Summary of Contents for Warmworld FFC 30/60
- Page 1 FFC 30/60 & FFC 65/80 Installation & Service Instruc- tions CONDENSING BOILERS Natural Gas Only GC No. 41 555 15 41 555 16 Serial Number: 0087 Note to the Installer: Please leave these Instructions adjacent to the meter.
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Page 2: Technical Data
Technical Data 30/60 Boiler Model 65/80 (min/max) (min/max) ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○... -
Page 3: Table Of Contents
They are suitable for connection to open vented or Contents sealed systems. These systems may be pumped central heating or pumped central heating combined Section Page with a pumped indirect domestic hot water circuit. Technical Data Gravity circuits must NOT be used. Introduction Boiler Location The boilers include a pump overrun device so it is... -
Page 4: Boiler Location
IMPORTANT. It is important that no external In siting the boiler, the following limitations MUST be control devices are directly connected to this appli- observed: ance - unless covered by these ‘Installation and 1. The position selected for installation MUST allow Servicing Instructions’... -
Page 5: Air Supply
7. Because the flue gases and terminal are at very Air Supply low temperature it is not necessary to fit a It is NOT necessary to have a purpose provided air Terminal guard to protect against burns. If a vent in the room or internal space in which the boiler guard is required for any other reason the is installed. -
Page 6: Sealed Systems
Sealed Systems Electricity Supply A sealed system should follow the guidelines given Refer to Figs. 3 and 4. in the Code of Practice BS 7074 :1. It should include Wiring external to the appliance MUST be in accord- a safety valve to BS 6750 Pt 1. fitted close to the ance with the current I.E.E. -
Page 7: Removing Case
Right or Left Outlet Removal of the Case 1. Secure the 50mm flue tube with ELBOW connec- tor on the saddle using the Velcro strap. Refer to Fig. 6 See Fig. 7 1. Lower the electrical cover. This is detached by pulling the cover towards you and carefully 2. -
Page 8: Plumbing
2. Pipes must be clipped every 1000mm, minimum. screws, and retain. For Twin Pipe Installations, also remove the Left Hand Side Trim. 3. The condensate connection from the Boiler Mounting Box must be connected to the Boiler 3. With the bottom of the boiler away from the wall, Condensate Drain Trap. -
Page 9: System Design
be in a minimum of 19mm pipe. External runs MUST The pump may be on the flow or return, but careful note of its position relative to the feed and vent be made in a minimum of 32mm pipe, starting inside MUST be made to avoid pumping over, or sucking in the building, and if possible insulated to defer prob- lems from freezing. -
Page 10: Commissioning
substantial amounts of air being dispersed through Commissioning the system as small bubbles. General Carry out electrical tests as stated in Electrical The elimination of air from systems is essential to Connections if not already done so. minimise the occurrence of heat exchanger and general system noise. - Page 11 Continue running for 15 minutes, venting every 5 Note: The boiler is fitted with a syphon trap minutes. that includes a blocked drain device. This is to safeguard the boiler and help defer The Pilot is factory set. the effects from the possible freezing of the condensate pipework in extreme The Main gas valve, GV2, gradually raises the pressure to the set point.
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Page 12: Fig 1. Gas Valve
Commission Check List (hydraulic) The key points which must be observed closely, are shown below. With radiator valves and vents open fill the Do not light boiler. system. Run pump for at least 30 minutes. Do not use pump. Do not light gas Stop at 5 minute intervals to vent. -
Page 13: Fig 2. Installation Dimensions
Installation Dimensions Service Access Pipe Connections & Locations Fig.2 Condensing Boiler 06/06/01... -
Page 14: Fig 3. Schematic Wiring
Schematic Wiring Fig.3 Condensing Boiler 14/12/00... -
Page 15: Fig 4. Physical Wiring
Physical Wiring Diagram Fig.4 Condensing Boiler 06/06/01... -
Page 16: Fig 5. Fixing Positions
Fixing Positions Fig.5 Condensing Boiler 06/06/01... -
Page 17: Fig 6. Boiler Panel Assembly
Boiler Panel Assembly Top Trim Twin Pipe Side Trim Boiler Mounting Concentric Flue Boiler Mounting Fan Protection Hoop Pressure Cover Lower Burner Baffle Front Burner Baffle Control Board Chassis Electrical Cover Fig.6 Condensing Boiler 06/06/01... -
Page 18: Fig 7. Concentric Flue & Air Duct
Concentric Flue, positions Fig.7 Twin Flue Positions 100mm Air Duct Flue Duct Twin Pipe Boiler Mounting Box Assembly Flue Spigot Adapter Drain Point Fig.8 Condensate Drain Connection (connects to drain point Connects to optional on Flue Spigot Adapter) condensate drain point on Condensate Drain Trap Condensing Boiler 06/06/01... -
Page 19: Fault Finding
Fault Finding The electrical sequence in the boiler is very straightforward and faults can easily be tracked down if this simple sequence is followed. System Controls - - - - Flue Stat - - - - Overheat Stat - - - - Pressure Switch - - - - Control Board - - - - Ignition The lamps on the front panel indicate several of the stages in the ignition sequence. -
Page 20: Fault Diagnosis
Fault Diagnosis Condensing Boiler... -
Page 21: Servicing
CHANGING COMPONENTS Servicing THERE ARE NO REPAIRABLE ITEMS, IF NOT WORKING AN ITEM MUST BE REPLACED. Health and Safety Statement : This product contains no asbestos. The boiler is in two major sections, the Case, and the Electrical Tray, The Major Components Routine Diagram shows where the items are to be To ensure continued efficient operation of the... - Page 22 2. Gas Valve 3. Fan Assembly Lower the Electrical Tray. Lower the Electrical Tray. Turn the Gas Cock off. Remove the Case. Pull off the electrical connector from the Gas Undo the wing nut holding the Fan Protec- Valve. tion Hoop. Release the pilot feed tube.
- Page 23 8. Electrode and HT Lead 12. Combustion Chamber Insulation Lower the Electrical Tray. Lower the Electrical Tray. Remove the Case Remove the Case. Pull off the HT lead from the Control board. Remove the Front Baffle, then undo the four Undo the left and right screws holding the M5 screws holding the lower baffle onto the Front Burner Baffle.
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Page 24: Fig 9. Spares
Spares 1st Line Spares: Item Part Number GC Number Primary Heat Exchanger (17 kW) M0142 Primary Heat Exchanger (24 kW) M0593 Secondary Heat Exchanger (17 kW) M0502 Secondary Heat Exchanger (17 kW) M0797 Burner (17 kW) M3726 Burner (24 kW) M3727 Ceramic Board Set (17 kW) 0524... -
Page 25: Fig 10. Major Components
Major Components Flue Gas Sampling Point Air Pressure Switch Fan Assembly Flue Hood Gasket Secondary Heat Exchanger Flue Thermostat Inspection Cover Condensate Outlet Fibre Washer ( 2 Places ) Primary Heat Exchanger O/H Stat Ceramic Board Main Injector Burner Condensate Trap Pilot Assembly Pilot Injector... -
Page 26: Fig 11. Example Condensate Disposal
Example Condensate Disposal Methods Note: Internal - minimum 19mm pipe External - minimum 32mm pipe 75mm Running Trap Air Break Strap-On Boss Insulate against freezing 150mm Land Drain 1:20 Fall ( 2.5 Degrees ) Filled with Gravel 750mm deep Soakaway 110mm Soil Pipe or Drain Air Gap Air Gap... - Page 27 The Company reserves the right to change specification without notice. Your statutory rights are not affected. 1 Hanham Business Park, Memorial Road, Bristol, BS15 3JE. Telephone: 0117 949 8800 Fax: 0117 949 8888 M3818...