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Halstead BFF100 Instructions For Use Manual

Balanced fanned flue boiler
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Installation and Servicing

Balanced Fanned Flue Boiler
Model: BFF100
G.C. No. 41-333-92
Model: BFF115
G.C. No. 41-333-93
This is a Cat I
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

Instructions for Use

To b e l e f t w i t h t h e u s e r
Appliance
2H
2000225116B.03.03

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Summary of Contents for Halstead BFF100

  • 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 To obtain service please call your installer or Halstead Boilers Ltd. using the telephone number given on the inside of the front WARNINGS panel.
  • Page 4 Instructions for Use To Turn the Appliance On Turn the electrical supply on to the boiler and check that all BOILER remote controls are calling for heat. The fan will operate. TEMPERATURE CONTROL It should be noted that this is a fanned flue appliance and fan operation may be heard.

  • Page 5: General Data

    Manufacturer’s instructions must not be taken as overriding The Seasonal Efficiency Domestic Boilers UK (SEDBUK) statutory requirements. is 'D' BFF100 = 79.9% & BFF115 = 78.7%. 1.4 B.S.I Certification The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data This boiler is certificated by B.S.I., for safety and performance.
  • Page 6 1 General Data 1.5 Gas Supply The gas installation shall be in accordance with the relevant standards. In GB this is BS6891. In IE this is the current edition of I.S.813 "Domestic Gas Installations". The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.
  • Page 7 1 General Data 1.7 Boiler Location The boiler may be installed in any room, although particular attention is drawn to the requirements of BS7671 with respect This boiler is not suitable for outside installation. to the installation of a boiler in a room containing a bath or The boiler casing can be fitted at two heights.

  • Page 8: Water Systems

    2 Water Systems The installation of the boiler must comply with the requirements 2.5 Circulation Pump of the current issue of BS6798, in Ireland, refer also to the Normally the pump should be set to give a temperature difference current edition of I.S.813 "Domestic Gas Installations". of 11 C (20 F) across the boiler.

  • 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 MINIMUM MINIMUM MAXIMUM FLUE 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 4.5. ( NOTE : The restrictor is fitted to the STANDARD 510mm REAR BFF100 Only) Engage the terminal restrictor on the flue terminal by hooking it over the terminal end and engaging the clamping bracket...
  • Page 12 4 Installation 4.6 Water Connections - Gravity Domestic and ALTERNATIVE Pumped Heating 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 NOTE: It is recommended that plastic pipes for primary...
  • Page 13 4 Installation 4.8 Thermistor Pocket Fit the thermistor phial pocket, supplied in the fittings pack, into the front tapping adjacent to the heating flow connection and plug the other front connection. Carefully unwind the thermistor capillary, insert phial fully into the pocket and secure with retaining wire.
  • Page 14 4 Installation 4.11 Side In-fill Panel (if required) 4.12 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 4.13 Flue / Boiler Connection Remove the three self-tapping screws from the lower part of the control box support bracket, see diagram 4.15. Undo the wing nut that secures the top of the heat shield and carefully hinge down control box and heat shield, see diagram 4.15.
  • Page 16 4 Installation 4.14 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.

  • Page 17: Electrical Wiring

    5 Electrical Wiring SECURING CONTROL BOX 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 IMPORTANT NOTE The control will conduct a purge before the ignition system will operate to light the boiler. After a pre-set time if ignition has not The WARNING NOTICE attached to the front casing must only 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 UNDER LIP and pilot lights are off. Gas rate: Buckingham 4 BFF100 : 3.3m /h (115ft Buckingham 4 BFF115 : 3.8m /h (136ft is for guidance only, dependent on the heat setting.

  • Page 20: Instructions To User

    Do not use 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...
  • Page 21 8 Servicing Note: When replacing the fan access door make sure the lip at IGNITION, SENSING & the top of door fits into and behind the slotted bracket located at EARTH LEADS the top of the boiler. Refer to diagram 8.7. Remove the electrical connections from the fan by pulling the insulation boots only.
  • Page 22 8 Servicing 8.4 Service Checks 8.2 Boiler Flueways Inspect the ignition and sensing electrodes and clean and Remove flueway baffles noting that there are 3 centre and 2 replace as necessary, 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.

  • 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: Electrical Supply Failure

    9 Fault Finding MAINS SUPPLY BOILER TEMPERATURE 230v ~ 50Hz CONTROL AIR PRESSURE SWITCH CONNECTIONS MAIN TERMINAL STRIP CONNECTIONS PRINTED CIRCUIT BOARD CONNECTIONS bk BLACK br BROWN gy GREY BLUE w WHITE Diagram 9.2 PURLPLE FUSE TYPE F3.15A 9.1 Electrical Gain access to the control box, refer to the relevant paragraph in section 8.1, then remove the control box cover, refer to section 5.1.
  • Page 25 9 Fault Finding KEY TO TERMINAL BLOCK PRESSURE BROWN BLACK SWITCH = LIVE (Switched) BLUE PURPLE = NEUTRAL GREEN/YELLOW = EARTH MAIN GREY WHITE CONTROL IGNITION VALVE ELECTRODE SENSING ELECTRODE THERMISTOR P.C.B (CONTROL BOARD) JUMPER POSITION 3.15A MAINS SUPPLY FUSE RESET 230V~50Hz INDICATOR...

  • Page 26: Replacement Of Parts

    Disconnect the ignition, sensing and earth leads. reconditioned or copy parts that have not been clearly authorised Carefully pull the board away from its supports bending back by Halstead Boilers Ltd. slightly the retaining latches. Replacement of parts must only be carried out by a competent When refitting refer to wiring diagram 9.4.
  • Page 27 10 Replacement of Parts 10.5 Solenoid 10.10 Insulation Remove front panel to gain access, see section 6.8. Refer to the relevant paragraphs of the servicing section to remove the burner from combustion chamber. Remove the electrical plug from the multifunctional control and remove the securing screw and then the solenoid assembly, Sides see diagram 10.4.

  • Page 28: Spare Parts

    2000461793 Electrical thermistor ****** 202635 Ignition electrode (R/H Burner) ****** 202635 Sensing electrode (L/H Burner) ****** 2000461714 Boiler temperature control knob ****** 2000461897 Injector BFF100 ****** 205746 Injector BFF115 ****** 202240 Fuse ****** 2000461896 Control board ****** 205657 Double Burner ****** Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

This manual is also suitable for:

Bff115

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