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Installation and Servicing
Balanced Fanned Flue Boiler
Model: BFF40
G.C. No. 41-333-88
Model: BFF50
G.C. No. 41-333-89
Model: BFF60
G.C. No. 41-333-90
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
2000225095B.10.02
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Summary of Contents for Halstead BFF40
- Page 1 (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.
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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. TEMPERATURE Turn the boiler temperature control clockwise to any position CONTROL between “0” and "Max", see diagram 1. "Max"...
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Page 5: General Data
This boiler is for use only on G20 gas. The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is 'D' BFF40 = 78.3%, BFF50 = 78.2% & BFF60 = 78.5%. The boiler is delivered in one pack and the flue pack is supplied The value is used in the UK Government’s Standard Assessment... - Page 6 It is, therefore, important that no alteration is made to the boiler unless agreed, in writing, by Halstead Boilers Ltd. Any alteration not approved by Halstead Boilers Ltd., could invalidate the B.S.I. certification, boiler warranty and could infringe the current issue of the Statutory Requirements.
- Page 7 1 General Data 1.7 Boiler Location WORKTOP 320 MIN. This boiler is not suitable for outside installation. The boiler casing can be fitted at two heights. Refer to diagram 1.5. The boiler is assembled at the factory with the control box and heat shield fitted in the lower position.
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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 15mm COLD FEED 27metres (90ft) which has an open vent in the system. The working pressure must be within the range 0.1bar to 2.7bar INDIRECT (1.3 to 39lbftin... -
Page 9: Flue And 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 Loosen the side insulation blankets by removing the securing When the front tappings are used, it is essential that any bracket, see diagram 4.12 and fit the two upper and two front pipework or fittings do not project more than shown in diagram casing brackets shown in diagram 4.13, using the No.8 screws 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 4.15, 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 4.17. Undo the wing nut that secures the top of the heat shield and carefully hinge down control box and heat shield, see diagram 4.17.
- 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 BOX SCREWS COVER TERMINAL BLOCK TERMINAL 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 The ignition system will operate to light the boiler. After a pre- IMPORTANT NOTE set time if ignition has not taken place the boiler will shutdown. The WARNING NOTICE attached to the front casing must only To re-start the lighting sequence, turn the boiler temperature be removed by the user control to “O”, then fully clockwise to “Max”. - Page 19 10 minutes after the burner has lit, making sure that all other gas burning appliances and pilot lights are off. The gas rates: Buckingham 4 BFF40 : 1.7m /h (49ft Buckingham 4 BFF50 : 2.1m /h (60ft Buckingham 4 BFF60 : 2.5m...
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Page 20: Instructions To The User
8.6. 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 8.7. 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. Remove the electrical connections from the fan by pulling the insulation boots only, see diagram 8.8.
- Page 22 8 Servicing 8.2 Boiler Flueways 8.3 Burner and Injector Remove flueway baffles noting that there are 1 centre and 2 Remove the two screws and nuts securing the burner support side flueway baffles, see diagram 8.8. bracket to the combustion chamber cover, see diagram 8.10. Place a sheet of paper in the combustion chamber to catch any Remove the graphite coated nuts on the supply feed pipe at the flue debris.
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Page 23: Fault Finding
8 Servicing ELECTRODE SPARK GAP = 3.6 SECURING SCREW GRAPHITE BURNER COATED INJECTOR NUT(2) Diagram 8.13 Diagram 8.12 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 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 the 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 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.
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Page 28: Spare Parts
The data label is positioned on the heat shield, see diagram 6.1. Diagram 11.1 Key No. Part No. Description GC Part No. 2000461752 Multifunctional control ****** 227131 ****** 227070 Air pressure switch BFF40-50 ****** 227097 Air pressure switch BFF60 ****** 2000461793 Electrical thermistor ****** 202635 Spark electrode ****** 2000461714...
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