.

Diagram 4.1

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

DISTRIBUTOR TUBE

Diagram 4.2

1277

UPPER
MARKER

DISTRIBUTOR
TUBE
must be in pumped
return connection

UPPER MARKER
must lie between the
outer NOTCHES

Diagram 4.3

WATER CONNECTIONS FULLY
PUMPED SYSTEMS

9859

ALTERNATIVE
FLOW
POSITIONS

ALTERNATIVE
RETURN
POSITIONS
With distributor
tube (not shown)

12

2000225008D

CASING BRACKETS FITTING Diagram 4.6

9858

FRONT
CASING
BRACKET

No.8
SCREW
(4)

CAPTIVE
NUT

UPPER CASING
BRACKET

CAPTIVE
NUT

No.8
SCREW
(4)

Diagram 4.4

PIPEWORK CASING
CLEARANCES

Diagram 4.5

REAR CONNECTION
PIPEWORK (28mm)

9861

FOR MINIMUM
CLEARANCE

9860

4.4 Pipework

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

4.4.
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 4.5.

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.

4.5 Casing Brackets

Fit the two upper and two front casing brackets shown in
diagram 4.6, using the No.8 screws provided.

NOTE: The screws will already be fitted.
Push the captive nuts, supplied loose, on to the casing brackets

as shown in diagram 4.6.

4 Installation

9863

SIDE CASINGS FITTING

Diagram 4.7

MAX.

SIDE
CASING
(R.H.)

MIN.

BOILER
PLINTH

FRONT
CASING
BRACKET

No. 8
SCREW
(4)

LOCATING
SLOTS

13

2000225008D

4.6 Side Casings

Fit the side casings by locating their lugs into the appropriate
slot in the boiler plinth, see diagram 4.7, 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 4.7
and 4.8.

Note: If the side in-fill panels are being fitted they should be fitted
at the same time as the side casing, see next section.

4.7 Side In-fill Panel (if required)

The side in-fill panel is supplied with the boiler, which can be
fitted at the rear of the left and 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 4.9.

NOTE

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

4 Installation

Diagram 4.10

0886

WING NUT

SELF
TAPPING
SCREWS
(3)

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

"LOW"
position

"HIGH"
position

"LOW"
position

"HIGH"
position

Diagram 4.9

PLASTIC
PEG

PLASTIC
PEG

SPRING
CLIP

SIDE
CASING
(R.H.SHOWN)

UPPER VIEW

LOWER VIEW

SPRING
CLIP

SIDE
CASING
(R.H. SHOWN)

IN-FILL
PANEL

IN-FILL
PANEL

Diagram 4.8

SCREW

UPPER
CASING
BRACKET

SIDE CASING
(R.H. SHOWN)

14

2000225008D

Diagram 4.12

FRONT AIR PRESSURE
SWITCH TUBE (CLEAR)

ELECTRICAL
CONNECTORS

REAR AIR PRESSURE
SWITCH TUBE (RED)

4 Installation

4.8 Flue / Boiler Connection

Remove the three self-tapping screws from the lower part of the
control box support bracket, see diagram 4.10.

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

4.10.
Release the toggle latches that secure the fan access door and

remove, see diagram 4.11.
Remove the electrical connections from the fan by pulling the

insulation boots only and disconnect the air pressure tubes from
the fan taking note of their positions, see diagram 4.12.

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 diagrams 4.12 & 4.13.

From the Chimney Flue Adapter Kit take the flue spigot, the
gasket is supplied in the fittings pack.

Connect the flue spigot and gasket to the top flue outlet of the
boiler using the self tapping screws provided, see diagram 4.14.

From the Chimney Flue Adapter Kit, take the chimney flue
adapter and remove restrictor securing screw, select and fit
appropriate restrictor :

Marked 'C'
then secure in place with the previously removed screw. To

connect a condensate drain, remove plastic end stop by
depressing the collet.

Slide the Chimney Flue Adapter into the flue spigot until it
engages in the bayonet connection, then twist clockwise to lock,
see diagram 4.14.

Rest the flue duct extension on the support bracket and engage
into the chimney flue adapter, see diagram 4.15. Refit fan
ensuring it is engaged into the flue duct extension and the
securing lugs are located correctly into the flue hood, secure
with fan securing screw. Replace electrical connections and air
pressure tubes.

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

diagram 4.12 and that the fan duct engages fully into the flue
duct extension piece.

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.

Flue Connection

NOTE: Fix and seal the flue to the hood of the chimney flue
adapter in accordance with normal practice.

The flue should be 125mm (5in) nominal diameter, refer to
section 3.

Diagram 4.13

SECURING
LUGS

Diagram 4.11

TOGGLE
LATCHES

FAN
ACCESS
DOOR

AIR
PRESSURE
TUBE (RED)

10259

FAN
SECURING
SCREW

15

2000225008D

4.9 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.

4.10 Condensate Drain Connection
(If Applicable)

With reference to Section 3, should your flue be greater than the
"Dry" flue length stated, then a condensation drain should be
fitted.

To use the condensate drain connection on the chimney flue
adapter, remove the end stop, see diagram 4.14. A 22mm
plastic overflow pipe should be used to fit on to the drain
connection and discharge to a drain. The drain pipe should have
a fall of at least 2.5° away from the boiler and should incorporate
a 'U' trap.

Condensate should, if possible be discharged into the household
internal drainage system. If this is not practicable, discharge
can be allowed into the external household drains or by a
purpose designed soak away.

It is recommended that any external condensate drain is insulated
and also preferably of 32mm diameter, to prevent freezing in
adverse weather conditions.

4 Installation

Diagram 4.16

TOP CASING

9865

SCREW (2)

PLASTIC
PEG (2)

CHIMNEY
FLUE
ADAPTER

Diagram 4.14

FLUE
SPIGOT

RESTRICTOR
SECURING SCREW

RESTRICTOR

END STOP

Diagram 4.15

FLUE DUCT
EXTENSION
PIECE

SUPPORT
BRACKET

4.11 Top Casing

Refer to diagram 4.16.
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 front of top casing with the two screws provided.

11341

SECURING
SCREW

CHIMNEY
FLUE
ADAPTER

FLUE HOOD

11339

16

2000225008D

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 (85

o

C) 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

CABLE
CLIPS

CABLE
CLIPS

HEAT RESISTANT
CABLE

bk

CONTROL
BOX
COVER

CONTROL
BOX

SECURING
SCREWS

BOILER
TEMPERATURE
CONTROL

Diagram 5.1

9905

TERMINAL BLOCK CONNECTIONS

TERMINAL
BLOCK

17

2000225008D

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.

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

E

D

A

G

Turn the boiler temperature control clockwise to “Max”.
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.

F

B

C

H

A

J

18

2000225008D

6 Commissioning

The correct working of the flame supervision is shown by the
“Burner On” neon going out and the ignition sequence starting
up.

After a short period the boiler will shut down.
If the lighting sequence described 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 80C FF : 2.8m

3

/h (87ft3/h)
is 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.

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.

Diagram 6.2

LOCATING
STUDS

LOCATE
UNDER LIP

FRONT
PANEL

Diagram 6.3

FRONT PANEL
SECURING SCREWS

BOTTOM PLINTH
PANEL

SECURING SCREWS

19

2000225008D

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.

8 Servicing

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 4.8. 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.

Diagram 8.2

GAS
SERVICE
COCK
UNION

ELECTRICAL
PLUG

Diagram 8.1

SAMPLE POINT

SECURING
SCREW

Diagram 8.3

ELECTRICAL
WIRE
RETAINING
CLIPS

CONTROL BOX
SUPPORT
BRACKET

20

2000225008D

8 Servicing

8.1 Access

Remove the boiler front casing panel, refer to section 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 four self-tapping screws that secure the combustion
chamber front and carefully withdraw it together with the burner
and gas valve assembly, taking care not to strain the ignition
and earth wire, see diagram 8.5.

Note: When replacing burner in combustion chamber make
sure it fits correctly on the guides.

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

8.5.
Remove the three self-tapping screws from the lower part of the

control box support bracket, see diagram 8.6.
Undo the wing nut that secures the top of the heat shield and

carefully hinge down control box and heat shield, see diagram

8.6.
Release the two toggle latches that secure the fan access door

and remove, see diagram 8.7.
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.

Disconnect the two silicone tubes from the fan taking note of
their positions.

Note: To ease removal of the right hand baffle from the heat
exchanger, remove both silicone tubes from the air pressure
switch.

Remove fan securing screw, electrical connections and air
pressure tubes, then remove fan and flue hood by sliding back
to disengage the retaining lugs then lift up.

Remove the flue hood.
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.

Diagram 8.4

BOTTOM PLINTH
PANEL

SECURING SCREWS

Diagram 8.5

COMBUSTION
CHAMBER
COVER

IGNITION AND
EARTH LEADS

GROMMET

21

2000225008D

8.2 Boiler Flueways

Remove flueway baffles noting that there are 2 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.

8.3 Burner and Injector

Remove the two screws and nuts securing the burner support
bracket to the combustion chamber cover, see diagram 8.9.

Remove the graphite coated nuts on the supply feed pipe at the
rear of the burner to release the burner, see diagram 8.10.

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 8.11.

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.

Diagram 8.8

FLUEWAY
BAFFLE

HEAT
EXCHANGER

8 Servicing

SIDE
FLUEWAY
BAFFLE

HEAT
EXCHANGER

TOGGLE
LATCHES

FAN

Diagram 8.6

0886

WING NUT

SELF
TAPPING
SCREWS
(3)

Diagram 8.7

SECURING
SCREW

FLUE HOOD

22

2000225008D

MAIN
BURNER

GRAPHITE
COATED
NUT(2)

SUPPLY
FEED
PIPE

Diagram 8.10

Diagram 8.9

BURNER
SUPPORT
BRACKET

SCREWS &
NUTS (2)

8.4 Service Checks

Inspect the spark electrode and clean and replace as necessary,
see diagram 8.12.

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.

Diagram 8.12

ELECTRODE

SECURING
SCREW

+

-

SPARK GAP
= 3.6 1.1

Diagram 8.11

BURNER
INJECTOR

GRAPHITE
COATED
NUT(2)

0939

8 Servicing

23

2000225008D

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.

9.1 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 9.2, Fault Finding
Wiring Diagram, see diagram 9.3, Pictorial Wiring Diagram, see
diagram 9.4.

Diagram 9.2

ELECTRICAL FAULT FINDING

9917

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

With electrical supply isolated remove the boiler 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?

NO

Check power supply

Is neon 2 lit?

NO

YES

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

NO

NO

YES

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.

NO

NO

Check continuity of
gas valve harness.

Faulty gas valve.
Replace.

Faulty harness.
Replace.

NO

YES

NO

Is the fan turning?

YES

NO

Is there 230Vac
on fan?

Faulty
PCB.

Faulty
fan.

Does burner light?

YES

YES

YES

YES

NO

NO

Is neon 4 lit?

NO

YES

Appliance working
satisfactorily.

Is integrity of
electrode and
HT lead good?

Replace as
necessary

Faulty
PCB.

YES

NO

YES

NO

NO

9 Fault Finding

Diagram 9.1

BOILER TEMPERATURE
CONTROL

10169

24

2000225008D

FUSE
TYPE F4A

AIR PRESSURE
SWITCH CONNECTIONS

FAN

EV1

EV2

SPARK
ELECTRODE

AIR
PRESSURE
SWITCH

SL

(N/O)

(C)

(N/C)

br

br

bk

p

r

gy

y

br

bk

KEY

bk BLACK
br BROWN
b BLUE
p PURLPLE

r RED
y YELLOW
gy GREY

MAIN TERMINAL
STRIP CONNECTIONS

PRINTED CIRCUIT
BOARD CONNECTIONS

b

b

b

N

b

N

MAINS SUPPLY
230v ~ 50Hz

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 reset neon on the control panel is lit, turn the burner
temperature control to “0”, wait 30 seconds, then fully clockwise
to “Max.” see diagram 9.1.

Diagram 9.3

10084

9 Fault Finding

25

2000225008D

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

p

y

g

p

b

bk

bk

bk

bk

b

bk

b

r

g

y

bk b

L

S

= LIVE (Switched)

N

L

S

N

br

r

g/yg/y

g/y

g/y

br

b

b

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

KEY

g/y

= NEUTRAL
= EARTH MAIN

KEY TO TERMINAL BLOCK

br

26

2000225008D

10 Replacement of Parts

Important notes

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.

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.

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

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

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 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.
Remove the electrical plug securing screw and disconnect the

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.

27

2000225008D

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 tubes 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

FRONT AIR PRESSURE
SWITCH TUBE (CLEAR)

AIR
PRESSURE
SWITCH

ELECTRICAL
CONNECTORS

REAR AIR PRESSURE
SWITCH TUBE (RED)

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.

10259

28

2000225008D

Diagram 11.1

11 Spare Parts

10177

3

6

9

7

2

4

5

1

8

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.

Key No. Part No. Description GC Part No.

1 2000461752 Multifunctional control ******
2 221732 Fan ******
3 2000461994 Air pressure switch ******
4 2000461985 Electrical thermistor ******
5 202635 Spark electrode ******
6 2000461714 Boiler temperature control knob ******
7 2000461924 Injector ******
8 227098 Fuse ******
9 227030 Control board ******
10 205656 Burner ******

10

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