Ideal Boilers Henrad SE 30 FF Installation And Servicing Manual
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Ideal Boilers Henrad SE 30 FF Installation And Servicing Manual

Ideal Boilers Henrad SE 30 FF Installation And Servicing Manual

Wall mounted, gas fired, fanned flue condensing boiler
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Summary of Contents for Ideal Boilers Henrad SE 30 FF

  • Page 2 Henrad SE FF - Installation...

  • Page 3: General Data

    GENERAL DATA Table 1 - Boiler Data Boiler Size SE 30 FF SE 40 FF SE 50 FF SE 60 FF SE 70 FF SE 80 FF Gas supply connection (in. BSP) " BSP Female) Flow connection 22mm copper (via adaptors 28mm copper (FEMALE) supplied)

  • Page 4: Table Of Contents

    CONTENTS SE FF Air Supply ............... 8 Natural Gas only Boiler Clearances ............5 SE 30 FF ....G.C. Appliance No. 41 387 46 Boiler Exploded Diagram ..........13 SE 40 FF ....G.C. Appliance No. 41 387 47 Electrical Connections ..........23 SE 50 FF ....

  • Page 5: Boiler Clearances

    GENERAL BOILER WATER CONNECTIONS The boiler flow and return pipes are supplied fitted to the boiler ready for top connection but can be removed and adapted for bottom connection, if required, either before or after the boiler is hung on the wall. Refer to Frame 43. Notes.

  • Page 6: Gas Safety Regulations

    GENERAL Detailed recommendations are contained in the following British INTRODUCTION Standard Codes of Practice: SE 30-80 FF are fully automatically controlled, wall mounted, BS. 6891 Low pressure installation pipes. low water content, balanced flue, fanned super efficient condensing gas boilers. They are spot-rated to provide central heating outputs of 8.8 kW (30,000 Btu/h) to 23.4 kW (80,000 BS.

  • Page 7: Flue Installation

    GENERAL 1. The boiler MUST be installed so that the terminal is exposed Bathroom Installations to external air. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. 2.

  • Page 8: Air Supply

    GENERAL Table 4 - Water flow rate and pressure loss IMPORTANT . It is absolutely ESSENTIAL to ensure, in practice, that products of combustion discharging from the terminal cannot Boiler size SE30FF SE40FF SE50FF SE60FF SE70FF SE80FF re-enter the building or any other adjacent building through ventilators, windows, doors, other sources of natural air infiltration, Boiler 11.7...

  • Page 9: Pump

    GENERAL all dimensions in mm (in.) OPEN VENT SYSTEM REQUIREMENTS The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.
  • Page 10 GENERAL LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT This arrangement is useful for large systems where radiators at the extremities are difficult to vent. This can lead to pumping over with conventional feed and vent arrangements.
  • Page 11 GENERAL SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel The static head available from the cistern should be A diaphragm type expansion vessel must be adequate to provide the desired initial system design connected to a point close to the inlet side of the pressure.

  • Page 12: Water Treatment

    GENERAL SEALED SYSTEM REQUIREMENTS - continued Safety valve setting 3.0 bar 2.5 bar 2.0 bar Vessel charge and initial system pressure Total water content of system Expansion vessel volume litres litres 11.8 10.0 11.7 10.0 17.7 15.0 10.9 15.6 13.4 23.7 11.3 20.0...

  • Page 13: Installation

    INSTALLATION 10 BOILER ASSEMBLY - Exploded view LEGEND Boiler drain point 11. Control thermostat 17. Fan assembly 24. Fan pressure sensing pipe Main burner 12. Overheat thermostat 18. Front panel 25. Heat exchanger Gas valve 13. Dry fire thermostat 19. Controls door 26.
  • Page 14 INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in one pack, together Boiler Pack Contents with a standard flue assembly for lengths up to 406mm, rear Hardware Pack (listed below). or side flue outlet, in Pack B2. These Installation & Servicing Instructions. Optional extras (Roof Flue Kit, Extension Duct Kit, Flue Elbow Kits), if ordered, are available in separate boxes.
  • Page 15 INSTALLATION 13 BOTTOM PANEL REMOVAL 1. Undo the 3 retaining screws. 2. Push the panel backward then to the right to withdraw it from the boiler. 3. Unpack the boiler flue kit (and extension packs, if used). 14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT.
  • Page 16 INSTALLATION 15 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 580mm "). Refer to Frame 14. 2. When cutting the ducts always use the cardboard support cutting aid provided. LEGEND 1.

  • Page 17: Mounting The Boiler

    INSTALLATION 18 CUTTING THE FLUE Wall thicknesses of 114 to 580mm 1. Measure and note wall thickness X. 2. Add 15mm ( ") to dimension X and, measuring from the groove, cut the tube. 3. To ensure the tube is cut square, mark the flue all the way round.
  • Page 18 INSTALLATION 21 CONNECTING THE FLUE TO THE BOILER Note. BEFORE fitting the flue turret, fill the condensate siphon within the boiler by pouring a cupful of water into the flue outlet A. 1. Insert the flue assembly through the prepared hole in the wall far enough to allow the rubber seal to unfold completely and form an adequate seal on the outside wall.
  • Page 19 INSTALLATION 23 FLUE ASSEMBLY - Exploded view 1. An optional flue duct extension kit is required for wall thicknesses greater than : 460 mm (18") for RHS flue 550 mm (21 ") for LHS flue (see Frame 14). LEGEND 1. Terminal. 2.
  • Page 20 INSTALLATION 25 PREPARING THE WALL IMPORTANT . Ensure that, during the cutting operation, masonry falling outside of 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. Both wall faces immediately around the cut hole should be flat.
  • Page 21 INSTALLATION 28 MOUNTING THE BOILER 1. Lift the boiler onto the wall mounting plate, as shown. 2. Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw. 3. Align the hole in the jacking plate with the pre- drilled hole in the wall and fix in position with the No.10 x 2"...
  • Page 22 INSTALLATION 30 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal. Its use is not essential if the flue hole and flue ducts have been accurately cut and the outside wall face is flat. 1.

  • Page 23: Electrical Connections

    INSTALLATION 33 FITTING THE KIT 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.

  • Page 24: Flow Wiring Diagram

    INSTALLATION 35 INTERNAL WIRING Note. If a timer kit is to be fitted refer to the instructions provided with the kit, and Frame 36. Incoming mains wiring detail A pictorial wiring diagram is shown in Frame 37 . 1. Route the mains cable into the bottom RHS rear of the casing. 2.
  • Page 25 INSTALLATION 37 PICTORIAL WIRING LEGEND - blue bk - black br - brown - red - white or - orange - yellow g/y - green/yellow 38 MID POSITION VALVE - pumped only 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring 2.
  • Page 26 INSTALLATION 39 DIVERTER VALVE - pumped only 1. Some earth wires are omitted for clarity - ensure proper earth continuity when wiring. 2. This is a fully controlled system - set the boiler thermostat to MAXIMUM. 3. Numbering of thermostat terminals applies only to the manufacturer mentioned.

  • Page 27: Frost Protection

    INSTALLATION 41 TWO SPRING CLOSED VALVES - pumped only 1. Some earth wires are omitted for clarity - ensure proper earth continuity when wiring. 2. This is a fully controlled system - set the boiler thermostat to MAXIMUM. 3. Numbering of thermostat terminals applies only to the manufacturer mentioned.

  • Page 28: Condensate Drain

    INSTALLATION 43 BOILER WATER CONNECTIONS The boiler flow and return pipes are supplied fitted to the boiler and ready for top connection. Note. For boiler sizes SE 30 FF to SE 60 FF use the 28mm x 22mm connectors supplied in the hardware pack, to reduce the boiler flow and return pipes to 22mm.

  • Page 29: Gas Connection

    INSTALLATION 45 GAS CONNECTION Ensure that the gas supply pipe does not foul the boiler casing. Note. If the pipe run from the meter to the boiler is greater than Refer to Frame 2 for details of the position of the gas connection. 3m (10') 22mm O.D.

  • Page 30: Handing Over

    INSTALLATION 48 GENERAL CHECKS Make the following checks for correct operation With the system HOT examine all water connections for soundness. 1. Operate the thermostat knob and check that the burner and 'Burner on' neon, light and extinguish in response. With the system still HOT, turn off the gas, water and electricity supplies to the boiler and drain down to 2.

  • Page 31: Servicing

    SERVICING 50 SERVICING SCHEDULE If this is the case, and the gas input is at least 90% of the nominal, then no further action need be taken. If not, proceed To ensure the continued safe and efficient operation of the to step 6 but see note above.

  • Page 32: Burner Removal And Cleaning

    SERVICING 53 FAN REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 2. Disconnect the pressure sensing pipe from the fan. Undo the 2 screws securing the pipe to the fan. Undo the 2 screws securing the pipe clamping plate to the manifold block.

  • Page 33: Cleaning The Heat Exchanger

    SERVICING 55 CLEANING THE HEAT EXCHANGER IMPORTANT. 1. Place a plastic sheet or similar beneath the boiler Deposits are most effectively removed from the fins if they are and remove all visible loose deposits from the heat dry. Ensure this by running the pre-service checks with the exchanger fins, using a suitable brush.
  • Page 34 SERVICING 59 CONTROL THERMOSTAT REPLACEMENT Refer also to Frame 10 - 'Boiler exploded view' and Frame 37 'Pictorial wiring.' 1. Refer to Frame 58. Note. The sealing panel need not be removed. 2. Remove the split pin and withdraw the thermostat phial from the pocket.
  • Page 35 SERVICING 62 FLUE THERMOSTAT REPLACEMENT Refer also to Frame 10 'Boiler exploded view' and Frame 37 'Pictorial wiring.' 1. Refer to Frame 58. 2. Disconnect the flue thermostat electrical leads. 3. Unscrew the thermostat from the side of the heat exchanger.
  • Page 36 SERVICING 65 BURNER REPLACEMENT 1. Refer to Frame 58. 2. Remove the fan assembly. Refer to Frame 53. 3. Disconnect the 2 ignition leads and one detection lead from the electrodes. 4. Undo the 3 fixing screws securing the burner assembly.
  • Page 37 SERVICING 67 GAS CONTROL VALVE REPLACEMENT Refer also to Frame 10 - 'Boiler exploded view.' 1. Refer to Frame 58. 2. Remove the casing bottom panel. Refer to Frame 3. Remove the control panel. Pull off the thermostat knob. Undo the control box retaining screw. Refer to Frame 59.
  • Page 38 SERVICING 68 GAS CONTROL VALVE REPLACEMENT - continued 10. Undo the retaining nut and withdraw the manifold from the gas valve mounting bracket. 11. Undo the 6 retaining screws and separate the gas valve from the mounting bracket. 12. Transfer the bracket and manifold to the new gas valve, ensuring that any damaged or deteriorating gaskets are replaced.
  • Page 39 SERVICING 70 FAN UNIT REPLACEMENT Refer also to Frame 10 - 'Boiler exploded view'. 1. Refer to Frame 58. 2. Disconnect the electrical leads from the fan. 3. Disconnect the pressure sensing pipe from the fan. Undo the 2 screws securing the pipe to the fan.
  • Page 40 SERVICING 72 PRINTED CIRCUIT BOARD REPLACEMENT Refer also to Frame 10 - 'Boiler exploded view' and Frame 37 - 'Pictorial wiring'. 1. Refer to Frame 58. Note. The sealing panel need not be removed. 2. Remove the boiler bottom panel. Refer to Frame 59, step 4. 3.
  • Page 41 SERVICING 75 HEAT EXCHANGER REPLACEMENT IMPORTANT. Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. Refer also to Frame 10 - 'Boiler exploded view'. Flow 1. Refer to Frame 58. 2. Drain down the system. 3.
  • Page 42 SERVICING 76 BOILER SEALING PANEL SEAL REPLACEMENT 1. Refer to Frame 58. 2. Remove the old seal from the casing and thoroughly clean the casing surfaces. 3. Fit the new self adhesive seals. 4. Re-assemble in reverse order. Note. Ensure that the boiler sealing panel is correctly seated, compressing the sealing strip to make an airtight joint.

  • Page 43: Fault Finding

    FAULT FINDING 78 FAULT FINDING CHART MAIN MENU Clear the blockage. BEFORE STARTING THE BOILER. Remove the fan and inspect the scroll for water ingress. Is the condensate drain blocked? Does the fan run correctly ? Go to Fault Finding Chart 1 Go to Fault Finding Chart 2 Is the correct (or higher) burner pressure indicated during an ignition attempt ?
  • Page 44 FAULT FINDING 79 FAULT FINDING CHART 1 - Fan Not Running Correctly NB: Mains supply for this boiler Does the fan run when LED 3, on is 230 V AC 50 Hz the PCB, is lit ? Change fan Is there mains voltage between supply terminals on fan motor ? Check mains supply and fuses.
  • Page 45 FAULT FINDING 80 FAULT FINDING CHART 2 - Burner Pressure Incorrect or Zero Notes. 1. The burner pressure is regulated by the gas valve, according to the air flow generated by the fan, and on cold ignition should be slightly higher than the value quoted on the Data badge. 2.
  • Page 46 FAULT FINDING 81 FAULT FINDING CHART 3 - Spark Generation and Ignition Fan and gas supply OK. Ignition spark suspect Is there mains voltage on Board 37 terminals for the spark generator during the Check connections on Board 37. If no fault 5 ignition trial periods? found check Board 37 by substitution Is there mains voltage at the spark generator...
  • Page 47 FAULT FINDING 82 FAULT FINDING CHART 4 - Flame Detection Boiler lights briefly then goes off, leaving LED2 on the PCB lit Is polarity of the supply correct ? Ensure that live is connected to L and neutral to N Remove the fan.

  • Page 48: Short List Of Parts

    SHORT LIST OF PARTS When ordering spares please quote: The following are parts commonly required as replacements, due to damage or expendability. Their failure or absence is likely to affect the safety and/or Boiler model. performance of this appliance. Appliance G.C. number. The list is extracted from the British Gas List of Parts which contains all Description.
  • Page 49 SHORT LIST OF PARTS 83 BURNER ASSEMBLY - Exploded view LEGEND 'O' ring Gasket Burner Burner injector Gas valve Detection electrode Ignition electrode 17. Fan 23. Low pressure sensing pipe 24. Fan pressure sensing pipe 37. Gas valve mounting bracket 40.
  • Page 50 SHORT LIST OF PARTS 85 SHORT PARTS 86 BOILER CASING ASSEMBLY Caradon Plumbing Limited, P .O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. T elephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Registered Office: National Avenue, Kingston upon Hull, HU5 4JN.
  • Page 51 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 52: 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 Name Address Post Code...

This manual is also suitable for:

Henrad se 40 ffHenrad se 50 ffHenrad se 80 ffHenrad se 60 ffHenrad se 70 ff

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