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2000225008D.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
Chimney Fanned Flue Boiler
Model: CFF80
G.C. No. 41-333-97
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 CFF80
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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
Important Information TESTING AND CERTIFICATION This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Halstead Boilers Ltd. Any alteration not approved by Halstead Boilers Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements, see Section 1.3. - Page 3 Instructions for Use Introduction Maintenance Please read these instructions and follow them carefully for the To ensure the continued efficient and safe operation of the boiler safe and economical use of your boiler. it is recommended that it is checked and serviced as necessary at regular intervals.
- 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 NOTE: The boiler casing can be set at two heights, MAX. and MIN. WATER CONNECTIONS Rc1 reduced with DISTRIBUTOR TUBE to in. B.S.P.T.) (pumped return) GAS CONNECTION in. B.S.P.T.) WATER CONNECTIONS Rc1 (1in. B.S.P.T.) INSIDE DIAMETER OF ADAPTER FOR 125mm (5in) NOMINAL DIAMETER FLUE TO BS567... - Page 6 1 General Data 1.3 Statutory Requirements floor The installation of this appliance must be carried out by a level competent person and must be in accordance with the relevant requirements of the current issue of: MAX.900 Manufacturer’s instructions supplied. MIN. 860 The Gas Safety (Installation and Use) Regulations, Building Regulations, Local Water Company Bye-laws, The Building Standards (Scotland) Regulations, (applicable in Scotland),...
- Page 7 1 General Data 1.9 Heating System Controls 1.8 Boiler Location The heating system should have installed: a programmer and This boiler is not suitable for outside installation. room thermostat controlling the boiler. The boiler casing can be fitted at two heights. Refer to Thermostatic radiator valves may be installed, however they 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 INDIRECT... -
Page 9: Flue & Ventilation
150mm (6in) plug of Mineral Wool or similar CFF, if the flue length exceeds the following ; CFF80 - 9m then provision must be made to ensure that the condensate products are drained away and that the flue liner is of the appropriate specification. - Page 10 3 Flue and Installation 3.4 Timber Frame Buildings AIR VENT TABLE FOR ROOM SPACE INSTALLATIONS If the boiler is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers EFFECTIVE AREA OF VENT document IGE/UP/7/1998.
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Page 11: Installation
4 Installation General Installation Notes ALTERNATIVE The appliance pack contains :- HEATING OR Boiler. DOMESTIC Casing panels, packed seperately. HOT WATER FLOW Loose items fittings pack, see list in pack. The chimney flue adapter with flue extension is supplied ALTERNATIVE seperately. - Page 12 4 Installation 4.4 Pipework When the front tappings are used, it is essential that any pipework or fittings do not project more than shown in diagram 4.4. When using a rear tapping with Rc (1in BSP) fitting for 28mm od UPPER CASING pipework, it is recommended that a short nipple and an Rc BRACKET...
- Page 13 4 Installation 4.6 Side Casings SIDE Fit the side casings by locating their lugs into the appropriate CASING SPRING slot in the boiler plinth, see diagram 4.7, depending on the (R.H.SHOWN) CLIP required height, there are two options, see section 1.7. Secure the casing sides to the front and rear upper casing brackets with self-tapping screws supplied, see diagrams 4.7 and 4.8.
- Page 14 4 Installation 4.8 Flue / Boiler Connection Remove the three self-tapping screws from the lower part of the control box support bracket, see diagram 4.10. Undo the wing nut that secures the top of the heat shield and ACCESS carefully hinge down control box and heat shield, see diagram DOOR 4.10.
- Page 15 4 Installation 4.11 Top Casing 4.9 Water & Gas connections Refer to diagram 4.16. Replace fan access door, heat shield and control box. Fit two plastic pegs, one on each side, in the holes on the top Note: When replacing the fan access door make sure the lip at casing.
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Page 16: Electrical Wiring
5 Electrical Wiring SECURING CONTROL SCREWS COVER TERMINAL BLOCK CONTROL BOILER TEMPERATURE CONTROL TERMINAL BLOCK CONNECTIONS 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 17: 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 be removed by the user. set time if ignition has not taken place the boiler will shutdown. To re-start the lighting sequence, turn the boiler temperature Please ensure the “Benchmark”... - Page 18 6 Commissioning The correct working of the flame supervision is shown by the 6.8 Completion “Burner On” neon going out and the ignition sequence starting Adjust the boiler temperature control and any system controls to their required settings. After a short period the boiler will shut down. Fit the bottom plinth panel and secure with two dog point If the lighting sequence described fails, refer to fault finding screws, see diagram 6.2.
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Page 19: Instructions To The User
7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the boiler, heating system and domestic hot water system. Advise the user, that to ensure the continued efficient and safe operation of the boiler, it is recommended that it is checked and serviced at regular intervals. - Page 20 8 Servicing 8.1 Access SECURING SCREWS Remove the boiler front casing panel, refer to section 6.8. Remove the bottom plinth panel by unscrewing the two dog point screws securing the panel to the boiler plinth, see diagram 8.4. Disconnect gas valve from gas cock and unplug electrical plug from gas valve, firstly removing electrical plug securing screw, see diagram 8.2.
- Page 21 8 Servicing 8.2 Boiler Flueways WING NUT Remove flueway baffles noting that there are 2 centre and 2 side flueway baffles, see diagram 8.8. Place a sheet of paper in the combustion chamber to catch any flue debris. Thoroughly clean boiler flueways and fins with a suitable stiff brush.
- Page 22 8 Servicing 8.4 Service Checks Inspect the spark electrode and clean and replace as necessary, see diagram 8.12. Check the condition of the side and rear insulation panels in the combustion chamber. Check the condition of the seals on the boiler access door and the combustion chamber cover.
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Page 23: Fault Finding
9 Fault Finding IMPORTANT. On completion of the Fault Finding task which has required the breaking and remaking of the electrical BOILER TEMPERATURE connections, the continuity, polarity, short circuit and resistance CONTROL to earth checks must be repeated using a suitable multimeter. WARNING. -
Page 24: Electrical Supply Failure
9 Fault Finding 9.2 Electrical Supply Failure MAINS SUPPLY 230v ~ 50Hz Failure of the electrical supply will cause the burner to go out. Operation will normally resume on the restoration of the electrical AIR PRESSURE SWITCH CONNECTIONS supply. If the burner does not relight after an electrical supply failure and MAIN TERMINAL the reset neon on the control panel is lit, turn the burner STRIP CONNECTIONS... - 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 Replacement of Parts Important notes Disconnect the electrical plugs from the control board (PCB) slightly bending back the retaining latches to allow withdrawal, REMEMBER, When replacing a part on this appliance, use only see diagram 10.2. spare parts that you can be assured conform to the safety and performance specification that we require. - 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
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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