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Henrad CC 80 FF Installation And Servicing Manual

Wall mounted, gas fired, fanned flue combination boiler
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Summary of Contents for Henrad CC 80 FF

  • Page 2 CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance, care should be taken when handling edges of sheet steel components. Henrad CC FF - Installation...

  • Page 3: Performance Data

    Width mm (in.) 436 (17 1/8) Depth mm (in.) 278 (10 15/16) CC 80 FF CC 100 FF CC 120 FF Average flue temp / mass flow rate C / 11.8 g/s C / 14.7 g/s C / 14.7 g/s Max.

  • Page 4: Table Of Contents

    Btu/h) minimum and 23.4 kW (80,000 Btu/h) maximum for CC 100/ Boiler Dimensions/Clearances ........6 120 FF and 17.6kW (60 000Btu/h) maximum for CC 80 FF. Boiler Exploded Diagram ..........12 Domestic hot water (DHW) output is also fully modulating, with a maximum of: Commissioning and Testing ........
  • Page 5 With no call for CH the boiler fires only when DHW is drawn off. maximum draw-off of : When there is a call for CH, the heating system is supplied at the selected temperature until DHW is drawn off. The full CC 80 FF 9.6 l/min (2.1 gpm) at 35...
  • Page 6 10mm in an adequately ventilated enclosed cupboard. However, 150 mm must Distance X is 20mm for DHW pipes and safety valve outlet. be available for servicing. Distance X is 23.5mm for CH pipes and gas inlet. Henrad CC FF - Installation...

  • Page 7: Air Supply

    3. In siting the air vents, care must be taken to avoid the freezing by the local authority. of pipework. The boiler must not be fitted outside. 4. If the boiler is NOT installed in a cupboard or compartment no air vent is necessary. Henrad CC FF - Installation...

  • Page 8: Gas Supply

    DHW flow rate. Refer to same wall 1500 mm (60") Table 1 on page 3. 12. Horizontally from a terminal on the wall 300 mm (12") The central heating system should be installed and Henrad CC FF - Installation...

  • Page 9: Electrical Supply

    2. BS. Requirements For further details refer to BS.5449:1 and the British Gas The installation must comply with the requirements of Corporation publication 'Specifications for Domestic Central BS. 6891:1988 and BS. 5449. Heating and Hot Water'. Henrad CC FF - Installation...
  • Page 10 None None None 11.7 10.5 13.9 10.6 12.4 16.1 12.2 14.2 18.4 Multiply this factor by system volume and 0.067 0.074 0.088 deduct 8 litres to obtain size of additional vessel for other system volumes. Henrad CC FF - Installation...
  • Page 11 It is therefore strongly recommended that, when Water Flow Rate and Pressure Loss thermostatic radiator valves are used, the space heating CC 80 FF CC 100/120 FF temperature control over a living/dining area or a hallway, having a heat requirement of at least 10% of the boiler Max CH Output 17.6...
  • Page 12 34. CH Lower flow pipe assy. 59. Turret clamp. Ignition electrode 22. DHW expansion vessel 35. CH Upper flow pipe assy. 67. Transformer. PCB 37 23. CH expansion vessel 36. DHW Upper cold pipe assy. PCB 40 Henrad CC FF - Installation...
  • Page 13 2. The top tray contains: Flue turret !" Mounting frame !" Hardware pack !" Stand-off channels !" Wall mounting template !" Installation instructions These contents can be removed, leaving the boiler in its protective package. Henrad CC FF - Installation...
  • Page 14 ") Three Extn Duct 4000mm (157 ") Four Extn Duct Pack B1 - supplied as standard. For side flue option PROCEED TO FRAME 20 Extension Duct Kit - optional extra kit, to extend the flue. Henrad CC FF - Installation...
  • Page 15 (refer to Table 5) then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided. (The terminal wall plate cannot be fitted close to a corner). Henrad CC FF - Installation...
  • Page 16 BEFORE the plate is screwed to the wall. Showing the use of 'stand-off' channels, to enable upward pipework. Make service water, gas & electrical connections. Go to Frames 35, 36 & 39 then return to Frame 15. Henrad CC FF - Installation...
  • Page 17 2. Pass the cut flue through the prepared hole, ensuring that the groove is uppermost. 3. Pull the flue back to compress the rubber seal and fix in place with the clamping/sealing rings. Henrad CC FF - Installation...

  • Page 18: Mounting The Boiler

    4. Lower the boiler into position. 5. Remove the bottom panel to access service connections. 6. CC 80 FF only. Fit the filter to the DHW inlet valve, as shown. CC 100 FF/120 FF only. Refer to Frame 7. Using the correctly sized fibre washers supplied in the hardware pack, engage then tighten the 4 water unions.
  • Page 19 4. Secure the plate with 4 of the No.10 x 2" screws provided in flue pack B. Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to 'Flue Installation', Page 7. Henrad CC FF - Installation...
  • Page 20 Extended the centre line as shown. Mark the flue duct centre from the corner (see diagram and template). Note. Mark the centre of the hole as well as the circumference. 4. Remove template from the wall. Henrad CC FF - Installation...
  • Page 21 BEFORE the plate is screwed to the wall. Make service water, gas & electrical connections. Go to Frames 35, 36 & 39 then return to Frame 15. Henrad CC FF - Installation...

  • Page 22: Fitting The Flue

    3. Pull the flue back to compress the rubber seal and fix in place with the clamping/sealing rings. Note. To facilitate turret fixing or removal do NOT make good the wall. Henrad CC FF - Installation...
  • Page 23 4. Lower the boiler into position. 5. Remove the bottom panel to access service connections. 6. CC 80 FF only. Fit the filter to the DHW inlet valve, as shown. CC 100 FF/120FF only. Refer to Frame 6. 7. Using the correctly sized fibre washers supplied in the hardware pack, engage and then tighten the 4 water unions.
  • Page 24 4. Secure the plate with 4 of the No.10 x 2" screws provided in flue pack B. Note. If the terminal is less than 2m (6' 6") above ground level, an approved terminal guard should be fitted. Refer to 'Flue Installation', Page 7. Henrad CC FF - Installation...
  • Page 25 Do not drill the inner flue duct. 5. Insert the self tapping screw provided to fix the air duct in position. 6. Repeat steps 1-5 if a second flue extension is required. Henrad CC FF - Installation...

  • Page 26: Service Connections

    If pipes are run vertically within the boiler back space provided by optional stand-off channel positions they must avoid any obstructions imposed by the channels and by a rear facing flue, should this position be selected. Henrad CC FF - Installation...

  • Page 27: Water Connections

    37 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 damage to electrical components and wiring. Henrad CC FF - Installation...

  • Page 28: Electrical Connections

    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. Henrad CC FF - Installation...
  • Page 29 41 FUNCTIONAL FLOW WIRING DIAGRAM *Timer kit LEGEND - blue bk - black br - brown - red - orange - white - yellow m - mauve pk - pink gy - grey y/g - yellow/green Henrad CC FF - Installation...

  • Page 30: Commissioning And Testing

    The means of isolation must be accessible to the user after installation. Internal Timer The Henrad Timer Kit is supplied with its own instructions. Associated controls should be wired as shown in Diagram A. External Single Channel Timer...

  • Page 31: Initial Lighting

    15. Refit the boiler front panel, using the screw previously pressure gauge via a flexible tube. removed. Be sure to select the correct pressure test point. Refer to Tables 2 & 3 on page 3 for pressures. 16. Switch the boiler on again. Henrad CC FF - Installation...

  • Page 32: Handing Over

    INSTALLATION 45 GENERAL CHECKS CC 80 FF 43.1 to 47.7 litres per minute 1.52 to 1.68 cu/ft per minute Make the following checks for correct operation: CC 100 FF 51.9 to 57.4 litres per minute 1.8 to 2.0 cu/ft per minute 1.

  • Page 33: Servicing Schedule

    1. Turn off the gas supply at the gas service cock and 3. Remove the screws and pull out the tabs from the slots. disconnect the electricity supply. 2. Remove the screw and lift off the boiler front panel. Henrad CC FF - Installation...

  • Page 34: Burner Removal And Cleaning

    - replace if necessary. 6. Check the spark and electrode gaps are correct. 7. Check that the spark and detection leads are in good condition and renew as necessary Henrad CC FF - Installation...

  • Page 35: Cleaning The Heat Exchanger

    Note. In order to assist fault finding, the printed circuit boards are fitted with indicator lights. Full details are found in the Fault- Finding section. IMPORTANT. When work is complete the sealing panel must be correctly fitted, ensuring that a good seal is made. THE BOILER MUST NOT BE OPERATED IF THE SEALING PANEL IS NOT FITTED. Henrad CC FF - Installation...
  • Page 36 4. Disconnect the leads from the thermostat. 5. Release the 2 securing screws and remove the old thermostat. 6. Fit the new thermostat, reconnect and re- assemble in reverse order. 7. Reconnect the supply and test fire the boiler. Henrad CC FF - Installation...
  • Page 37 (if fitted). 4. Disconnect the electrical leads from the spark generator. 5. Withdraw the spark generator. 6. Fit the new spark generator and re-assemble in reverse order. 7. Check the operation of the boiler. Henrad CC FF - Installation...
  • Page 38 61 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 48. 2. Unscrew the injector from the gas injection pipe. 3. Check that the new injector is of the correct size then screw in place. 4. Re-assemble in reverse order. Henrad CC FF - Installation...
  • Page 39 To replace ONLY the SOLENOIDS a. Follow steps 3, 6 and 7. b. Undo the 2 retaining screws on the solenoids then pull the solenoid to release. c. Re-assemble in reverse order. Ensure step 13 (Frame 63) is followed. Henrad CC FF - Installation...
  • Page 40 9. Fit the filling loop. Fill the boiler with water and pressure to 1 bar (as appropriate). Reconnect services. 10. After satisfactory test firing and removal of air from the system remove the filling loop. Henrad CC FF - Installation...
  • Page 41 Drain using the valve nipple. Undo the bulk head fitting shown. Slacken the nut on the other end of the lower cold pipe assembly. 6. Clean or renew as necessary. Re-assemble in reverse order. Henrad CC FF - Installation...
  • Page 42 If necessary, remove the fan (see Frame 65). To access use a spanner on the hexagon nut behind the vessel. 6. Replace with new sealing gasket and vessel. Reassemble in reverse order and test fire. Henrad CC FF - Installation...

  • Page 43: Electrical Connections

    2. Isolate the water and gas supplies by closing 3 cocks below the boiler. Note. Do not close the DHW restrictor ball valve. 3. Remove the boiler front panel and inner sealing panel. Refer to Frame 48. Henrad CC FF - Installation...
  • Page 44 19. Unscrew and remove the automatic air vent from the top of a requirement of the water bylaws). the heat exchanger. 20. Remove the 2 screws securing the heat exchanger to the support brackets, together with the top clamping screw. Henrad CC FF - Installation...

  • Page 45: Water Pressure Switch

    6. Compress the clips on the sides of the timer and withdraw it from the retaining bracket. 7. Fit the new timer and re-assemble in reverse order. 8. Check the operation of the new timer. Henrad CC FF - Installation...
  • Page 46 3. Release the screws securing the PCB cover and remove the cover. 4. Disconnect the transformer electrical leads at the in-line connector 5. Release the transformer mounting screws. 6. Fit the replacement transformer and complete the reassembly in reverse order. Henrad CC FF - Installation...
  • Page 47 In this case, access to the water connection of the expansion vessel will be possible by removing the RH boiler side panel. For option B, proceed as follows: B1. Isolate the electric, gas, and water services. Henrad CC FF - Installation...
  • Page 48 C6. Follow instructions B3 to B6. C7. Return the boiler to the wall mounting frame, remaking all connections, including the flue. C8. Fill, pressurise and test. C9. Remove the filling loop. Henrad CC FF - Installation...

  • Page 49: Fault Finding

    - HW takes priority, i.e. pump OFF, fan running at (apply the other probe of the meter to mains neutral, e.g. on full speed, power to PCB 37. terminal N of the timer terminal strip). Henrad CC FF - Installation...
  • Page 50 At room temperature expect 9,000 to 11,000 Ohms lead to the flow switch at PCB At 60°C. expect 2,000 to 2,500 Ohms Change faulty At 85°C. expect 1,000 to 1,500 Ohms flow switch Does the boiler now give CH ? Henrad CC FF - Installation...
  • Page 51 Check for moisture on At room temperature expect 9,000 to 11,000 Ohms PCB 40. At 60°C. expect 2,000 to 2,500 Ohms If no fault found check PCB 40 by substitution. At 85°C. expect 1,000 to 1,500 Ohms Henrad CC FF - Installation...
  • Page 52 Foot Note: Presence of live supply on a terminal may be checked with a multimeter set to the appropriate AC range (apply the other probe of the meter to mains neutral, e.g. on terminal N of the timer terminal strip). Henrad CC FF - Installation...
  • Page 53 Is burner pressure check continuity of leads from each socket correct ? unit back to the corresponding terminals in the control box. Are leads in good order ? Replace gas valve solenoids Return to main menu Henrad CC FF - Installation...
  • Page 54 With gas OFF, do another ignition cycle. Is the spark OK now ? Re-assemble and Fit a new restore gas supply. ignition Return to main electrode Boiler should now menu light and the assembly 'Burner On' neon illuminate Henrad CC FF - Installation...
  • Page 55 Use a multimeter (set to measure 230 V AC or more), connecting the black lead to a reliable Earth point ( not Neutral for this particular test) . You should find 230 V on terminal L and zero (or a small reading) on terminal N. N.B. Some meters may trip residual current devices during this test. Henrad CC FF - Installation...
  • Page 56 / repressurise closed position ? Has it been discharging water ? Clear and re-adjust the valve. Recheck for leaks on pipes and radiators Repressurise the system Henrad CC FF - Installation...
  • Page 57 54. Fan / burner mounting 'O' ring. Flame sensing electrode. 68. Gas cock ". 55. Fan 'O' ring. Ignition electrode. 74. Injector pipe 'O' ring. 56. Pressure pipe 'O' ring. 19. Fan assembly. 75. Gas elbow 'O' ring. Henrad CC FF - Installation...
  • Page 58 SHORT LIST OF PARTS 88 CONTROLS AREA - Exploded View Legend Fan speed control board PCB 37. EMC filter. Spark generator assembly. PCB 40. Transformer assembly. Henrad CC FF - Installation...

  • Page 59: Short List Of Parts

    Main burner , c/w: 1 off burner gasket, 3 off M4 shakeproof washers, 3 off M4 x 6 lg. pozi pan hd. screws, 1 off 'O' ring, 1 off fan and burner mount E02-142 CC 80 FF 075214 E01-765 CC 100 FF/120 FF...
  • Page 60 Automatic air vent (Caleffi ref. CA 502630), including 'O' ring 113116 Pressure sensing pipe assembly c/w:gas valve mount 'O' ring, 2 off M4 x 8 lg. pozi pan hd. screw CC 80 FF 152036 E02-110 CC 100 FF/120 FF 150554...
  • Page 61 SHORT LIST OF PARTS 89 SHORT PARTS LIST 90 BOILER CASING ASSEMBLY Henrad CC FF - Installation...

  • Page 62: Servicing

    Registration No. London 322 137. performance of its products. The right is therefore reserved to vary specification without notice. June 2001 153 964 A05 Henrad Installer/Technical Helpline: 01482 498663 Henrad CC FF - Installation...
  • Page 63 Your feedback and your chance to win a free boiler At Henrad we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service. We'll be giving away a free boiler for the five best ideas every year (to be selected by our Technical Director).

  • Page 64: Further Information

    Further information If you would like information about Henrad Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing Limited, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Installer details...

This manual is also suitable for:

Cc 100 ffCc 120 ff

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