Wickes C80FF Installation & Servicing Manual

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INSTALLATION & SERVICING MANUAL

Models covered by these instructions

C80FF

C95FF

THE WICKES MANUAL

C80 FF

the combi boiler

C95 FF

the combi boiler

Wall mounted, gas fired fanned flue combination boiler

Addendum to these Instructions

Page 4 Option Kits

For details of option kits available for this boiler range contact the Installer helpline: details on back page

Data badge: located inside left hand side casing.

BENCHMARK LOG BOOK DETAILS

Boiler

Make and model

Appliance Serial No. on Data Badge

Controls as applicable

Forall boilers

Flushing to BS.7593

Inhibitor

Gas inlet working pressure

Burner operating pressure

Heat input.. to be calculated

Temperature differential....measure and record

For combination boilers only

For domestic hot water mode ...... measure and record

For condensing boilers..... not applicable

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

For assistance see Technical Helpline number on the back page.

(47-348-05) WICKES C80FF

(47-348-06) WICKES C95FF

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Summary of Contents for Wickes C80FF

Page 1 INSTALLATION & SERVICING MANUAL Models covered by these instructions C80FF (47-348-05) WICKES C80FF C95FF (47-348-06) WICKES C95FF THE WICKES MANUAL C80 FF the combi boiler C95 FF the combi boiler Wall mounted, gas fired fanned flue combination boiler Addendum to these Instructions...
Page 2 NOTE: TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER. ALSO COMPLETE THE BENCHMARK LOG BOOK AND GIVE THIS TO THE CUSTOMER. CE certified P.I.N. No. 0063AQ6877 Destination Countries GB, IE. NOTE: TO THE INSTALLER: leave these instructions adjacent to the gas meter. GENERAL Boiler Water Circuit Diagram Boiler Dimensions, Services &...
Page 3 Short list of parts INTRODUCTION C80FF and C95FF are wall mounted, low water content, balanced flue combination gas boilers of type C1 intended for use with gas group Central heating (CH) output and domestic hot water (DHW) output are both fully modulating: - between 9.16 (31 200) and 23.26 (79 300) kW (btu/h) for model C80FF,...
Page 4 1. BOILER WATER CIRCUIT DIAGRAM PERFORMANCE DATA Table 1 - General Data C80FF C95FF Gas supply type & connection 2H - G20 - 20 mbar, 22 mm copper Inlet connection - Domestic Hot Water 15 mm copper Outlet connection - Domestic Hot Water 15 mm copper Flow &...
Page 5 C80FF C95FF Internal fuse rating T 2A Water content Central heating litre (gal.) 1.8 (0.396) Domestic Hot Water litre (gal.) 0.2 (0.044) Dry weight kg (lb.) 50 (110) Boiler size Height mm (in.) 850 (33 ½) Width mm (in.) 400 (15 ¾) Depth mm (in.)
Page 6 NOTE: For the C80FF and C95FF central heating circuit 22 mm (¾″) pipes may be used. 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.
Page 7 Front clearance The minimum front clearance when built in to a cupboard i 5mm (1/4″) from the cupboard door but 450mm (17 ¾″) overall clearance is still required, with the cupboard door open, to allow for servicing. See Table Table 4 Clearances LH side 15 mm (½″)
Page 8 Vent level Model Air direct from outside cm High/Low 266 (41) 133 (21) C80FF 282 (44) 141 (22) C95FF AIR SUPPLY Detailed recommendations for air supply are given in BS.5440:2. The following notes are for general guidance: 1. 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.
Page 9 Check that the appliance is suitable for the proposed gas supply. A working gas pressure of 20 mbar MUST be available at the boiler inlet. IMPORTANT: Installation pipes MUST be fitted in accordance with BS. 6891. Pipework from the meter to C80FF/C95FF boilers MUST be of an adequate size, i.e. not less than 22 mm O.D. copper or ¾″ BSP iron.
Page 10 4 SEALED SYSTEM REQUIREMENTS Central Heating NOTE: C80FF/C95FF combination boilers are suitable for fully pumped pressurised sealed systems only. REQUIREMENTS 1. General...
Page 11 a. The connection is made through a double check valve assembly or some other no less effective device which is permanently connected to that circuit; b. The temporary connection is removed after use.″ The method described in this instruction complies with that Byelaw. 2.
Page 12 Garston Watford WD2 7JR tel: 01923 664258. The boiler is fitted with an automatic internal bypass. No further system bypass is required. 8 Hydraulic Loss Both the C80FF and the C95FF operate at a temperature differential of 20 °C (36 °F) Remaining pump capacity...
Page 13 6 DOMESTIC HOT WATER REQUIREMENTS 1. The domestic hot water service must be in accordance with BS 5546 and BS 6700. 2. For the minimum and maximum working pressures of the C80FF and C95FF domestic hot water circuit refer to Table 1, page 6.
Page 14 8 UNPACKING The boiler is supplied fully assembled in one pack A, together with a standard flue assembly for lengths up to 600 mm, rear or side flue outlet, in pack B. Unpack and check the contents. Pack A contents •...
Page 15 • Flue turret • Hardware pack • Internal wall finishing gasket Optional extras, if ordered, are available in separate boxes. • Programmer kits, digital or analogue • Roof flue kit • Extension duct kit D • 90° Elbow kit • 45° Elbow kit •...
Page 16 10 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED The maximum total equivalent horizontal flue length Is: 3 m for model C80FF 1.85 m for model C95FF. For the number of Extension Ducts required see the Flue kit requirements table below. When using elbow kits, each 90° elbow is equivalent to 1 metre flue length and each 45°...
Page 17 Rear flue mounting cut flue to length: for C80FF C+185=D C+7 ¼″ = D for C95FF C+160=D C+ 6 3/8″ =D Having cut length D mark around the end of the air duct 10 mm from the cut end then cut the air duct only to be 10 mm shorter than the flue duct to allow for...
Page 18 Flue kit requirements Total length of flue Extra packs required 600 mm (23 5/8″) None ∗ 1550 mm (61″) One pack D ∗ 2500 (98 7/16″) Two pack D ∗ 3000 (118 1/8″) Three pack D ∗ Pack B - supplied as standard Pack D - optional extra kit, to extend the flue ∗...
Page 19 3. Mark onto the wall the following: a.. the wall mounting plate screw positions b.. the position of the flue duct. (Mark the centre of the hole as well as the circumference) c.. the lower fixing point screw position 4. Remove the template from the wall 13 WALL MOUNTING TEMPLATE (side flue) IMPORTANT: 1.
Page 20 14 DRILLING THE WALL Rear flue shown IMPORTANT: Ensure that, during the cutting operation, masonry falling outside the building does not cause damage or personal injury. 1. Cut the flue hole (preferably with a 5″ core boring tool), ensuring that the hole is square to the wall. 2.
Page 21 1. The flue cut length is calculated as detailed in Frame 2. Measure from the groove and mark the tube. 3. To ensure the tube is cut square, mark the flue all the way round, using, e.g. a long straight strip of paper with its ends overlapped. 4.
Page 22 Push the front panel upwards to disengage and store in a safe place. Lift the boiler onto the wall mounting plate locating the bar at the rear of the back panel assembly into the bracket Lower the boiler into position. Secure the appliance to the wall by fixing a screw through the lower fixing point.
Page 23 If the terminal is less than 2m (6′ 6″) above ground level, an approved terminal guard should be fitted. Refer to ‘Flue Installation’, 21 FLUE EXTENSION DUCT PACK D CONTENTS Use a maximum of: 2 extension ducts on model C95FF 3 extension ducts on model C80FF 22 ASSEMBLING THE EXTENDED FLUE...
Page 24 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 3.2 mm (1/8″) dia hole through the outer air duct. Do not drill the Inner flue duct. 5.
Page 25 1. Insert the flue into the prepared hole. Refer to Frame 17 for details. 2. Mate the flue to the turret. Refer to Frame 19 for details. NOTE: To facilitate turret fixing or removal do not make good the wall. Use the finishing gasket provided.
Page 26 Fit the service valves washers and tail pipes as shown. Connect to the tail pipes by proprietory fittings. The pipework may be directed up, down or through the rear wall as required. To allow for any future removal of the boiler it is suggested that union joints be incorporated into the upward pipework. See additional illustration for upward pipework routing 26 SAFETY VALVE DRAIN The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or...
Page 27 NOTE: Ensure that the lengths of the current conductors are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor. 29 PICTORIAL WIRING 30 FUNCTIONAL FLOW DIAGRAM...
Page 28 31 EXTERNAL ELECTRICAL CONTROLS Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations. The fuse rating should be 3A. Optional Programmer Kits These are supplied in either digital or analogue options, each with the relevant instructions. External Programmers This should be of the single channel type (as this boiler does not incorporate a pre-heat facility for the istantaneous hot water service).
Page 29 Diagrams B & C show applications to boilers fitted with alternative time controls. Designation of the terminals will vary but the programmer and thermostat manufacturers' leaflets will give full details. NOTE: If the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework. Earths are not shown for clarity but must never be omitted.
Page 30 IMPORTANT: Before lighting the boiler you should note especially that: 1. Check that all the drain cocks are closed and any valves in the flow and return are open. 2. Check that the system has been filled and pressurised and that the boiler is not air locked. 3.
Page 31 8. Set the main switch (A) to ‘ON’. Following a pre-purge period the gas control solenoid valve should open and the spark commence, continuing until the burner is established. 9. Check that the burner lights smoothly. If this does not occur within 20 seconds, turn the on/off switch to OFF, wait for 5 seconds then try again. If the burner still does not light, refer to the ‘Fault Finding’...
Page 32 5. Close the DHW tap and replace the cover A. Maximum central heating setting Adjust the CH maximum burner pressure potentiometer F to: 9.5 (3.8) mbar (in w.g.) for C80FF model 11.0 (4.4) mbar (in w.g.) for C95FF burner pressure.
Page 33 If this check is not possible, ensure that the burner pressure is: 9.5 (3.8) mbar (in. w.g.) for the model C80FF. 11.0 (4.4) mbar (in. w.g.) for the model C95FF.
Page 34 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. 5.
Page 35 Switching the boiler on/off switch ‘off’ when a frost thermostat is wired directly from the mains may leave a live feed to the boiler. ALWAYS test for gas soundness and carry out functional checks on reassembly. IMPORTANT: When work is complete the boiler inner front sealing panel MUST be correctly refitted, making a good seal. DO NOT OPERATE THE BOILER IF THE SEALING PANEL IS NOT FITTED.
Page 36 5. Check that the impeller runs freely. Clean with a soft brush or renew as necessary. Refer to frame 53 for replacement. NOTE: Always take care when handling the fan, in order to preserve the balance of the impeller. 40 BURNER REMOVAL AND CLEANING 1.
Page 37 41 CLEANING THE HEAT EXCHANGER 1. Open the combustion chamber as explained in steps 1 and 2 of frame 2. Place a plastic sheet or similar beneath the boiler and remove all visible loose deposits from the heat exchanger fins, using a suitable brush. 42 RE-ASSEMBLY Re-assemble the boiler in the following order: 1.
Page 38 If the burner pressures require adjustment refer to frame 33 “To adjust pressures”. If the appliance still does not operate correctly refer to the appropriate fault finding chart. REPLACEMENT OF COMPONENTS 44 GENERAL When replacing any component: 1 Isolate the electricity supply at the switched spur. N.B.
Page 39 1. Disconnect the electrical supply. 2. Gain access to the controls area by removing the boiler front panel, the right hand panel and inner case cover (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel. 3.
Page 40 1. Disconnect the electrical supply. 2. Gain access to the controls area by removing the boiler front panel, (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel. 3. Undo the screw A that fits the ignition pcb on the gas valve. 4.
Page 41 4. Re-assemble in reverse order. 5. Check the operation of the boiler. 51 GAS VALVE REPLACEMENT 1. Turn off the gas supply at the gas service cock and disconnect the electricity supply. 2. Gain access to the controls area by removing the boiler front panel, (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel.
Page 42 9. Fit the filling loop. Fill the boiler with water and pressure to bar (as appropriate), reconnect services. 10. After satisfactory test firing and removal of air from the system, remove the filling loop. 53 FAN REPLACEMENT 1. Disconnect the electrical supply. 2.
Page 43 1. Disconnect the electrical supply. 2. Remove the inner case cover as explained in frame 3. Disconnect the pressure sensing pipe from the - ve side of the air pressure switch. 4. Disconnect the electrical harness from the air pressure switch. 5.
Page 44 10. If gas pressure adjustment is necessary refer to frame 56 PUMP REPLACEMENT 1. Disconnect the electrical supply. 2. Gain access to the controls area by removing the boiler front panel and the right hand panel (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel.
Page 45 8. Fit the parts in reverse order. Two different sizes of flow limiter are available. Table 8 Nominal flow rate (litres/min) Colour Blue 58 PRIMARY HEAT EXCHANGER REPLACEMENT 1. Disconnect the electrical supply. 2. Remove the inner case cover as explained in frame 3.
Page 46 1. Disconnect the electrical supply. 2. Gain access to the controls area by removing the boiler front panel, (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel. 3. Close off the isolating cocks of the CH and DHW circuits at the bottom of the boiler. 4.
Page 47 61 DIVERTER VALVE MEMBRANE REPLACEMENT 1. Disconnect the electrical supply. 2. Gain access to the controls area by removing the boiler front panel, (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel. 3.
Page 48 62 CH FLOW SWITCH MEMBRANE REPLACEMENT 1. Disconnect the electrical supply. 2. Gain access to the controls area by removing the boiler front panel, (refer to frame 38), remove the boiler bottom panel (held with 2 screws) and lower the control panel. 3.
Page 49 A If it has a punctured diaphragm, but is otherwise leak free, than it can be left in place and a new vessel added to the system, external to the boiler, provided it is of adequate capacity and pre charge pressure. B If there is at least 300 mm (12 “) clearance above the boiler, the expansion vessel can be changed without removing the boiler (rear exit flues will have to be disturbed).
Page 50 WARNING: Care must be taken when conducting fault finding tests to guard against the risk of electric shock NOTE: 230vac is the nominal UK supply voltage this may vary between 253vac and 196vac When checking continuity ensure the power is off to the appliance Re-connect power to continue fault finding...
Page 51 67 HOT WATER MODE FAULT FINDING WARNING: Care must be taken when conducting fault finding tests to guard against the risk of electric shock NOTE: 230vac is the nominal UK supply voltage this may vary between 253vac and 196vac When checking continuity ensure the power is off to the appliance Re-connect power to continue fault finding The reference ∗’X3″...
Page 52 68 HEATING MODE FAULT FINDING WARNING: Care must be taken when conducting fault finding tests to guard against the risk of electric shock NOTE: 230vac is the nominal UK supply voltage this may vary between 253vac and 196vac When checking continuity ensure power is off to the appliance - re-connect power to continue fault finding The reference “X3″...
Page 53 the code of practoce for the installation commissioning & servicing of central heatsystems 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.
Page 54 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. January 2001 156342 A01 Installer/Technical Helpline: 01482 498 663...

This manual is also suitable for:

C95ff 47-348-05 47-348-06