Henrad WH 30 FF, WH 50 FF, WH 60 FF, WH 70 FF, WH 40 FF Installation And Servicing Manual

2

Henrad WH FF - Installation

GENERAL

Boiler Size 30 FF 40 FF 50 FF 60 FF 70 FF 80 FF 100 FF

Boiler input MINIMUM kW 5.6 11.3 15.0 18.5 22.5 26.3 31.6

(Gross) Btu/h x 1000 19.1 38.5 51.2 63.3 76.9 89.7 107.8

Gas consumption l/s 0.15 0.29 0.38 0.49 0.58) 0.67 0.80

ft

3

/h 19.4 37.1 48.7 62.9 73.1 86.3 101

MID kW 8.3 13.0 16.7 20.3 24.0 27.8 34.2

Btu/h x 1000 28.5 44.3 56.85 69.2 82.0 94.9 116.7

Gas consumption l/s 0.22 0.34 0.43 0.53 0.62 0.71 0.87

ft

3

/h 28.1 42.7 54.5 67.6 78.8 91.3 110.0

MAXIMUM kW 11.0 14.7 18.3 22.0 25.6 29.3 36.6

Btu/h x 1000 37.5 50.0 62.5 75.0 87.5 100.0 125.0

Gas consumption l/s 0.28 0.38 0.47 0.57 0.66 0.76 0.95

ft

3

/h 36.1 48.2 60.2 72.3 84.3 96.3 121

Boiler output MINIMUM kW 4.4 8.8 11.7 14.7 17.6 20.5 24.9

Btu/h x 1000 15 30 40 50 60 70 85

MID kW 6.6 10.3 13.2 16.1 19.0 22.0 27.1

Btu/h x 1000 22.5 35 45 55 65 75 92.5

MAXIMUM kW 8.8 11.7 14.7 17.6 20.5 23.4 29.3

Btu/h x 1000 30 40 50 60 70 80 100

Burner Setting
pressure (HOT) MINIMUM mbar (in.w.g.) 3.3 (1.3) 6.7 (2.7) 9.1 (3.6) 10.0 (4.0) 9.2 (3.7) 10.6 (4.2) 10.4 (4.2)

MID mbar (in.w.g.) 7.5 (3.0) 8.7 (3.5) 11.1 (4.4) 12.1 (4.8) 10.4 (4.2) 12.0 (4.8) 12.3 (4.9)

MAXIMUM mbar (in.w.g.) 12.8 (5.1) 11.0 (4.4) 13.5 (5.4) 13.9 (5.6) 12.0 (4.8) 13.2 (5.3) 14.5 (5.8)

*Seasonal efficiency (SEDBUK)* [76.2]% [75.8]% [76.2]% [76.7]% [77.1]% [76.0]% [76.4]%

Note. Gas consumption is calculated using a calorific value of

38.7 MJ/m

3

(1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a different calorific value:-

a. FOR L/S - divide the gross heat input (kW) by the gross

C.V. of the gas (MJ/m

3

)

b. FOR FT3/H - divide the gross heat input (Btu/h) by the gross

C.V. of the gas (Btu/ft3)

Table 1 - General Data

Table 2 - Performance Data

*The value is used in the UK government's Standard Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been certified by BGplc 0087

Boiler Size 30 FF 40 FF 50 FF 60 FF 70 FF 80 FF 100 FF

Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female)

Flow connection 22mm 28mm copper

copper (FEMALE)

Return connection 22mm 28mm copper

copper (FEMALE)

Maximum static water head m (ft.) 30.5 (100)

Minimum static water head m (ft.) 0.45 (1.5)

Electrical supply 230 V 50 Hz Boiler power consumption; 100W

Fuse rating External; 3A Internal; F1A to BS.4265

Water content litre (gal.) 2.7 (0.6) 3.65 (0.8) 4.65 (1.0) 4.65(1.0)

Dry Weight kg (lb) 40.9 (90.3) 46.6 (102.8) 52.6 (116.0) 52.6(116)

Maximum installation weight kg (lb) 31.4 (69.3) 37.4 (82.5) 43.1 (95) 43.1(95)

Boiler size Height mm (in.) 700 (27.5)

Width mm (in.) 380 (15.0)

Depth mm (in.) 300 (11.8)

Flue duct diameter mm (in.) 100 (4.0)

Flue duct length (max) m (ft) 3 (9.8) 0.6 (2)

Henrad WH FF - Installation

3

GENERAL

CONTENTS

Air Supply. .................................................................. 6/7

Boiler Clearances ......................................................... 5

Boiler Exploded View .................................................. 9

Burner Exploded View .............................................. .34

Control Box Exploded View ..................................... .34

Electrical Connections .............................................. 20

Electrical Regulations ................................................. 7

Extension Ducts - Fitting ........................................... 18

External Controls .......................................................20

Fault Finding .............................................................. 32

Flue Installation ............................................................ 6

Rear installation ...................................................... 12

Side installation ...................................................... 15

Gas Safety ..................................................................... 4

Gas Supply ................................................................... 6

Initial Lighting . .......................................................... 23

Installation .................................................................... 9

Mandatory Requirements ............................................4

Pump ............................................................................. 8

Servicing ..................................................................... 25

Short List of Parts ...................................................... 32

Spares Replacement .................................................. 27

System Diagrams ....................................................... 21

Terminal Guards........................................................... 6

Water and Systems ...................................................... 7

Water Treatment ........................................................... 7

WH FF

Key to symbols

IE = Ireland

GB = United Kingdom (Countries of destination)

PMS = Maximum operating pressure of water

C

12

& C32 =

A room sealed appliance designed for connection via
ducts to a horizontal or vertical terminal, which admits
fresh air to the burner and discharges the products of
combustion to the outside through orifices which, in
this case, are concentric. The fan is down stream of
the combustion chamber.

I

2H

= An appliance designed for use on 2nd Family gas,

Group H only.

B.G. Certified - P.I. No. 87 AP 107

Destination Countries: GB and IE

Natural Gas only
Appliance type: C12 & C

32

Data badge - top of controls support.

Model G.C. Appliance No.

WH 30 FF 41 349 87

WH 40 FF 41 349 88

WH 50 FF 41 349 89

WH 60 FF 41 349 90

WH 70 FF 41 349 91

WH 80 FF 41 349 92

WH 100 FF 41 349 93

(WH 100 FF is a type C

12

appliance only)

BENCHMARK LOG BOOK DETAILS

Boiler Page

Make and model ........................................................3

Appliance Serial No. on Data Badge ......................... 9

Controls ....................................................... as applicable

For all boilers

Flushing to BS.7593 ..................................................4

Inhibitor ......................................................................7

Gas inlet working pressure ........................................ 6

Burner operating pressure ......................................... 2

Heat input .......................................... to be calculated

Temperature differential .............. measure and record

For combination boilers only ................... Not applicable

For domestic hot water mode .................. Not applicable

For condensing boilers ............................. Not applicable

For all boilers: complete, sign & hand over to customer

For assistance see Technical Helpline on the back page

CAUTION.

To avoid the possibility of injury during the installation, servicing or cleaning of

this appliance, care should be taken when handling edges of sheet steel components.

4

Henrad WH FF - Installation

GENERAL

INTRODUCTION

The WH 30 FF-100 FF is a range of automatically fully controlled,

wall mounted, balanced flue, fanned gas boilers.

The heat exchanger is cast iron. The boiler casing is of white
enamelled mild steel.

The boiler casing has a removable controls pod containing a drop­down door. The boiler thermostat is located behind the drop- down

door.

Note. These boilers cannot be used on systems which
include gravity circulation.

See Frame 1 for details of the correct boiler tappings to use.

The boilers are supplied with a standard flue kit suitable for rear or
side outlet applications from 114 mm (4

1/2") to 600 mm

(23 1/2").

The boilers are suitable for connection to the following open
vented or sealed systems:

z Fully pumped CH and indirect DHW

z Pumped heating only.

z Pumped indirect DHW only.

OPTIONAL EXTRA KITS

Downward Piping Kit.

Roof Flue Kit.*

90° Flue Elbow Kit.*

Extension ducts* Up to 3m (118").

* Not available for 100 FF

BS.6891 Low pressure installation pipes.

BS.6798 Installation of gas fired hot water boilers of rated

input not exceeding 60 kW.

BS.5449 Forced circulation hot water systems.

BS.5546 Installation of gas hot water supplies for domestic

purposes (2nd Family Gases).

BS.7593 Treatment of water in domestic hot water central

heating systems.

BS.5440.1 Flues for gas appliances of rated input not exceeding

60 kW.

BS.5440.2 Ventilation for gas appliances of rated input not

exceeding 60 kW.

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

Manufacturer’s notes must NOT be taken in any way as
overriding statutory obligations.

IMPORTANT. These appliances are certificated by the British
Standards Institution for safety and performance. It is, therefore,
important that no external control devices, e.g. flue dampers,
economisers etc., are directly connected to these appliances ­unless covered by these Installation and Servicing instructions or
otherwise recommended by Caradon Plumbing Limited in
writing.
If in doubt please enquire.

Any direct reconnection of a control device not approved by
Caradon Plumbing Limited could invalidate the BSI Certification
and the normal appliance warranty. It could also infringe the Gas
Safety Regulations and the above regulations.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation panels
which can cause irritation to the skin. No asbestos, mercury or CFCs
are included in any part of this boiler.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical wall, capable of
adequately supporting the weight of the boiler and any ancillary
equipment.

The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary - unless required
by the local authority. The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should be
fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.

CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS, or rules in force.

It is law that all gas appliances are installed by a CORGI

registered installer (identified by ) in accordance with the
above regulations. Failure to install appliances correctly could
lead to prosecution. It is in your own interest, and that of safety, to
ensure the law is complied with.

The installation of the boiler MUST also be in accordance with the
latest I.E.E (BS.7671) Wiring Regulations, local building
regulations, bylaws of the local water authority, the Building
Regulations and Building Standards (Scotland) and any relevant
requirements of the local authority. Detailed recommendations
are contained in the following British Standard Codes of Practice:

NOTE TO THE INSTALLER:

LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK

AND GIVE THIS TO THE CUSTOMER.

Henrad WH FF - Installation

5

GENERAL

This appliance in NOT suitable for use in a direct
hot water system or for gravity circulation.

70 FF, 80 FF & 100 FF ONLY

must be fitted with the 22mm x 28mm copper sockets,
provided in the Hardware Pack, (or equivalent 22mm x
28mm compression fittings ) and the pumped flow and
return pipes run in 28mm pipe.

1

BOILER WATER CONNECTIONS

The following minimum clearances
must be maintained for operation and
servicing.

Additional space will be required for
installation, depending upon site
conditions.

Side and Rear Flue

a. Provided that the flue hole is cut

accurately, e.g. with a core drill, the
flue can be installed from inside the
building.

Installation from inside ONLY

b. If a core boring tool is to be used

inside the building; the space in
which the boiler is to be installed
must be at least wide enough to
accommodate the tool.

Pelmet restrictions.

If the ability to fit or remove the
casing during installation and
subsequent servicing is impaired
by pelmets etc. this operation can
be made easier by first removing
the controls pod casing in line with
the following instructions:

a. Release the controls pod

casing fixing screws (a) 3 full
turns only. Remove the pod by
pulling it forward to disengage
from the keyhole slots.

b. Undo the 2 screws (b)

retaining casing to the back
panel.

c. The casing can now be

removed in the direction of the
arrow, first lifting the casing
slightly to disengage the
casing top return from the
back panel. (For this purpose
a minimum clearance of 12mm
is required between the top of
the boiler and pelmet or other
similar obstruction.

Front clearance: 450mm (17

3/4")

from the front of the boiler casing.

Minimum front clearance when
built in to cupboard is 75 mm (3").

2

BOILER CLEARANCES

6

Henrad WH FF - Installation

GENERAL

Bathrooms

The boiler may be installed in any room or internal space, although
particular attention is drawn to the requirements of the current I.E.E.
(BS.7671) Wiring Regulations and, in Scotland, the electrical
provisions of the building regulations applicable in Scotland with
respect to the installation of the boiler in a room or internal space
containing a bath or shower.

Where a room-sealed appliance is installed in a room containing a
bath or shower then the appliance and any electrical switch or
appliance control utilising mains electricity should be so situated
that it cannot be touched by a person using the bath or shower.

Where installation will be in an unusual location, special procedures
may be necessary and BS.6798 gives detailed guidance on this
aspect.

Compartment Installations

A compartment used to enclose the boiler MUST be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided it is
modified for the purpose.

In both cases details of essential features of cupboards/compartment
design, including airing cupboard installation, are to conform to the
following :

z BS. 6798.
z The position selected for installation MUST allow adequate

space for servicing in front of the boiler and for air circulation
around the boiler. Refer to 'Air Supply' on pages 6/7.

z For the minimum clearances required for safety and

subsequent service refer to the Wall mounting diagram,
Frame 2. In addition, sufficient space may be required to allow
lifting access to the wall mounting plate.

GAS SUPPLY

The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.

The boiler is to be installed only on a gas supply with a governed
meter.

A gas meter can only be connected by the local gas supplier or by
a local regional contractor.

An existing meter should be checked, preferably by the gas supplier,
to ensure that the meter is adequate to deal with the rate of gas
supply required. A MINIMUM pressure of 20 mbar MUST be available
at the boiler inlet with the boiler operating.

Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to the boiler MUST be of an adequate
size. 100 FF models should be piped in 22mm minimum. (The final
1 metre may be run in 15mm piping if it is visible.)

The complete installation MUST be tested for gas soundness and
purged as described in the above code.

FLUE INSTALLATION

The flue must be installed in accordance with the recommendations
of BS. 5440:1. The following notes are intended for general
guidance:-

1. The boiler MUST be installed so that the terminal is exposed to
external air.

2. It is important that the position of the terminal allows the free
passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to obstructions
and ventilation openings are specified in Table 3.

4. Where the lowest part of the terminal is fitted less than 2m
(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be protected
by a purpose designed guard. The minimum spacing in Table
3, Nos. 2, 3, 4, 5 and 6 would be 75mm, in order to allow a
terminal guard to be fitted.

Terminals guards are available from boiler suppliers - ask for
Tower Flue Guard, Model K1. In case of difficulty seek advice
from:

Tower Flue Components Ltd.,
Vale Rise, Tonbridge, Kent TN9 1TB (Model K1)
Telephone No. 01732 351 555

Ensure that the guard is fitted centrally.

5. Where the terminal is fitted within 1000mm (39 1/2") of a plastic
or painted gutter or 500mm (19 1/2") of painted eaves then an
aluminium shield at least 1000mm (39 1/2") long should be
fitted to the underside of the gutter or painted surface.

6. The air inlet/products outlet duct and the terminal of the boiler
MUST NOT be closer than 25mm (1") to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS.5440: 1990.

7. Where it is essential that the terminal wall plate is fitted, i.e.
wall thicknesses over 600mm (23 1/2") or with an inaccurately
cut hole, the minimum spacing in Table 3 Nos. 2,3, 4, 5 and 6
would be 60mm (2 1/2") in order to allow the terminal wall plate
to be fitted.

Table 3 - Balanced flue terminal position

Terminal Position

Minimum Spacing

1. Directly below or alongside an

opening window, air vent or other
ventilation opening 300 mm (12")

2. Below guttering, drain pipes or soil pipes 25 mm ( 1")

3. Below eaves 25 mm ( 1")

4. Below balconies or a car port roof 25 mm ( 1")

5. From vertical drain pipes or soil pipes 25 mm ( 1")

6. From internal or external corners 25 mm ( 1")

7. Above adjacent ground, roof or

balcony level 300 mm (12")

8. From a surface facing the terminal 600 mm (24")

9. From a terminal facing a terminal 1200 mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling 1200 mm (48")

11. Vertically from a terminal on the same wall 1500 mm (60")

12. Horizontally from a terminal on the wall 300 mm (12")

IMPORTANT. It is absolutely ESSENTIAL to ensure, in practice,

that products of combustion discharging from the terminal cannot
re-enter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air infiltration,
or forced ventilation/air conditioning.

If this should occur, the appliance MUST be turned OFF, labelled
'unsafe' and corrective action taken.

TERMINAL

The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 8.

AIR SUPPLY

Detailed recommendations for air supply are given in
BS.5440:2.

Henrad WH FF - Installation

7

GENERAL

Maximum boiler operating temperature should be 82ºC (180ºF).

WATER TREATMENT

These boilers incorporate a cast iron heat exchanger. As part of
the installation the central heating system should be thoroughly
flushed with appropriate water treatment in order to comply with
BS7593:1992.

Caradon Plumbing Ltd recommend the use of Fernox or Betz
Dearborn water treatment products which must be used in
accordance with the manufacturers instructions. For further
information contact :­Fernox Manufacturing. Co. Ltd, Tandem House, Marlowe Way,
Croydon, Surrey CRO 4XS, tel [phone] or

Betz Dearborn Ltd, Widnes, Cheshire, tel. [phone]

Important: Any other treatment for this product will render the

guarantee of Caradon Plumbing Ltd INVALID.

Notes.

1. If an inhibitor is used, and in hard water areas where treatment
to prevent lime deposits is necessary, it is most important that
the water treatment MUST be maintained at the correct
concentrations recommended by the treatment manufacturer.

2. Artificially softened water must not be used in the system, under
any circumstances

.

THERMOSTATIC RADIATOR VALVES

Caradon Plumbing Limited recommend that heating systems

utilising full thermostatic radiator valve control of temperature in
individual rooms should also be fitted with a room thermostat
controlling the temperature in a space served by radiators not
fitted with such a valve as stated in BS. 5449.

When thermostatic radiator valves are used, the space heating
temperature control over a living / dining area or hallway having a
heating requirement of at least 10% of the boiler heat output
should be achieved using a room thermostat, whilst other rooms
are individually controlled by thermostatic radiator valves.
However, if the system employs thermostatic radiator valves on
all radiators, or two port valves without end switches, then a
bypass must be fitted to ensure a flow of water should all valves
be in the closed position.

ELECTRICAL SUPPLY

WARNING. The appliance MUST be efficiently earthed.

Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply.

The point of connection to the mains should be readily accessible
and adjacent to the boiler, except that for bathroom installations;
the point of connection to the mains MUST be situated outside of
the bathroom.

Note. Where a room sealed appliance is installed in a room
containing a bath or shower then the appliance and any electrical
switch or appliance control utilising mains electricity should be so
situated that it cannot be touched by a person using the bath or
shower. See Frame 36 for details.

The following notes are for general guidance:

1. It is NOT necessary to have a purpose provided air vent in the
room or internal space in which the boiler is installed.

2. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for cooling purposes) in the
cupboard/compartment, at both high and low levels. The air vents
must either communicate with room/internal space, or be direct
to outside air. The minimum effective areas of the permanent
air vents, required in the cupboard/compartment, are specified
as follows and are related to maximum rated heat input.

3. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.

4. In siting the air vents care must be taken to avoid the freezing of
pipework.

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply. For the
types of system and correct piping procedure refer to 'Introduction'
and Frame 1.

The central heating system should be in accordance with BS.6798
and, in addition, for Smallbore and Microbore systems, BS. 5449.

The domestic hot water system, if applicable, should be in
accordance with the relevant recommendations of BS. 5546. Copper
tubing to BS. 2871:1 is recommended for water carrying pipework.

The hot water storage cylinder MUST be of the indirect type and
should preferably be manufactured of copper.

Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating, nor
are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated under floor spaces.

Boilers not fitted to a sealed system must be vented.

IMPORTANT

Draining taps MUST be located in accessible positions, which permit
the draining of the whole system - including the boiler and hot water
storage vessel. They should be at least 1/2" BSP nominal size and
be in accordance with BS. 2879.

The boiler is fitted with a special drain plug, which is provided, to
drain the BOILER ONLY, in the event of the system drain plug being
unable to do so. The hydraulic resistance of the boilers, at MAXIMUM
OUTPUT with an 11

O

C (20OF) temperature differential, are shown in

Table 5.

Boiler Size

FF 30 40 50 60 70 80 100

Boiler kW 8.8 11.7 14.6 17.6 20.5 23.4 29.3
Output

Btu/h x 1000

30 40 50 60 70 80 100

Water Flow l/min 11.4 15.2 19.0 22.8 26.5 30.3 38.0
Rate gal/h 150 200 250 300 350 400 500

Pressure mbar 22.0 20.4 31.5 41.7 54.8 77.0 106
Loss in wg 8.9 8.3 12.6 16.7 22.0 30.9 42.5

Table 5 - Water flow rate and pressure loss

Table 4 - High and low vent areas

Boiler Air from room/internal Air direct from

space, cm (in2 ) outside, cm (in2)

30 FF 102 (16) 51 (8)

40 FF 135 (21) 68 (11)

50 FF 170 (26) 83 (13)

60 FF 198 (31) 102 (16)

70 FF 231 (36) 116 (18)

80 FF 264 (41) 132 (21)

100 FF 340 (52) 170 (26)

8

Henrad WH FF - Installation

GENERAL

Minimum Requirements

Note. The pump manufacturers minimum

requirements must be complied with

System
return

Connections
to boiler

Inverted cold
feed entry

System
flow to
pump

150 (6")
Max

15mm
Cold
feed

450 (18")
Mimimum

450 (18")
Mimimum

22mm
Open vent

Feed / expansion
cistern

Water
level
(cold)

Surge
arrester

75 (3)
Min.

450
(18)
Min.

200
(8)
Min.

Highest
point of
flow or
return

150

(6)

Max

Max. practical

length

To pump

Cold

water

level

Feed / expansion

cistern

75 (3) Min.

Flow

Return

22 (3/4)

Open vent

All dimensions in mm (in.). N.B. Imperial dimensions are approximate

4

LOW HEAD INSTALLATIONS

The system should be vented directly off the boiler flow
pipe, as close to the boiler as possible. The cold feed entry
should be inverted and MUST be positioned between the
pump and the vent, and not more than 150mm (6") away
from the vent connection.

There should be a minimum height - 450mm (18") - of open
vent above cistern water level. If this is impossible refer
below.

The vertical distance between the highest point of the
system and the feed/expansion cistern water level MUST
not be less than 450mm (18").

The pump MUST be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of
providing an 11°C (20°F) temperature differential (e.g.
Grundfos UPS 15/50 or equivalent). The vertical distance
between the pump and feed/expansion cistern MUST
comply with the pump manufacturers minimum
requirements to avoid cavitation. Should these conditions
not apply, either lower the pump position or raise the
cistern above the minimum requirement specified by

Caradon Plumbing Limited.

Note. A cold water feed must be available back to the

boiler, when all automatic valves are in the closed position
(refer to BS. 6798) and when close coupled the feed must
not be in a vertical leg.

The WH FF range of boilers can be
installed in low head situations by fitting a
'surge arrester' in the expansion pipe as
shown.

The following conditions MUST be
observed:

1. The surge arrester must be at least
42mm in diameter x 150mm long,
thus ensuring a MINIMUM air gap and
a MINIMUM depth of water below the
static water level (cold) of 75mm.

2. The static water level (cold) must be
at least 200mm above the top of the
horizontal flow pipe, fitted as shown.
The vent connection MUST NOT be
made immediately off the top of the
boiler, as venting is made less
efficient.

3. The maximum practical length of
15mm cold feed pipe should be used
in order to reduce the effective
volume of system water expanding
into the feed/expansion cistern to a
minimum.

3

OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED.

Henrad WH FF - Installation

9

INSTALLATION

5

BOILER ASSEMBLY - Exploded view

WH 30 FF shown

LEGEND

1A. Heat exchanger.

2. Flue baffles.

3. Tie rods.

4A. Pumped flow pipe.

5A. Pumped return pipe.

6. Collector hood assembly.

7. Combustion chamber.

12. Main burner.

19. Control box .

24. Pressure switch.

30. Fan.

40. Wall mounting plate.

44B. Programmer (optional).

52. Back panel.

INSTALLATION

10

Henrad WH FF - Installation

INSTALLATION

The boiler is supplied fully assembled in one pack, together
with a standard flue assembly for lengths up to 600mm (23 1/2"
rear or side flue outlet, in Pack B1.

Optional extras, if ordered (Downward Piping Kit, Extension
Duct Kit, Roof Flue Kit and 90° Flue Elbow Kit ) are available in
separate boxes.

Unpack and check the contents.

Pack B1 Contents

z Duct cutting support, 2 off

(cardboard )

z Terminal wall plate, 1 off.

z Terminal grille assy., 1 off.

z Polyurethane foam seal 400 lg., 1 off.

z No. 8 x 8 lg. Pozi pan hd. screws, 3 off.

6

UNPACKING

Boiler Pack Contents

z The complete boiler
z Installation & Servicing Instructions
z User's Instructions
z Hardware Pack (listed below)
z Wall mounting template
z Wall mounting plate
z Side outlet terminal mounting plate
z Flue extension tube, 1 off

z Boiler sealing plate, 1 off

Hardware Pack Contents

z 50mm x No. 14 wood screw, 4 off

z 50mm x No. 10 wood screw, 8 off

z Wall plug, 12 off

z Data badge indicator arrow, 1 off

z M8 washer, 1 off

z 22mm x 28mm copper reducing socket

(70 FF, 80 FF & 100 FF ONLY), 2 off

z M5 wing nut, 3 off

z Sealing plate, 1 off

z M8 x 12 Hx. Hd. screw, 1 off

INSTALLATION

Henrad WH FF - Installation

11

INSTALLATION

Flue length
for rear

Flue length for side

Jacking screw for
boiler alignment

1. Unpack the boiler.

2. Remove the casing as follows and place to one side to

avoid damage.

a. Undo the 2 casing retaining screws (a) retaining the

casing to the back panel.

b. Swing the bottom of the boiler casing up until the

controls pod casing has cleared the controls then
unhook the top from the back panel.

3. Remove the boiler from its packaging base. The boiler may
now be stood upright on its controls support protection
frame to ease handling and installation.

4. Unpack the boiler terminal box and, if applicable, the
extension flue box(es).

7

PACKAGING AND CASING REMOVAL

SIDE FLUE
INSTALLATION

REAR FLUE
INSTALLATION

FLUE KITS

Pack B1: supplied as standard.

Extn Duct Kit* : optional extension kit for side flue

or rear flue outlet. Refer to 'Flue Extension Ducts'

1. A maximum of 2 extension ducts (plus the
standard flue duct) may be used together.

2. Flue extensions of greater than 1m (39") should
be supported with the bracket provided. If the
stand-off brackets have been used it is
necessary, in order to keep the flue aligned, to
use the spacer bracket with the support
bracket.

It is MOST IMPORTANT that the boiler is installed
in a vertical position.

(a) Casing retaining
screws, 2 off

Packing base

Controls pod casing

8

DETERMINING THE FLUE LENGTH

* Not for 100 FF model

Flue length

mm

Accessories Product No.

Up to 600 B1 Pack, 1 off 153930

600 to 1550* B1 Pack 1 off + Extn Duct, 1 off 153930+153931

1550 to 2500* B1 Pack 1 off + Extn Duct, 2 off 153930+

153931, 2 off

2500 to 3000* B1 Pack 1 off + Extn Duct, 3 off 153930+

153931, 3 off

Note.

Vertex and roof flue kits are available as optional
extras for vertical flue installation, supplied with
separate fitting instructions.

INSTALLATION

12

Henrad WH FF - Installation

INSTALLATION

REAR FLUE OUTLET

Note. If the

terminal is to be
sited within 25­40mm of a corner
or vertical pipe
(refer to Table 3)
then the hole
MUST be
accurately cut and
the rubber
weather seal
trimmed around
the groove
provided.
The terminal wall
plate need not be
fitted.

Note. Check all of the hole
positions BEFORE drilling

9

FLUE ASSEMBLY - Exploded View

LEGEND

1. Terminal.

2. Weather seal.

3. Flue assembly.

4. Boiler sealing ring

5. Flue extension tube.

1. An optional flue

duct extension kit
is required for
wall thicknesses
greater than
600mm (23 1/2")
Refer to Frame 8.

2. When cutting the
ducts, always use
the cardboard
support rings
provided.

IMPORTANT.
100 FF models only

The flue extension
tube includes an air
deflector ring.

10

WALL MOUNTING TEMPLATE

Note. The template shows the positions for the fixing holes

and the flue hole centres for standard installation. Care must
be taken to ensure the correct holes are drilled.

1. Separate the templates.

2. Tape the templates into the selected position.

3. Ensure squareness by hanging a plumb line as shown.

4. Mark onto the wall (if required) the following:

a. The wall mounting plate screw positions (choose

one from each group). Note. Mark the centre of the
flue hole as well as the circumference.

b. The position of the flue duct hole.

c. Downward pipe routing bracket screw positions.

5. Remove the templates from the wall.

IMPORTANT. Ensure that, during the cutting operation,

masonry falling outside of the building does not cause
damage or personal injury.

1. Cut the flue hole, preferably with a 125mm (5") core

boring tool, ensuring that the hole is square to the wall.
If the hole has been quite accurately cut with a drill
then making good the wall faces is not essential as
seals are provided at both ends of the flue. However,
both wall faces immediately around the cut hole should
be flat; make good if necessary. For less accurate
holes make good to approximately 125mm (5")
diameter at the 2 wall faces.

2. Drill 4 holes for the wall mounting plate with an 8mm

(

5/16") masonry drill. If the stand-off brackets are used

ensure the correct holes are chosen.

3. Insert the plastic plugs provided.

11

PREPARING THE WALL

Henrad WH FF - Installation

13

INSTALLATION

REAR FLUE OUTLET

12

CUTTING THE FLUE - wall thicknesses of 114 to 600mm

Note. If the stand-off brackets are used it is essential that

30mm is added to the measured wall thickness when marking
the flue (to allow for the thickness of the brackets).

1. Measure and note the wall thickness X.

2. Mark the wall thickness onto the flue.

3. To ensure the tube is cut square, mark the flue all the way

round.

4. Cut to length X, using the cardboard ring for support.

5. Remove cardboard ring and remove any burrs.

13

FITTING THE BOILER SEALING RING TO THE FLUE

2. Drill 3 holes 3.2mm (1/8") dia. through the outer flue duct

and boiler sealing ring.

Do NOT drill the inner flue

duct.

3. Insert the self-tapping screws, provided, in order to fix the

boiler sealing ring in position.

1. Fit the boiler sealing ring inside the outer flue duct. Ensure
the boiler sealing ring is fully engaged.

Ensure the notch aligns with the groove on the outer flue
duct. This ensures correct alignment of the flue terminal.

4. Stick the self-adhesive
foam strip, provided in the
hardware pack, onto the
flue immediately behind
the boiler sealing ring.

15

WALL MOUNTING PLATE

1. Fix the mounting plate to the wall with the No.14 x 50mm wood

screws.

2. If downward routing of pipes is required then the downward
routing pipe brackets and M8 spacer (supplied in the Downward
Piping Kit) should be fitted to the wall mounting plate now.

3. Fit the bottom 2 screws to secure the bracket(s) to the wall,
through the wall mounting plate.

4. Check with a spirit level that the plate is vertical.

14

FITTING THE FLUE ASSEMBLY

1. Insert the flue extension tube into the flue assembly.

2. Insert the flue assembly through the hole far enough to allow

the rubber seal to unfold completely and form an adequate
seal on the outside wall.

3. Ensure the notch is at the top. This will aid the location of
the studs into the boiler back panel.

14

Henrad WH FF - Installation

INSTALLATION

REAR FLUE OUTLET

1. Pull the flue through the wall mounting plate and

locate the 3 studs in the holes in the back panel.

2. Secure the flue to the boiler using the three M5
wing nuts provided.

3. Pull the flue extension tube and engage onto the
fan. Locate and secure with the M4 screw
attached to the fan.

Note.

The sealing ring studs will locate in the back panel
one way only. This will ensure that the terminal grille
is correctly aligned.

16

MOUNTING THE BOILER

Note. Have ready to hand the M8 screw, washer

and rectangular plate supplied in the hardware
pack. For downward routing of pipes the M5
spacer supplied in the Downward Piping Kit,
should now be fitted to the back of the boiler.

1. Lift the boiler onto the wall mounting plate
hooks as shown.

Do not use the burner / controls for lifting

2. Fit the M8 screw, washer and rectangular
plate to retain the boiler.

Note.

Before fully tightening the M8 screw, check the
boiler alignment, using a spirit level, and adjust
as necessary with the jacking screw.

17

CONNECTING THE FLUE TO THE BOILER

18

TERMINAL WALL PLATE

This plate allows neat concealment and full compression of
the rubber seal. Its use is not essential if the flue hole and
flue ducts have been accurately cut and the outside wall face
is flat.

1. Position the terminal wall plate over the terminal.

2. Mark and drill 4 fixing holes with an 7mm (

9/32") masonry

drill.

3. Insert the 4 plastic plugs provided.

4. Secure the plate with 4 of the No.10 x 2" screws provided.

Note. If the terminal is less than 2m (6' 6") above ground

level, an approved terminal guard should be fitted. Refer to
the Contents List on Page 3.

IMPORTANT. 100 FF models only

The flue extension tube includes an air deflector ring.

Henrad WH FF - Installation

15

INSTALLATION

SIDE FLUE OUTLET

Extended centre

line

Terminal
mounting
plate screw
and flue
duct hole
positions

1. An optional flue duct
extension kit is required
for lengths (distance from
the outside wall to the
relevant side of the boiler
casing) greater than
600mm (23

1/2") Refer to

Frame 8.

2. When cutting the ducts
always use the cardboard
support provided.

19

FLUE ASSEMBLY - Exploded view

For wall thickness 114mm to 600mm

1. Separate the templates.

2. Tape both templates into the selected position locating

template B through an extended centre line as shown.

3. Ensure squareness by hanging a plumb line as shown.

4. Mark onto the wall (if required) the following:

a. The 4 wall mounting plate screw positions (choose one

from each group). If the downward routing pipe brackets
are used ensure the correct holes are chosen.

b. The 4 screw positions for the side outlet plate.

c. The position of the flue duct hole (ensure that the correct

centre is marked depending on whether the downward
routing pipe brackets are used or not).

21

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting operation, masonry falling

outside of the building does not cause damage or personal injury.

1. Cut the flue hole, preferably with a 125mm (5") core boring tool,
ensuring that the hole is square to the wall. If the hole has been
accurately cut with a drill then making good the wall faces is not
essential as seals are provided at both ends of the flue. However,
both wall faces immediately around the cut hole should be flat; make
good if necessary. For less accurate holes make good to
approximately 125mm (5") diameter at the 2 wall faces.

2. Drill 4 holes with an 8mm (

5/16") masonry drill and insert the plastic

plugs provided, for the wall mounting plate.

3. Drill 4 holes with a 7mm (9/32") masonry drill and insert the plastic
plugs provided, for the side mounting plate.

Note. If the terminal is to be sited within 25-40mm of a corner or vertical pipe (refer to

Table 3) then the hole MUST be accurately cut and the rubber weather seal trimmed
around the groove provided. The terminal wall plate need not be fitted.

Note. Mark the centre of the hole as well as the
circumference.

d. The side of the casing nearest the flue outlet.

5. Remove both templates from the wall.

20

WALL MOUNTING TEMPLATE

Note. The template shows the positions for the fixing holes and the flue hole

centres for standard installation.
If the flow and return pipes are to be routed down behind the boiler the downward
routing pipe brackets, supplied in the Downward Piping Kit, must be used. These
brackets are secured to the wall mounting plate and it is essential to use only
those holes as shown on the wall mounting template.
Care MUST be taken to ensure the correct holes are drilled.

3. Flue assembly.

4. Boiler sealing plate.

5. Flue extension tube.

LEGEND

1. Terminal.

2. Weather seal.

IMPORTANT.
100 FF models only. The flue extension tube includes an air deflector ring.

16

Henrad WH FF - Installation

INSTALLATION

SIDE FLUE OUTLET

For flue lengths greater than 600mm, refer
to Frames 32 & 33 - Flue extension ducts.

Flue assembly

23

FITTING THE FOAM SEAL

1. To determine the position for the foam seal measure the

wall thickness and mark it onto the flue, measuring from
the groove near the terminal.

2. Wrap the self-adhesive foam strip round the flue,
ensuring that the foam is on the terminal side of the
line. This seals the gap between the flue and the wall.

22

CUTTING THE FLUE
For flue lengths 114 to 600mm ONLY

1. Measure the flue length required (i.e. the distance from

the side of the boiler to the outside face of the wall).
Refer to Frame 9.

2. Mark the flue length required onto the flue, measuring
from the groove near the terminal.

3. To ensure the tube is cut square, mark the flue all the
way round.

4. Insert the cardboard duct ring for support and cut to
length.

5. Remove cardboard duct ring and remove any burrs.

24

FITTING BOILER SEALING RING
TO THE FLUE

1. Fit the boiler sealing ring inside the outer flue duct.

Ensure the boiler sealing ring is fully engaged.
Ensure the notch aligns with the groove on the outer flue
duct. This ensures correct alignment of the flue terminal.

2. Drill 3 holes 3.2mm (

1/8") dia. through the outer flue duct

and boiler sealing ring. Do not drill the inner flue duct.

3. Insert the self tapping screws, provided, in order to fix the
boiler sealing ring in position.

25

FITTING THE FLUE ASSEMBLY

1. Insert the flue assembly through the hole far enough to

allow the rubber seal to unfold completely and form an
adequate seal on the outside wall. This will also ensure
the correct alignment of the flue terminal.

2. Ensure the notch is at the top. This will aid the location of
the studs into the boiler back panel.

Henrad WH FF - Installation

17

INSTALLATION

SIDE FLUE OUTLET

1. The boiler is supplied for

rear outlet installation.
Remove the blanking plate
from the direction required
and use this to blank off the
rear outlet.

2. Lift the boiler onto the wall
mounting plate hooks as
shown.

Do not use the burner/
controls for lifting.

3. Fit the M8 screw, washer
and rectangular plate to
retain the boiler.

Note. Before fully tightening
the M8 screw check the boiler
alignment, using a spirit level,
and adjust as necessary with
the jacking screw.

27

WALL MOUNTING PLATE

1. Fix the mounting plate to the wall with the No.14 x 50mm

wood screws.

2. If downward routing of pipes is required then the
downward routing pipe brackets and M8 spacer (supplied
in the Downward Piping Kit) should be fitted to the wall
mounting plate now.

3. Fit the bottom 2 screws to secure the bracket(s) to the
wall, through the wall mounting plate.

4. Check with a spirit level that the plate is vertical.

Notes 1. Have ready to hand the M8 screw, washer and rectangular plate supplied in the hardware pack.

2. For downward routing of pipes the M5 spacer (supplied in the Downward Piping Kit) should now be

fitted to the back of the boiler.

26

FITTING THE SIDE OUTLET PLATES

28

MOUNTING THE BOILER

Note. If the boiler is fitted closer than 25mm to the side wall

the side outlet plate must be fitted now.

1. Split the side outlet plate into 2 down the split line.

2. Fit the 2 halves of the side outlet plate to the wall,

ensuring they are behind the boiler sealing ring.

18

Henrad WH FF - Installation

INSTALLATION

SIDE FLUE OUTLET

31

FLUE EXTENSION DUCTS - For flue lengths greater than 600mm (Not for 100 FF model)

30

TERMINAL WALL PLATE

29

CONNECTING THE FLUE TO THE BOILER

1. Pull the flue through the side outlet plate and locate

the 3 studs in the hole in the side of the boiler.

2. Secure the flue to the boiler using the three M5 nuts
provided.

3. Insert the flue extension tube into the flue.

4. Fit the 90° flue elbow, supplied with the boiler, onto

the fan in the direction required, after first removing
the underside screw, which is not required. Secure
in position with the screw attached to the fan.

5. Pull the flue extension tube and engage onto the fan
elbow and secure with the screw attached to the
elbow.

Note. The sealing ring studs will locate in the back
panel one way only. This will ensure that the terminal
grille is correctly aligned.

This plate allows neat concealment and full
compression of the rubber seal. Its use is not essential
if the flue hole and flue ducts have been accurately cut
and the outside wall face is flat.

1. Position the terminal wall plate over the terminal.

2. Drill 4 fixing holes with a 7mm (

9/32") masonry drill.

3. Insert the 4 plastic plugs provided.

4. Secure the plate with 4 of the No.10 x 2" screws

provided.

Note. If the terminal is less than 2m (6' 6") above
ground level, an approved terminal guard should be
fitted. Refer to the contents list on Page 3.

Flue extension duct kit contents.

Henrad WH FF - Installation

19

INSTALLATION

REAR & SIDE FLUE OUTLET

General arrangement

Note. Side flue shown.

1. A maximum of 2 extension ducts (plus the standard flue

duct) may be used together.

2. Flue extensions of greater length than 1m (39") should be
supported with the bracket provided. If the stand-off
brackets have been used it is necessary, in order to keep
the flue aligned, to use the spacer bracket with the support
bracket.

32

FLUE EXTENSION DUCTS - continued

Flue length

Extension duct

Flue connector

Standard flue

Terminal grille

Boiler

Extension

tube

* Not for 100 FF model

33

FITTING THE KIT

1. Remove the cardboard support aid from the

flue and place safely to one side.

2. Fit the inner flue extension duct onto the inner
flue duct.

3. Fit the outer flue extension duct onto the
outer air duct.

4. Drill one - 3.2mm (

1/8") dia. holes through the

outer air duct. Do not drill the inner flue

duct.

5. Insert the self tapping screw provided to fix
the air duct in position.

6. Repeat steps 1-5 if a second flue extension is
required.

Flue length Accessories Product No.

Up to 600 B1 Pack, 1 off see Frame 8

600 to 1550* B1 Pack 1 off + Extn Duct, 1 off see Frame 8

1550 to 2500* B1 Pack 1 off + Extn Duct, 2 off see Frame 8

2500 to 3000* B1 Pack 1 off + Extn Duct, 3 off see Frame 8

20

Henrad WH FF - Installation

INSTALLATION

35

WATER CONNECTIONS

1. Remove the plastic plugs from the flow and return pipes.

2. Make all water connections and check for water

soundness.

36

ELECTRICAL CONNECTIONS

WARNING. The appliance must be efficiently earthed.

A mains supply of 230 V ~ 50 Hz is required.

All external controls and wiring must be suitable for mains
voltage. Wiring should be in 3-core PVC insulated & sheathed
cable, not less than 0.75mm

2

(24 x 0.2mm) to BS. 6500 Table

16 Wiring Regulations and local regulations.

Connection must be made in a way that allows complete
isolation of the electrical supply - such as a double pole switch,
having a 3mm (1/8") contact separation in both poles, serving
only the boiler and system controls. The means of isolation
must be accessible to the user after installation.

34

GAS CONNECTION

37

EXTERNAL CONTROLS

The wiring diagrams illustrated in Frames 39-41 cover the
systems most likely to be fitted to this appliance.

For wiring external controls to the WH FF boiler, reference
should be made to the system wiring diagrams supplied by
the relevant manufacturer, in conjunction with the wiring
diagrams shown in Frames 39-41.

Difficulty in wiring should not arise, providing the following
directions are observed:

1. Controls that switch the system on or off, e.g. a time
switch, must be wired, in series, in the live mains lead
to the boiler.

2. Controls that override an on/off control, e.g. frost thermostat,
must be wired into the mains lead, in parallel, with the
control(s) to be overridden. Refer to Frame 41.

3. If a proprietary system is used, follow the instructions supplied
by the manufacturer.

4. System designs featuring controls or wiring arrangements
which allow the boiler to fire when there is no pump circulation
taking place should not be fitted.

Advice on required modifications to the wiring may be obtained
from the component manufacturers.

Notes.

1. Connection between a frost thermostat and the time control

should be made without disturbing other wiring.

2. A frost thermostat should be sited in a cool place in the house,
but where it can sense heat from the system.

Refer to 'Gas Supply ', page 6.
Refer to Frame 2 for gas inlet service dimensions.

A minimum pressure of 20 mbar MUST be available at the
boiler inlet with the boiler operating. The main gas cock is on
the left hand side of the gas control valve, as shown. To
facilitate connection the gas cock may be removed from the
gas control valve.

Flow wiring diagram

Note. If a timer kit is to be fitted refer to the

instructions provided with the kit and Frame 37.

1. Remove the control box securing screws.
Swing the box down into the servicing
position. Refer to Frame 44.

2. Route the mains cable into the box from the
RHS of the boiler.

3. Connect the live, neutral and earth wires into
the terminal strip as shown.

4. Secure the mains lead with the cable clamp.

5. On completion of all wiring connections,

relocate the control box and secure.

LEGEND
b blue
bk black

v violet
pk pink
g/y green/yellow

br brown
r red
y yellow

w white
gy grey
or orange

INSTALLATION

Henrad WH FF - Installation

21

INSTALLATION

Notes.

1. Some earth wires are omitted for

clarity. Ensure proper earth continuity
when wiring.

2. Numbering of terminals on thermostats
is specific to the manufacturer.

3. This is a fully controlled system - set
the boiler thermostat to maximum.

4. Switchmaster 'Midi' is similar in
operation but the wiring differs slightly ­see the manufacturer's literature.

LEGEND

b blue

bk black

br brown

r red

w white

y/g yellow/green

or orange

gy grey

38

PICTORIAL WIRING

LEGEND

b blue

bk black

br brown

r red

y yellow

w white

or orange

v violet

p pink

gy grey

y/g yellow/green

39

MID POSITION VALVE

Pumped only

INSTALLATION

22

Henrad WH FF - Installation

INSTALLATION

Notes.

1. Some earth wires are omitted for

clarity. Ensure proper earth continuity
when wiring.

2. Numbering of terminals on
thermostats is specific to the
manufacturer.

3. This is a fully controlled system - set
the boiler thermostat to maximum.

4. Switchmaster valve has grey and
orange auxiliary switch leads but the
grey wire must be connected to the
live supply.

40

TWO SPRING CLOSED VALVE

Pumped only

w white

gy grey

y/g yellow/green

or orange

v violet

pk pink

LEGEND

b blue

bk black

br brown

r red

y yellow

41

FROST PROTECTION

Central heating systems fitted wholly inside the house do not

normally require frost protection as the house acts as a 'storage

heater' and can normally be left at least 24 hrs. without frost

damage. However, if parts of the pipework run outside the house

or if the boiler will be left off for more than a day or so, then a frost

thermostat should be wired into the system.

This is usually done at the timer, in which case the programme

selector switches are set to OFF and all other controls MUST be

left in the running position.

The frost thermostat should be sited in a cold place but where it

can sense heat from the system.

Wiring should be as shown, with minimal disturbance to other wiring

of the timer.

Designation of the terminals will vary but the timer and thermostat

manufacturer's leaflets will give full details.

If a boiler is installed in a garage it may be necessary to fit a pipe

thermostat.

Diagram A shows a double pole frost thermostat, which should

suffice for all systems which do not use the OFF terminals of the

timer.

Diagram B shows a 'change-over' frost 'stat, which will cover most

systems which do use CH OFF. If, however, on such a system the

HW pipework is in an isolated part of the house, a second frost

'stat may be used to protect it. If in doubt, ask your installer for

advice.

INSTALLATION

Henrad WH FF - Installation

23

INSTALLATION

42

COMMISSIONING AND TESTING

(a) Electrical Installation

1. Checks to ensure electrical safety should be carried out

by a competent person.

2. ALWAYS carry out preliminary electrical system checks,
i.e. earth continuity, polarity, resistance to earth and short
circuit using a suitable test meter.

WARNING. Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and
doors, extinguish naked lights and DO NOT SMOKE.

(b) Gas Installation

1. The whole of the gas installation, including the meter,

MUST be inspected and tested for soundness, and purged
in accordance with the recommendations of BS. 6891.

2. Purging air from the gas installation may be expedited by
loosening the union on the gas service cock on the boiler
and purging until gas is detected.

3. Retighten the union and check for gas soundness.

TO LIGHT THE BOILER

1. Check that all the drain cocks are closed, and any valves in

the flow and return are open.

2. Check that the gas service cock (B) is OPEN and the boiler
mains On/Off switch is OFF.

3. If the boiler output is to be set to minimum or mid, affix the
appropriate indicator label supplied in the hardware pack to
the data badge, located on the controls support.

4. Fitting the Boiler Casing

The boiler casing must be refitted with the controls support
casing attached for alignment purposes. Lift the boiler casing
up to the boiler assembly, with the casing top angled forward.
Hook the top edge of the boiler casing into the channel on the
top of the boiler assembly. Swing the bottom of the casing
down and secure with the 2 captive screws.

The casing must seat correctly and compress the sealing strip
to make an airtight joint.
Visually check the side seals but, if side clearances are limited,
then check that the top and bottom edges of the casing are
correctly located.

If the Sealed System Unit is fitted remove the unit casing in
order to inspect the top casing seal.

To gain access to the gas valve:

a. Remove the controls support casing. Release the controls

support front fixing screws 3 turns only. Remove the pod by
pulling it forward to disengage from the keyhole slots.

b. Remove the control box securing screws and swing it down

into the servicing position. See diagram B.

5. Slacken the screw in the burner pressure test point (F) and
connect a gas pressure gauge via a flexible tube.

6. Swing the control box back into its working position.

43

INITIAL LIGHTING

7. Press the overheat thermostat reset button (J).

8. Switch the electricity supply ON and check that all external

controls are calling for heat.

9. Set the boiler thermostat knob (D) to position 6 and the boiler
Mains on/off switch to ON. The fan will start. After the fan has
run for a few seconds the pilot solenoid valve should open
and the intermittent spark commence, continuing until the
pilot is established. The main burner will then cross-light
smoothly. If this sequence does not occur, refer to the Fault
Finding section.

10. Test for gas soundness around ALL boiler gas components
using leak detection fluid.

11. Operate the boiler for 10 minutes to stabilise the burner
temperature.

12. The boiler is pre-set at the factory to its highest nominal rating
but can be range rated to suit the system design requirements.
Refer to Table 2 (page 2):

a. Set the mains On/Off switch to OFF.

b. Switch the electricity supply OFF.

c. Swing the control box down into the servicing position.

d. Remove the main burner adjuster cover.

e. Turn the adjusting screw clockwise to INCREASE the

pressure, or anticlockwise to DECREASE the pressure.

f. Swing the control box back into its working position.

g. Switch the electricity supply ON.

h. Set the mains On/Off switch to ON and check the new

setting pressure.

13. If necessary repeat steps 12a to h until the required pressure
is achieved. Record this value in the Benchmark log book.

14. Set the main On/Off switch to OFF.

15. Switch the electricity supply OFF.

16. Swing the control box down into the servicing position.

17. Refit the main burner pressure adjuster cover.

18. Remove the pressure gauge and tube. Retighten the sealing

screw in the pressure test point. Ensure a gas tight seal is
made.

LEGEND

A Sightglass.
B Gas service cock.
C Inlet pressure test point.
D Thermostat knob

E Main burner pressure adjuster.
F Burner pressure test point.
H Boiler mains on/off switch.
J Overeheat thermostat reset

button.

INSTALLATION

24

Henrad WH FF - Installation

INSTALLATION

44

INITIAL LIGHTING - continued

1. Hand the User's Instructions to the Householder and explain

his or her responsibilities under the Gas Safety (Installation
and Use) Regulations or rules in force.

2. Draw attention to the Lighting Instruction label affixed to the
controls pod door.

3. Explain and demonstrate the lighting and shutting down
procedures.

4. The operation of the boiler and the use and adjustment of
ALL system controls should be fully explained to the
Householder, to ensure the greatest possible fuel
economy, consistent with household requirements of both
heating and hot water consumption.

Advise the User of the precautions necessary to prevent

damage to the system and to the building, in the event of
the system remaining inoperative during frosty conditions.

5. Explain the function and the use of the boiler thermostat
and external controls.

6. Explain the function of the boiler overheat thermostat and
emphasise that if cutout persists, the boiler should be turned
off and a registered CORGI installer consulted.

7. Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the economic
use of the system.

8. If any Timer Kit is fitted draw attention to the Timer Kit User's
Instructions and hand them to the Householder.

9. After installation, commissioning and customer hand-

over instructions please complete the
appliance log book and leave this with the customer.

10. Stress the importance of regular servicing by a CORGI

registered installer and that a comprehensive service should
be carried out AT LEAST ONCE A YEAR.

After completing the installation and commissioning of
the system the installer should hand over to the
householder by the following actions:

46

HANDING OVER

45

GENERAL CHECKS

Make the following checks for correct operation:

1. Set the boiler thermostat knob to position 6 and operate the

mains on/off switch. Check that the main burner lights and
extinguishes in response.

2. The correct operation of ANY timer and all other system
controls should be proved.
Operate each control separately and check that the main
burner or circulating pump, as the case may be, responds.

3. Check that the casing is sealed correctly and compressing
the sealing strip all around the casing.

4. Water Circulating System

a. With the system HOT, examine all water connections for

soundness.

b. With the system still hot, turn off the gas, water and electricity

supplies to the boiler and drain down, in order to complete
the flushing process.

c. Refill and vent the system, clear all air locks and again check

for water soundness.

Knob Setting Flow Temperature

°C °F

1 54 130

2 60 140

3 66 150

4 71 160

5 77 170

6 82 180

WARNING. The boiler MUST NOT be operated with the

casing removed.

d. Balance the system.

5. Finally, set the controls to the user's requirements.

The temperatures quoted below are approximate and vary between
installations.

INSTALLATION

Henrad WH FF - Installation

25

SERVICING

To ensure the continued safe and efficient operation of the
appliance, it is recommended that it is checked at regular
intervals and serviced as necessary.
The frequency of servicing will depend upon the installation
condition and usage, but should be carried out at least
annually. It is the law that any service work must be carried out
by a CORGI registered installer.

As the installer you may wish to undertake the service contract
yourself or alternatively offer to the customer the benefits of the
Caradon Ideal Services, details of which are outlined in the
household pack supplied with this boiler.

a. Light the boiler and carry out a pre-service check, noting

any operational faults. Operate the boiler for at least 20
minutes. Check the gas consumption.

b. Connect a suitable gas analyser to the sampling point on

the top RHS of the back panel. For correct boiler operation
the CO/CO

2

content of the flue gas should not be greater
than 0.004 ratio. If this is the case and the gas input is at
least 90% of the nominal, then no further action need be
taken. If not, proceed to paragraph c.

3. Pull the HT lead connection off the printed circuit board and
pull the lead upwards through the bottom panel grommet.

4. Remove the 4 screws retaining the air box/pilot assembly to
the vertical manifold and carefully remove the assembly.

49

BURNER AND AIR BOX REMOVAL

1. Remove the screw retaining the front burner support strap to

the combustion chamber. Remove the M5 pozi situated at
the LH bottom rear of the burner and pull the burner
downwards to disengage the retention tab. Remove the
burner to a safe place for inspection and cleaning.

2. Remove the control box fixing screw. Pull the box forward
and downward to disengage.

1. Open the controls pod door and release the 2
captive screws at the bottom of the casing. Swing
the bottom of the boiler casing out until the
controls pod casing has cleared the controls, then
unhook the casing top from the back panel.
Retain the casing in a safe place. Where the
removal of the casing is impaired by a pelmet, the
instruction in Frame 2 should be followed.

2. Isolate the gas supply at the service cock fitted to
the boiler.

48

BOILER CASING REMOVAL

47

SCHEDULE

c. Clean the main burner. Refer to Frame 51.
d. Clean the heat exchanger. Refer to Frame 50.
e. Clean the main and pilot injectors. Refer to Frame 51.
f. Remove any debris from inside the base of the casing.
g. Check that the flue terminal is unobstructed and that the flue

system is sealed correctly.

h. If the appliance has been installed in a compartment, check

that the ventilation areas are clear.

The servicing procedures are covered more fully in Frames 48 to
52 and must be carried out in sequence.

WARNING

.

Disconnect the electrical supply and turn off gas supply.
IMPORTANT. After completing the servicing or exchange of

components always test for gas soundness and carry out functional
checks as appropriate.

When work is complete the casing MUST be correctly refitted,
ensuring that a good seal is made.

T

he boiler must NOT be operated if the casing is not fitted.

Note. In order to carry out either servicing or replacement of
components, the boiler casing must be removed. Refer to Frame 48.

SERVICING

26

Henrad WH FF - Installation

SERVICING

9. Remove all loose deposits from the heat exchanger,

particularly between the fins, using a suitable brush.

10. Re-assemble in reverse order, ensuring the fan leads and
3 sensing tubes are reconnected.

52

RE-ASSEMBLY

Re-assemble the boiler in the following order.

1. Refit the flue baffles.

2. Inspect the collector hood rope gasket and replace, if

necessary, ensuring that the self adhesive rope is fitted
centrally on to the lip of the collector hood / fan
assembly. The boiler efficiency will be adversely affected
if incorrectly fitted. Refit the collector hood and retain
with the 2 front tie rods and the rear central fixing screw.
Tighten the nuts and screw. Ensure that the sealing
gasket is compressed. Refit the pressure pipe.

3. Refit the positive pressure tubes on the top of the fan
housing. Reconnect the electrical leads.

4. Refit the air box assembly and burner. Ensure that the
burner front fixing is refitted.

1. Remove the 2 silicon rubber tubes from the fan sensing
points.

2. Disconnect the fan leads.

3a. Rear flue

Slacken the M4 screw securing the flue connector to the
fan. Disconnect the connector from the fan and slide into
the flue.

3b. Side or top flue

Slacken off two M4 screws securing the flue elbow and
flue connector. Disconnect the flue connector from the
elbow and slide into the flue. Remove the flue elbow.

4. Disconnect the silicon rubber tube from the rear of the
collector hood.

5. Slacken the two M5 nuts on the front tie rods, releasing
the tie rods from the combustion chamber.

6. Remove the M5 central fixing screw at the rear of the
collector hood and remove collector hood/fan assembly.

7. Check that the fan impeller runs freely. Remove any
debris from the impeller with a soft brush.

8. Remove the flue baffles.

50

CLEANING THE FAN ASSEMBLY / THE FLUEWAYS

51

CLEANING THE BURNER AND PILOT ASSEMBLY

1. Brush off any deposits that may have fallen on to the

burner head (ensuring the flame ports are unobstructed)
and remove any debris that may have collected.

Note. Brushes with metallic bristles must not be used.

2. Remove the main burner injector and ensure there is no

blockage or damage. Clean or renew as necessary.

3. Refit the injector, using an approved jointing compound
sparingly.

4. Inspect the pilot burner and ignition / detection electrode.
Ensure that they are clean and in good condition.

Check that:

a. The pilot burner injector is not blocked or damaged. Refer to

Frame 58 for removal details.

b. The pilot burner is clean and unobstructed.

c. The ignition / detection electrode is clean and undamaged.

d. The ignition / detection lead is in good condition.

e. The spark gap is correct (Frame 58). Clean or renew as

necessary.

Note. The pilot shield is located around the pilot assembly
bracket and is located by the electrode retaining nut.

5. Reconnect the gas supply and the electrical wiring. Refer
to Frames 34 & 36.

6. Check the sightglass in the boiler casing. Clean or renew
as necessary. Refer to Frame 55.

7. Check for gas soundness. Check the gas service cock
and pressure test point.

8. Refit the boiler casing (Refer to Frame 43, item 4). Note
that it is not necessary to disturb the controls casing pod.

9. Close the controls pod door.

SERVICING

Henrad WH FF - Installation

27

SERVICING

MAIN BURNER

After any servicing, reference should be made to Table 2
which quotes details of the rated output with the related
burner setting pressure and the heat input. Any required
adjustments should be made by using the pressure
adjustment screw.

Refer to 'initial Lighting', Frame 43.

REPLACEMENT OF PARTS

56

OVERHEAT THERMOSTAT REPLACEMENT

54

GENERAL

When replacing any component:

1. Isolate the electricity supply.

2. Turn OFF the gas supply.

3. Remove the boiler casing. Refer to Frame 48.

IMPORTANT. When work is complete the casing must be

correctly refitted, ensuring that a good seal is made.

53

GAS PRESSURE ADJUSTMENT

PILOT

The pilot is factory set to maximum and no further
adjustment is possible. If, after removing and checking the
injector (as detailed in Frame 58) and ensuring that there is
an inlet pressure of 20 mbar available, the pilot does not
light then contact Caradon Plumbing Limited.

Relight in accordance with 'Initial Lighting', Frame 43.

Note. In order to assist fault finding, the control box printed
circuit board is fitted with 2 indicator lights which represent the
following boiler conditions:

Neon I3. Mains electricity ON.

Neon SG1. Flashes to indicate ignition operation (stops after

detection).

The boiler MUST NOT be operated if the casing is not fitted.

55

SIGHTGLASS REPLACEMENT

1. Refer to Frame 54.

2. Unfasten the 2 nuts and washers holding the sightglass

assembly to the casing front panel.

3. When fixing the new assembly ensure that the parts are in
the correct order. The frame must have the return edge at
the bottom.

4. Retighten the 2 nuts to ensure an airtight seal. Do NOT
overtighten.

6. Replace the boiler casing. Refer to Frame 52.

1. Refer to Frame 54.

2. Remove the control box fixing screws.

3. Swing the control box down into the servicing position.

4. Pull off the electrical connections at the thermostat. Remove

the backnut retaining the thermostat to the bracket. Withdraw
the thermostat phial from the heat exchanger pocket.

5. Fit the new thermostat and re-assemble in reverse order.

6. Check the operation of the boiler.

SERVICING

28

Henrad WH FF - Installation

SERVICING

Refer also to Frame 54.

A. Remove the fixing screws

B. Swing the control box down into the servicing position.

Thermostat control

1. Pull the knob off the shaft.

2. Remove the backnut securing the thermostat control to

the control box.

3. Pull off the Molex connector from the printed circuit
board.

4. Replace and re-assemble in reverse order.

Thermistor sensor lead

5. Pull the sensor lead connector off the printed circuit

board.

6. Remove the sensor from the heat exchanger pocket
and unclip from the back panel.

7. Remove the strain relief bush from the back panel
base.

8. Remove the sensor lead through the grommet in the
control box.

9. Replace and re-assemble in reverse order.

On/off switch

10. Disconnect the electrical connectors from the rear of

the switch.

11. Press in the 2 side retaining clips and remove the
switch.

12. Re-assemble in reverse order.

57

THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and ON/OFF SWITCH
REPLACEMENT

58

PILOT BURNER REPLACEMENT

1. Refer to Frame 54.

2. Remove the burner and air box assembly.

Refer to Frame 49.

3. Remove the electrode retaining nut and remove the pilot
shield and electrode.

4. Unscrew the central pilot fixing screw and lift the pilot clear
of the pilot injector. The pilot injector may now be
unscrewed if required.

5. Replace the pilot burner (injector if necessary) and retain
with the M4 screw previously removed. Ensure that the

copper sealing washer is replaced when refitting the pilot
injector.

6. Replace the electrode and pilot shield, retaining both with
the electrode nut. Check the spark gap.

7. Reassemble in reverse order.

8. Check the operation of the boiler.

9. The pilot is factory set to maximum and no further

adjustment is possible. Ensure that there is an inlet
pressure of 20 mbar available. Also check burner ignition
and cross-lighting.

SERVICING

Henrad WH FF - Installation

29

SERVICING

1. Refer to Frame 54.

2. Remove the burner and air box assembly. Refer to Frame 49.

3. Remove the electrode retaining nut.

4. Remove the pilot shield.

5. Remove the ignition electrode and integral lead.

6. Refit the new electrode and lead in reverse order.

Ensure that the pilot shield is replaced.

7. Check the spark gap. Refer to Frame 58.

8. Reassemble in reverse order.

9. Check operation of the boiler.

59

IGNITION ELECTRODE AND LEAD REPLACEMENT

1. Refer to Frame 54.

2. Remove the screw retaining the front burner support

strap to the combustion chamber.

3. Remove the M5 pozi screw, situated at the left hand
bottom rear of the burner. Pull the burner downward to
disengage the retention tab and remove the burner.

4. At this stage the main burner injector can be removed,
checked, cleaned or replaced as required. Ensure that
an approved jointing compound is used sparingly.

5. Fit the new burner, ensuring that the retention tab is
correctly located in the air box slot and reassemble in
reverse order.

6. Check the burner for cross-lighting and flame stability.

60

MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT

61

GAS CONTROL VALVE REPLACEMENT

Note. Refer also to Frame 69 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 54.

2. Remove the burner and air box assembly. Refer to

Frame 49.

3. Remove the fixing screws.
Swing the control box down into the servicing position.

4. Disconnect the gas control valve electrical leads.

5. Undo the gas cock union .

6. Whilst supporting the gas control valve, remove the 2

screws retaining the manifold to the back panel.

7. Remove the gas control / manifold assembly.

8. Remove the 4 screws retaining the manifold to the gas

control valve, and fit the manifold to the new valve.
Ensure that the new control is fitted the correct way
round (an arrow engraved on back indicates the
direction of flow).

9. Transfer the gas cock union to the new gas control
valve, using an approved jointing compound.

10. Re-assemble in reverse order.

11. Check the operation of the boiler.

SERVICING

30

Henrad WH FF - Installation

SERVICING

63

AIR PRESSURE SWITCH (APS) REPLACEMENT

62

FAN REPLACEMENT

64

PRINTED CIRCUIT BOARD (PCB) REPLACEMENT

65

COMBUSTION CHAMBER INSULATION REPLACEMENT

1. Refer to Frame 54.

2. Remove the burner and air box assembly.

Refer to Frame 49.

3. Remove the 4 tie rods.

4. Remove the combustion chamber.

5. Remove the 2 side panel retaining brackets.

6. Remove the side insulation panels.

7. Remove the front and rear

insulation panels.

8. Fit the new front and rear
insulation panels.

9. Fit the new side panels and
retain with the brackets and
screws previously removed.

10. Re-assemble in reverse order.

1. Refer to Frame 54

2. Remove the 2 silicon rubber tubes from the fan sensing points.

3. Disconnect the fan leads.

4a. Rear flue. Slacken the M4 screw securing the flue connector to the

fan. Disconnect the connector from the fan and slide into the flue.

4b. Side or top flue. Slacken off two M4 screws securing the flue elbow

and flue connector. Disconnect the flue connector from the elbow
and slide into the flue. Remove the flue elbow.

5. Disconnect the silicon rubber tube from the rear of the collector hood.

6. Slacken the two M5 nuts on the front tie rods, releasing the tie rods

from the combustion chamber.

7. Remove the M5 central fixing screw at the rear of the collector hood
and remove collector hood / fan assembly.

8. Remove the three M4 screws retaining the fan to the collector hood.

9. Fit the new fan and re-assemble in reverse order, ensuring the fan

leads, and 3 sensing tubes are reconnected.

10. Check the operation of the boiler.

1. Refer to Frame 54.

2. Remove the APS fixing screw.

3. Remove both sensing tubes from the APS.

4. Remove the 3 electrical connections from the APS.

5. Fit the new APS and reassemble in reverse order.

6. Check the operation of the boiler.

5. Disengage the PCB from the mounting posts and withdraw from

the control box.

6. Fit the new PCB and re-assemble in reverse order.

7. Check the operation of the boiler.

Fuse.

To change the fuse, prise it out of the holder and disengage the
fuse. Refer to Frame 70 for fuse location.

Note. Refer to Frames 70 of 'Exploded Views' for

illustration of the procedure detailed below.

1. Refer to Frame 54.

2. Remove the fixing screws and swing the control box

down into the servicing position.

3. Disconnect the detection lead from the PCB.

4. Unplug all the Molex connectors from the PCB.

SERVICING

Henrad WH FF - Installation

31

SERVICING

67

CASING SEAL REPLACEMENT

8. Slacken 3 turns only the 4 heat exchanger / inter-panel

retaining screws.

9. Lift the heat exchanger / inter-panel assembly upward and
forward to disengage key hole fixings. Pull the assembly
downwards to clear the water pipes from the back panel.

10. Remove the 2 rubber sealing grommets from the top of the
back panel to facilitate fitting the new assembly.

11. Fit the new heat exchanger assembly, complete with water
pipes, and hang it on the key hole slots and screws. Retighten
the screws.

12. Replace the 2 rubber sealing grommets.

13. Re-assemble in reverse order.

14. Remake all water connections, ensuring that the compression

fittings (if used) are correctly refitted.

15. Fully test all functions, including water and gas soundness.

66

HEAT EXCHANGER REPLACEMENT

Note. Refer to Frame 5 (Boiler assembly - Exploded view) for

illustration of the procedure detailed below.

1. Refer to Frame 54.

2. Remove the burner / air box assembly. Refer to Frame 49.

3. Drain the system.

4. Disconnect the water connections. If compression fittings are

used then cut the pipes both above and below the fittings in
order to allow the heat exchanger assembly to be removed.
Remove the heat exchanger drain plug and drain the residual
water into a suitable receptacle.

5. Remove the fan / collector hood assembly.
Refer to Frame 50.

6. Remove the combustion chamber by unscrewing the 4 tie rods.

7. Remove the thermostat sensors from the pockets on the heat

exchanger by removing the M3 screws and plates.

1. Refer to Frame 54.

2. Remove the old seal from the casing surround and

thoroughly clean the casing surfaces.

3. Fit the new self adhesive seals.

4. Replace the boiler casing.

Model 100 FF does not have air deflector baffles fitted to
jacket bottom.

SERVICING

32

Henrad WH FF - Installation

Check all connections to PCB.

If no fault found, replace PCB

FAULT FINDING

Reset the overheat 'stat. Set control

'stat to maximum. Allow the boiler to

reach temperature - if the overheat

'stat trips again, measure flow

temperature.

If above 90°C replace control 'stat.

If below 90°C replace overheat 'stat.

START

Check that the mains on neon

'I3' is illuminated.

YES

NO

YES

YES

NO

Is there a live supply to both

terminals of overheat 'stat?

Is the ignition electrode sparking?

YES

YES

YES

Change fan

YES

NO

Rectify bad connection

Check mains supply and fuses.

Check timer and system thermostats

are all ON. Check that boiler plug and

socket are OK and fully connected.

Check that the boiler thermostat

is set at maximum and the mains

on/off switch is ON.

Is the fan turning ?

YES

Check connections to pressure

switch. If no faults found, change

pressure switch.

Replace the sensor

Check connections and leads to

pressure switch/boiler thermostat

and check that fan is operating.

Check all connections to PCB.

If no fault found change PCB.

YES

Check pressure switch sensing

pipes for blockages, bad

connections and reversed

connection.

Is pressure difference at switch

greater than 0.9 mbar?

Change fan

YES

NO

Change

pressure switch

Is the boiler casing

correctly fitted?

Does the pilot light ?

NO

YES

NO

YES

Does the

spark stop

after pilot is

lit?

NO

Is there a gas supply

to the boiler?

Is the pilot injector

blocked?

YES

Replace

gas valve

NO

Is there a supply on terminals

of main gas valve?

YES

NO

YES

NO

NO

Is there a supply on the fan

connector at PCB ('Molex '

marked 'FAN'?).

YES

YES

NO

NO

Check the polarity of

the mains supply.

Check the continuity of

the ignition lead from

connector to electrode.

Does the spark now

cease when gas is lit ?

Ensure pilot and

main gas valve

leads are not

crossed over.

Is there a supply

voltage at pilot

gas valve?

Is there a live

supply on the red

lead to pressure

switch?

NO

Is there a regular

spark from tube 'SG1'

on the PCB?

Can the overheat 'stat

be reset when the

system is cold ?

NO

YES

NO

Replace fuse BUT, before

attempting to start boiler, check

for short between live and

neutral, also between live and

earth, on all items plugged into

PCB

Check all connections to PCB.

If no error found replace PCB.

Remove the sensor

(NTC) from the PCB.

Is the fan turning ?

YES

NO

NO

YES

Has the fuse blown on PCB ?

NO

NO

Is there a live supply on the

violet lead to pressure switch?

Is there a

supply at
the fan ?

Replace the overheat thermostat

Does main burner

cross-light from pilot?

Is the main burner

injector clear?

Replace main gas

solenoid valve

Check gap at ignition electrode.

Check electrode and lead are

undamaged, and not close to

earthed metalwork.

FAULT FINDING

Henrad WH FF - Installation

33

SHORT LIST OF PARTS

Key No. GC Part No. Description Qty. Product No.

9 308 365 Sightglass assembly kit 1 079602

12 Main burner

AEROMATIC No.AC 19/123 306; FF 230 & FF 240 1 155396
AEROMATIC No.AC 19/123 305; FF 250 & FF 260 1 155397
AEROMATIC No.AC 19/123 292; FF 270, FF 280 & FF 2 100 1 111709

13 Main burner injector

Injector 044-01-344 256; FF 230 1 155398
Injector 044-01-344 300; FF 240 1 155399
Injector 044-01-344 330; FF 250 155400
Injector 044-01-344 359; FF 260 1 155401
Injector 044-01-344 400; FF 270 1 156313
Injector 044-01-344 420; FF 280 1 156314

Aeromatic Pt. No. 939021, 4.6mm; FF 2 100 1 152320

13A Copper washer, Aeromatic 914176(for injector); all models 1 152426

14 397 943 Pilot burner injector: HONEYWELL 4580 1075002 ; FF 230-280 1 004982

Pilot burner injector: HONEYWELL 4580 1075001 ; FF 2 100 1

15 308 358 Pilot burner head Q359A with:

Honeywell 4580 1075002 injector FF 230-280 1 079599
Honeywell 4580 1075001 injector FF 2 100 1 079590

17 Gas valve kit VR 4601AA1036, 230 V 1 075698

18 G308 549 Ignition electrode complete with lead and backnut 410 mm lg. 1 111881

19 308 522 Control box assembly, including thermostat, knob, PCB,

potentiometer and on/off switch 1 111973

23 386 149 Automatic ignition printed circuit board :

PACTROL PCB 25 B 1 079716

24 385 861 Pressure switch: HONEYWELL YAMATAKE C6065 F 1373:2 1 155412

26 308 283 Thermostat knob 1 079601

30 E02-661 Fan assembly: SIFAN No.WFFB 0221-039 FF 230-280 1 151586

SIFAN No.WFFB 0226-028 FF 2 100 1

35 E04-503 Boiler casing assembly complete with sightglass assy, insulation

& M5 x 16 dogpoint pozi pan hd FF 230-280 1 075391

FF 2 100 1 075523

37 308 541 Controls casing door with Lighting Instructions 1 079941

39 E04-504 Casing seal pack complete with screws 1 075392

45 386 144 Overheat thermostat, RANCO LM7 P 8508 1 113200

The following are parts commonly required due to damage or expendability.
Their failure or absence is likely to affect safety or performance of this appliance.

The list is extracted from the British Gas List of Parts, which contains all avail­able spare parts.

The full lists is held by British Gas, Caradon Plumbing Limited distributors
and merchants.

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers

34

Henrad WH FF - Installation

SHORT LIST OF PARTS

69

BURNER ASSEMBLY - Exploded View

70

CONTROL BOX - Exploded View

LEGEND

10. Burner manifold

11. Air box and pilot assembly.

12. Main burner.

13. Main burner injector.

16. Pilot shield.

17. Gas control valve.

42. Gas service cock.

LEGEND

19. Control box.

21. Thermostat potentiometer.

23. Printed circuit board.

26. Thermostat knob.

58. Mains on/off switch.

Henrad WH FF - Installation

35

SHORT LIST OF PARTS

71

BOILER CASING ASSEMBLY

72

SHORT PARTS LIST

H

enrad Installer/Technical Helpline: 01482 498663

FF.87/AP/107
RS.87/AP/108

Natural Gas

appliances are

service listed by

British Gas

Caradon Plumbing Limited pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.

April 2001 UIN 156 645 A02

CERTIFIED PRODUCT
Manufactured under a BS EN ISO 9001:1994
Quality System accepted by BSI.

Caradon Plumbing Limited, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone:
01482 492 251 Fax: [phone]. Registration No. London 322 137.

These appliances are designed for use with Natural
Gas only. They have been tested and conform with
the provisions of BS. 6332 and BS. 5258.

THIS SYMBOL IS YOUR
ASSURANCE OF QUALITY

The code of practice for the installation,

commissioning & servicing of central heating systems

The Caradon Plumbing Limited Technical Training Centre
offers a series of first class training courses for domestic,
commercial and industrial heating installers, engineers and
system specifiers.

For details of courses please ring: ............... 01482 498432

Technical Training