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IDEAL Henrad SEC 80FF Installation & Servicing Manual

Wall mounted, gas fired, fanned flue combination condensing boiler
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Summary of Contents for IDEAL Henrad SEC 80FF

  • Page 2 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. Henrad SEC FF - Installation...

  • Page 3: General Data

    GENERAL Table 1 - General Data Gas supply Gas Supply Connection 22mm copper Inlet Connection Domestic Hot Water 15mm copper Outlet Connection Domestic Hot Water 15mm copper Flow Connection Central Heating 22mm copper Return Connection Central Heating 22mm copper Flue Terminal Diameter 100 mm Maximum Working Pressure (Sealed Systems) 2.65 bar...

  • Page 4: Table Of Contents

    CONTENTS SEC FF (Natural gas only) Air Supply ................. 6 G.C. Appliance No. 47 348 10 Boiler Clearances ............9 Destination Countries: GB and IE Boiler Exploded Diagram ..........12 Data badge : front of sealing panel Commissioning and Testing ......... 33 Condensate Drain ............
  • Page 5 GENERAL OPERATION With no call for CH the boiler fires only when DHW is drawn At low DHW draw-off rate the maximum temperature is limited off, or periodically for a few seconds without any DHW to 60 C by the modulating gas control. draw-off, in order to maintain the DHW calorifier in a heated Refer also to Frame 1 - 'Boiler Water Circuit Diagrams' condition.

  • Page 6: Air Supply

    GENERAL GAS SAFETY The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary, unless Current Gas Safety (Installation and Use) Regulations, required by the local authority. or rules in force. The boiler must not be fitted outside.

  • Page 7: Flue Installation

    GENERAL GAS SUPPLY 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 The local gas supplier should be consulted, at the installation which people have access then the terminal MUST be planning stage, in order to establish the availability of an adequate protected by a purpose designed guard.

  • Page 8: Water Connections

    GENERAL Ancillary pipework not forming part of the useful heating Notes. surface should be lagged to prevent heat loss and any It is most important that the correct concentration of the possible freezing - particularly where pipes run through roof water treatment product is maintained in accordance with spaces or ventilated underfloor spaces.

  • Page 9: Boiler Clearances

    GENERAL ELECTRICAL SUPPLY accessible and adjacent to the boiler, except for bathroom installations where the point of connection to the mains MUST be situated outside of the bathroom. WARNING. This appliance must be efficiently earthed. Note. Where a room sealed appliance is installed in a room Wiring external to the appliance MUST be in accordance with containing a bath or shower then the appliance and any the current I.E.E.

  • Page 10: Sealed System Requirements

    GENERAL SYSTEM REQUIREMENTS - Central Heating Notes The method of filling, refilling, topping up or flushing Safety valve setting sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable Vessel charge pressure 0.5 to 0.75 to the local water authority.

  • Page 11: Condensate Drain

    GENERAL SYSTEM REQUIREMENTS - CH (continued) and HOT WATER Filling. The system may be filled by one of the following DOMESTIC HOT WATER methods: Domestic Hot Water Requirements a. Through a temporary hose connection from a 'draw-off' tap, supplied from a service pipe under mains The boilers are suitable for connection to most types of pressure.

  • Page 12: Boiler Exploded Diagram

    INSTALLATION BOILER ASSEMBLY - Exploded View Gas inlet pipe egend Automatic air vent DHW plate heat exchanger Burner Fan pressure sensing pipe Gas valve CH return pipe Diverter valve Detection electrode Pump inlet pipe Exp. vessel flexible hose Heat exchanger Ignition electrodes Boiler return pipe Prepiping frame...
  • Page 13 INSTALLATION UNPACKING BOILER PACK CONTENTS Unpack and check the pack contents Complete boiler assembly Hardware Pack (listed separately below) The boiler Wall mounting plate Wall mounting template These Installation and Servicing Instructions User's Instructions Stand-off brackets (optional use) (1 pair) Concealment panels (optional use) (1 pair) Inner flue seal Piping frame...

  • Page 14: Flue Length & Types

    INSTALLATION 10 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED Calculate the total length of flue by the following: Rear flue length = Dim. X + 40mm (1 ") Dimension X - Wall thickness RHS flue length = Dim. Y + 188mm (7 ") LHS flue length = Dim.
  • Page 15 INSTALLATION 11 REAR FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for rear flue lengths greater than 580mm "). Refer to Frame 11. When cutting the ducts always use the cardboard support cutting aid provided. LEGEND Terminal Weather seal...
  • Page 16 INSTALLATION 13 PREPARING THE WALL WARNING. Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. Cut the flue hole (preferably with a 5" core boring tool), ensuring that the hole is square to the wall.

  • Page 17: Water Connections

    INSTALLATION WATER CONNECTIONS Note. Do not subject any of the isolating valves to heat as the seals may be damaged. CH CONNECTIONS DHW CONNECTIONS For top connections: For top connections: Use straight pipe and elbow (not supplied) Reverse 15mm pipe 16 GAS CONNECTION Bottom and top connections Extend a gas supply pipe of not less than 22mm...

  • Page 18: Mounting The Boiler

    INSTALLATION 17 MOUNTING THE BOILER Remove the boiler casing: a. Undo the securing screw. b. Disengage the casing from the back panel and lift it from the boiler. Undo the 2 screws and remove the boiler bottom panel. Lift the boiler on to the wall, locating the CH flow and return pipes, DHW inlet and outlet pipes and gas pipe to the service pipes.
  • Page 19 INSTALLATION 19 ASSEMBLING THE FLUE Fit the 'cut to length' flue on to the flue turret. Note. Ensure the top groove in the flue aligns with the top of the turret. Drill a 3.2mm dia. hole through the flue via the hole present in the turret.
  • Page 20 INSTALLATION 21 SIDE FLUE ASSEMBLY - Exploded view An optional flue duct extension kit is required for flue lengths greater than : 410 mm (16") for RHS flue 540 mm (21 ") for LHS flue (Refer to Frame 11). When cutting the ducts always use the cardboard support cutting aid provided.
  • Page 21 INSTALLATION 23 PREPARING THE WALL WARNING Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. Cut the flue hole (preferably with a 5" core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should be flat.

  • Page 22: Gas Inlet Working Pressure

    INSTALLATION WATER CONNECTIONS Note. Do not subject any of the isolating valves to heat as the seals may be damaged. CH CONNECTIONS DHW CONNECTIONS For top connections: For top connections: Use straight pipe and elbow (not supplied) Reverse 15mm pipe 26 GAS CONNECTION Bottom and top connections Solder the...
  • Page 23 INSTALLATION 27 MOUNTING THE BOILER Lift the boiler onto the wall mounting piping frame, as shown. 28 CUTTING THE FLUE - For flue lengths 114 to 600mm ONLY The flue cut length is calculated as follows:- a. Measure and note the wall thickness X b.

  • Page 24: Connecting The Flue To The Boiler

    INSTALLATION 29 ASSEMBLING THE FLUE Fit the 'cut to length' flue on to the flue turret. GROOVE Note. Ensure the groove in the flue aligns with the top of the turret. Drill a 3.2mm dia. hole through the flue via the hole present in the turret.

  • Page 25: For Condensing Boilers

    INSTALLATION 31 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. Position the terminal wall plate over the terminal.

  • Page 26: Flue Extensions

    INSTALLATION 33 SAFETY VALVE DRAIN The safety valve is located at the bottom LHS of the boiler. Using the pressure relief valve outlet pipe, nut and olive from the hardware pack, assemble into safety valve as shown. If access to the nut is difficult remove the socket screw from inside of fitting and pull the valve from the pipe to allow the piping nut to be tightened.
  • Page 27 INSTALLATION 36 FITTING THE KIT Remove the cardboard support aid from the flue and place safely to one side. Fit inner flue seal. Fit the inner flue extension duct onto the inner flue duct. Fit the outer flue extension duct onto the outer air duct.
  • Page 28 INSTALLATION 37 FILLING - Central Heating Refer also to Frame 4 Ensure that the CH isolating valves are open. Release the securing screw and swing the control panel down. Fill and vent the system. Check for water soundness Diverter valve shown in CH position.
  • Page 29 INSTALLATION 38 FILLING - continued IMPORTANT - when filling: Remove the diverter valve actuator and depress the spindle several times during filling. Replace diverter valve actuator. The cap on the automatic air vent MUST be loose at all times. When filling, there may be a slight water leak from the vent therefore electrical connections should be...

  • Page 30: 39 Electrical Connections

    INSTALLATION 39 ELECTRICAL CONNECTIONS WARNING. This appliance must be efficiently earthed. Wiring should be 3 core PVC insulated cable, not less than 0.75 mm (24 x 0.2mm). A mains supply of 230 V ~ 50 Hz is required. Connection must be made in a way that allows complete The fuse rating should be 3A.

  • Page 31: Wiring Diagrams

    INSTALLATION 41 EXTERNAL WIRING Wiring External to the Boiler WARNING. This appliance must be efficiently earthed. A mains supply of 230 V ~ 50 Hz is required. The fuse rating should be 3A. Wiring external to the boiler MUST be in accordance with the current I.E.E.
  • Page 32 INSTALLATION 42 PICTORIAL WIRING DIAGRAM Henrad SEC FF - Installation...

  • Page 33: Commissioning And Testing

    INSTALLATION 43 FLOW WIRING DIAGRAM - CH Legend blue pink black brown Note. white grey Water pressure switch effective in both CH & DHW yellow purple operation (linked internally for DHW) yellow / green orange 44 COMMISSIONING AND TESTING A. Electrical Installation B.

  • Page 34: Initial Lighting

    INSTALLATION 45 INITIAL LIGHTING LEGEND A. Gas control valve B. Inlet pressure test point C. Burner pressure test point D. Offset adjuster (sealed) Fan pressure test point (Hi) Fan pressure test point (Lo) G. Control panel H. Display board Gas service cock (hidden) On/off switch K.

  • Page 35: For Domestic Hot Water Mode

    INSTALLATION 46 INITIAL LIGHTING - continued simultaneously (to simulate a call for maximum heat). If ignition does not occur within 8 seconds or if the burner The display will read: lights and flame presence is not detected then the ignition sequence is repeated for a maximum of 5 times. To check the minimum pressure If ignition is still unsuccessful the display flashes: Select TEST mode by pressing MODE and ' - ' buttons...
  • Page 36 INSTALLATION 48 GENERAL CHECKS The display sequence should read: Make the following checks for correct operation: DOMESTIC HOT WATER (DHW) MODE Close the DHW tap. The burner should go off and the Set the CH switch (K) to OFF. pump continue to run. The display sequence should Switch ON the electricity supply.
  • Page 37 INSTALLATION 49 GENERAL CHECKS - continued WATER TEMPERATURES The design water output temperatures are as follows: Central Heating C maximum Domestic Hot Water C maximum These temperatures can be checked and settings changed (if required) as follows: To check the temperatures: a.

  • Page 38: Servicing

    INSTALLATION 50 HANDING OVER Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the After completing the installation and commissioning of the economic use of the system. system the installer should hand over to the householder by the following actions: If an optional timer kit is fitted then draw attention to the Timer Kit User Instructions and hand them to the...

  • Page 39: Casing Removal

    SERVICING 52 SAFETY Do NOT OPERATE the boiler if the IMPORTANT. sealing panel is not fitted Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the Note. appliances before servicing. In order to carry out servicing, the boiler casing and sealing panel must be removed .

  • Page 40: Burner Removal And Cleaning

    SERVICING 55 FAN REMOVAL AND CLEANING Legend Venturi Sensing pipe Undo the fan inlet venturi top securing screw. Slacken the other 2 securing screws. Slide the venturi upward to disengage the sensing pipe from the gas manifold. Withdraw the venturi, complete with sensing pipe, from the boiler.

  • Page 41: Cleaning The Heat Exchanger

    SERVICING 57 CLEANING THE HEAT EXCHANGER IMPORTANT This MUST be done with the heat exchanger and deposit in a DRY condition. Prior to cleaning, run the boiler until a flow temperature of 80 C is reached - refer to Frame 51, step 1 (Servicing schedule).

  • Page 42: Replacement Of Components

    SERVICING REPLACEMENT OF COMPONENTS 60 GENERAL WHEN REPLACING ANY COMPONENT : Isolate the electricity supply. Turn off the gas supply. IMPORTANT. When work is complete, if the sealing panel has been removed, it must be correctly refitted - ensuring that a good seal is made. THE BOILER MUST NOT BE OPERATED IF THE SEALING PANEL IS NOT FITTED Note.

  • Page 43: Burner Replacement

    SERVICING 62 FAN UNIT REPLACEMENT Legend Venturi Sensing pipe Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Remove the boiler sealing panel. Refer to Frame 54. Undo the fan inlet venturi top securing screw. Slacken the other 2 securing screws. Slide the venturi upward to disengage the sensing pipe from the gas manifold.

  • Page 44: Burner Injector Replacement

    SERVICING 64 SPARK AND DETECTION ELECTRODE REPLACEMENT Fit new electrodes as required, ensuring that the gaskets are in good condition and are sealing correctly - renew as necessary. Check the spark / detection gaps. Re-assemble in reverse order ensuring that the 'O' ring seal in the burner mounting flange is in place.

  • Page 45: Gas Control Valve Replacement

    SERVICING 66 GAS CONTROL VALVE REPLACEMENT Note. Ensure that the valve is the correct one for the boiler. The valve is factory set and sealed. No adjustment is required. Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Remove the boiler sealing panel.
  • Page 46 SERVICING 68 GASMODUL CONTROL UNIT REPLACEMENT Ensure that the control unit is the correct one for the boiler. Unplug the spark and detector leads. Undo the 4 securing screws and withdraw the control unit from the panel. Fit the new control unit and re-assemble in reverse order.

  • Page 47: Draining The Boiler

    SERVICING 71 DIVERTER VALVE ACTUATOR REMOVAL Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Swing the control panel down. Unplug the electrical lead from the diverter valve. Press the release catch in the direction shown, and rotate the actuator anticlockwise to disengage it from the valve body.
  • Page 48 SERVICING 73 CONDENSATE TRAP REPLACEMENT Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Remove the boiler sealing panel. Refer to Frame 54. Remove the fan assembly. Refer to Frame 55. Pull off the condensate trap from the bottom panel and carefully empty the contained water into a receptacle.
  • Page 49 SERVICING 75 CH THERMISTOR SENSOR REPLACEMENT Note. There are 2 control thermistors - one on the boiler flow boss and one on the return boss. Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Drain the boiler. Refer to Frame 72. Disconnect the flexible hose from the expansion vessel.
  • Page 50 SERVICING 77 PRESSURE GAUGE REPLACEMENT Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Drain the boiler. Refer to Frame Swing the control panel down. Unscrew the 3 screws and unclip the plastic cover from the back of the control panel. Disengage the capillary from the control panel.
  • Page 51 SERVICING 79 PUMP REPLACEMENT Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Drain the boiler. Refer to Frame 72. Swing the control panel down. Undo the pump top and bottom union connections and draw the pump forward.
  • Page 52 SERVICING 81 AUTOMATIC AIR VENT REPLACEMENT Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Drain the boiler. Refer to Frame 72. Disconnect the flexible hose from the expansion vessel. Release the expansion vessel retaining bracket, allowing the vessel to be removed to gain access to the air vent.

  • Page 53: Heat Exchanger Replacement

    SERVICING 83 CH EXPANSION VESSEL REPLACEMENT Refer to Frame 60. Remove the boiler casing. Refer to Frame 53. Drain the boiler. Refer to Frame 72. Undo the expansion vessel flexible hose connection. Undo the top retaining bracket screw and remove. Slide the expansion vessel out of the support rails.

  • Page 54: Boiler Sealing Panel Seal Replacement

    SERVICING 85 HEAT EXCHANGER REPLACEMENT - continued Legend Flow Return 15. Pull out the flow pipe retaining pin. 16. Pull the flow pipe down and out of the flow boss. 17. Rotate the pipe to the right and withdraw it from the bottom socket. 18.

  • Page 55: 87 Fault Finding

    FAULT FINDING 87 FAULT FINDING Note. To gain access to the Gas module control buttons In normal standby mode the first digit of the display indicates remove the cover plate . Refer to Frame 92. the boiler sequence, and the last 2 digits the boiler flow temperature.
  • Page 56 FAULT FINDING 88 FAULT FINDING - continued If a fault condition develops, the first digit and the last 2 digits of the internal failure - electronic display flash alternately the following codes, according to the fault. Code Fault Code Fault False flame Short circuit 24V No flame detection...

  • Page 57: Short List Of Parts

    SHORT LIST OF PARTS The following are parts commonly required as replacements, When ordering spares please quote: due to damage or expendability. Boiler model Their failure or absence is likely to affect the safety and / or Appliance G.C. No. performance of this appliance.
  • Page 58 SHORT LIST OF PARTS 89 SHORT PARTS LIST Henrad SEC FF - Installation...
  • Page 59 LIST OF PARTS 90 BURNER ASSEMBLY / GAS CONTROL - Exploded View Legend Burner Burner injector Gas valve Detector electrode Ignition electrode 13. Fan 14. Fan inlet venturi 19. Fan pressure sensing pipe 42. 'O' ring 43. 'O' ring 44. 'O' ring 45.
  • Page 60 LIST OF PARTS 91 CONTROL PANEL ASSEMBLY - Exploded View Legend Gasmodul control Display board Fan speed control board 11. CH pressure gauge 12. Rocker switch 50. Control panel 58. Relay Henrad SEC FF - Installation...
  • Page 61 SHORT LIST OF PARTS 92 BOILER CASING ASSEMBLY Henrad SEC FF - Installation...
  • Page 62 Caradon Plumbing Limited P .O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Registered Office: National Avenue, Kingston upon Hull, HU5 4JN. A subsidiary of Caradon plc The code of practice for the installation, commissioning &...
  • Page 63 YOUR FEEDBACK and your chance to win a free boiler At Henrad we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service. We will be giving away a free boiler for the five best ideas every year (to be selected by our Technical Director).

  • Page 64: Further Information

    Further information If you would like information about Henrad Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing Limited, PO Box 103, National Ave., Kingston upon Hull, HU5 4JN. Installer details Name Address Post Code...

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