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221992D.10.02
Instructions for Use
Installation and Servicing
To b e l e f t w i t h t h e u s e r
Balanced Fanned Flue Boiler
Model: BFF80
G.C. No. 41-333-91
This is a Cat I
Appliance
2H
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.
Halstead Boilers Limited, 20/22 First Avenue, Bluebridge Industrial Estate, Halstead, Essex CO9 2EX
Tel: 01787 272800. Sales Direct Line: 01787 475557. Fax: 01787 474588. Service Helpline: 01926 834834.
e-mail: sales@halsteadboilers.co.uk or service@halsteadboilers.co.uk Website: www.halsteadboilers.co.uk
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Summary of Contents for Halstead BFF80
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Page 1: Instructions For Use
(Installation and Use) Regulations, be handed to the user on completion of the installation. Halstead Boilers Limited, 20/22 First Avenue, Bluebridge Industrial Estate, Halstead, Essex CO9 2EX Tel: 01787 272800. Sales Direct Line: 01787 475557. Fax: 01787 474588. Service Helpline: 01926 834834. -
Page 2: Table Of Contents
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. - Page 3 The frequency of servicing will depend upon The Halstead Buckingham 4 B FF series are balanced fanned the particular installation conditions and usage, but in general flue boilers.
- Page 4 Instructions for Use To Turn the Appliance On BOILER Turn the electrical supply on to the boiler and check that all TEMPERATURE remote controls are calling for heat. CONTROL Turn the boiler temperature control clockwise to any position between “0” and "Max", see diagram 1. "Max"...
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Page 5: General Data
1 General Data GAS CONNECTION WATER CONNECTIONS Rc1 reduced NOTE: The boiler casing can be in. B.S.P.T.) with DISTRIBUTOR TUBE to set at two heights, in. B.S.P.T.) (pumped return) MAX. and MIN. WATER CONNECTIONS Rc1 (1in. B.S.P.T.) GENERAL DIMENSIONS - given in millimetres Diagram 1.1 700 558 294 364 555 442 Max 900/... - Page 6 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 407 MIN. WORKTOP invalidate the B.S.I.
- Page 7 1 General Data 1.7 Boiler Location 1.8 Heating System Controls This boiler is not suitable for outside installation. The heating system should have installed: a programmer and room thermostat controlling the boiler. The boiler casing can be fitted at two heights. Refer to diagram 1.3.
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Page 8: Water Systems
2 Water Systems 2.1 Water Pressure Head REFER TO BS 5546 The boiler shall only be connected to a cistern water supply with 22mm VENT a minimum head of 1metre (3ft3in) and a maximum head of 27metres (90ft) which has an open vent in the system. 15mm COLD FEED The working pressure must be within the range 0.1bar to 2.7bar (1.3 to 39lbftin... -
Page 9: Flue & Ventilation
Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from the local gas undertaking or Halstead Boilers Ltd. 3.3 Terminal Guard A terminal guard is required if persons come into contact with the terminal or the terminal could be subject to damage. -
Page 10: Installation
4 Installation INCREASE TO 30mm IF A FLUE COLLAR IS ADDED FLUE & AIR DUCT LENGTH = A + 15 + 3 FLUE MINIMUM MINIMUM MAXIMUM PACKS WALL FLUE FLUE THICKNESS LENGTH LENGTH REAR STD. REAR NOTE : IF IT IS NECESSARY TO CUT THE DUCTS TO ACHIEVE THE "FLUE LENGTH"... - Page 11 4 Installation Fit the self adhesive foam seal provided in the flue pack around 4.3 Flue Hole Cutting the air duct at the position shown in diagram 4.1. Mark out the flue centre, see diagram 4.2, then cut a hole for the Make sure that the ductings do not slope down towards the flue using, preferably, a 115mm minimum core drill.
- Page 12 4 Installation 4.6 Water Connections - Gravity Domestic and Pumped Heating ALTERNATIVE HEATING OR Fit suitable fittings into the boiler tappings, see diagram 4.7. DOMESTIC Make sure that all pipes are taken backwards and will clear the HOT WATER casings, see diagram 1.1. FLOW Heating flow: Any one of the four upper connections may be used.
- Page 13 4 Installation 4.9 Casing Brackets 4.8 Pipework Fit the two upper and two front casing brackets shown in When the front tappings are used, it is essential that any diagram 4.12, using the No.8 screws provided. pipework or fittings do not project more than shown in diagram 4.10.
- Page 14 4 Installation 4.10 Side In-fill Panel (if required) 4.11 Side Casings A side in-fill panel is supplied with the boiler, which can be fitted Fit the side casings by locating their lugs into the appropriate at the rear of the left or right hand side casing but can be slot in the boiler plinth, see diagram 4.13, depending on the discarded if the water connections are made on both sides of required height, there are two options, see section 1.7.
- Page 15 4 Installation 4.12 Flue / Boiler Connection Remove the three self-tapping screws from the lower part of the control box support bracket, see diagram 4.16. Undo the wing nut that secures the top of the heat shield and carefully hinge down control box and heat shield, see diagram 4.16.
- Page 16 4 Installation 4.13 Water & Gas connections Replace fan access door, heat shield and control box. Note: When replacing the fan access door make sure the lip at the top of door fits into and behind the slotted bracket located at the top of the boiler.
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Page 17: Electrical Wiring
5 Electrical Wiring SECURING CONTROL SCREWS COVER TERMINAL TERMINAL BLOCK BLOCK CONNECTIONS CONTROL BOILER TEMPERATURE CONTROL Diagram 5.1 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. -
Page 18: Commissioning
6 Commissioning Turn the boiler temperature control clockwise to “Max”. IMPORTANT NOTE The ignition system will operate to light the boiler. After a pre- The WARNING NOTICE attached to the front casing must only set time if ignition has not taken place the boiler will shutdown. be removed by the user To re-start the lighting sequence, turn the boiler temperature Please ensure the “Benchmark”... - Page 19 BOTTOM PLINTH Diagram 6.2 PANEL Gas rate: Buckingham 4 BFF80 : 2.8m /h (79ft is for guidance only, dependent on the heat setting. Turn the boiler temperature control fully anti-clockwise to “0”. LOCATE Isolate from the electrical supply.
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Page 20: Instructions To The User
8.5. reconditioned or copy parts that have not been clearly authorised Remove the three self-tapping screws from the lower part of the by Halstead Boilers Ltd. control box support bracket, see diagram 8.6. Products of Combustion Check Undo the wing nut that secures the top of the heat shield and... - Page 21 8 Servicing Note: When replacing the fan access door make sure the lip at the top of door fits into and behind the slotted bracket located at the top of the boiler. Note: To ease removal of the right hand baffle from the heat exchanger, remove both silicone tubes from the air pressure switch.
- Page 22 8 Servicing 8.4 Service Checks 8.2 Boiler Flueways Inspect the spark electrode and clean and replace as necessary, Remove flueway baffles noting that there are 2 centre and 2 see diagram 8.12. side flueway baffles, see diagram 8.8. Check the condition of the side and rear insulation panels in the Place a sheet of paper in the combustion chamber to catch any combustion chamber.
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Page 23: Fault Finding
8 Servicing ELECTRODE SPARK GAP = 3.6 SECURING SCREW GRAPHITE COATED BURNER NUT(2) INJECTOR Diagram 8.12 Diagram 8.11 9 Fault Finding 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. - Page 24 9 Fault Finding 9.1 Electrical BOILER TEMPERATURE Gain access to the control box, refer to the relevant paragraph CONTROL in section 8.1, then remove the control box cover, refer to section 5.1. Refer to: Boiler Fault Finding, see diagram 9.1, Fault Finding Wiring Diagram, see diagram 9.3, Pictorial Wiring Diagram, see diagram 9.4.
- Page 25 9 Fault Finding NEON KEY (see P.C.B) PRESSURE SWITCH NEON 1 = = MAINS ON NEON 2 = = DEMAND ON NEON 3 = = FAN RUNNING NEON 4 = = BURNER LIT = SAFETY NEON 5 = TEMPERATURE LIMITER NEON 6 = = FLAME FAILURE CONTROL...
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Page 26: Replacement Of Parts
10.2. by Halstead Boilers Ltd. Disconnect ignition lead. Replacement of parts must only be carried out by a competent Carefully pull the board away from its supports bending back person. - Page 27 10 Replacement of Parts 10.5 Solenoid 10.10 Insulation Remove the electrical plug from the multifunctional control and Refer to the relevant paragraphs of the servicing section to remove the securing screw and then the solenoid assembly, remove the burner from combustion chamber. see diagram 10.4.
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Page 28: Spare Parts
11 Spare Parts 11.1 Part Identification 11.2 Ordering The key number in diagram 11.1 and the first column of the list When ordering any spare part please quote the part number will help identify the spare part. and the description from the list together with the model name and serial number information from the data label.
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