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IDEAL Henrad WH 30 FF Installation And Servicing Manual

Wall hung, fanned flued, gas fired boiler
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  • Page 2 GENERAL Table 1 - General Data Boiler Size 30 FF 40 FF 50 FF 60 FF 70 FF 80 FF 100 FF Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female) Flow connection 22mm 28mm copper copper (FEMALE) Return connection 22mm 28mm copper...

  • Page 3: Key To Symbols

    GENERAL WH FF CONTENTS Air Supply..............6/7 B.G. Certified - P.I. No. 87 AP 107 Boiler Clearances ............5 Destination Countries: GB and IE Natural Gas only Boiler Exploded View ..........9 Appliance type: C & C Burner Exploded View ..........34 Data badge - top of controls support.

  • Page 4: Location Of Boiler

    GENERAL INTRODUCTION BS.6891 Low pressure installation pipes. BS.6798 Installation of gas fired hot water boilers of rated The WH 30 FF-100 FF is a range of automatically fully controlled, input not exceeding 60 kW. wall mounted, balanced flue, fanned gas boilers. BS.5449 Forced circulation hot water systems.

  • Page 5: Boiler Water Connections

    GENERAL BOILER WATER CONNECTIONS This appliance in NOT suitable for use in a direct hot water system or for gravity circulation. 70 FF, 80 FF & 100 FF ONLY must be fitted with the 22mm x 28mm copper sockets, provided in the Hardware Pack, (or equivalent 22mm x 28mm compression fittings ) and the pumped flow and return pipes run in 28mm pipe.

  • Page 6: Gas Supply

    GENERAL Bathrooms Table 3 - Balanced flue terminal position The boiler may be installed in any room or internal space, although Terminal Position Minimum Spacing particular attention is drawn to the requirements of the current I.E.E. (BS.7671) Wiring Regulations and, in Scotland, the electrical Directly below or alongside an provisions of the building regulations applicable in Scotland with opening window, air vent or other...

  • Page 7: Water Treatment

    GENERAL Table 5 - Water flow rate and pressure loss The following notes are for general guidance: 1. It is NOT necessary to have a purpose provided air vent in the Boiler Size room or internal space in which the boiler is installed. Boiler 8.8 11.7 14.6 17.6 20.5 23.4 29.3 2.

  • Page 8: Low Head Installations

    GENERAL OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED. The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry Feed / expansion should be inverted and MUST be positioned between the 450 (18") cistern Mimimum...
  • Page 9 INSTALLATION BOILER ASSEMBLY - Exploded view WH 30 FF shown LEGEND 1A. Heat exchanger. Fan. Collector hood assembly. Flue baffles. Wall mounting plate. Combustion chamber. Tie rods. 44B. Programmer (optional). Main burner. 4A. Pumped flow pipe. Back panel. Control box . 5A.
  • Page 10 INSTALLATION UNPACKING Boiler Pack Contents The boiler is supplied fully assembled in one pack, together The complete boiler with a standard flue assembly for lengths up to 600mm (23 1/2" Installation & Servicing Instructions rear or side flue outlet, in Pack B1. User's Instructions Optional extras, if ordered (Downward Piping Kit, Extension Hardware Pack (listed below)

  • Page 11: Determining The Flue Length

    INSTALLATION PACKAGING AND CASING REMOVAL (a) Casing retaining 1. Unpack the boiler. screws, 2 off 2. Remove the casing as follows and place to one side to avoid damage. a. Undo the 2 casing retaining screws (a) retaining the casing to the back panel. b.

  • Page 12: Wall Mounting Template

    INSTALLATION FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than 600mm (23 ") Refer to Frame 8. 2. When cutting the ducts, always use the cardboard support rings LEGEND provided. IMPORTANT.

  • Page 13: Fitting The Flue Assembly

    INSTALLATION 12 CUTTING THE FLUE - wall thicknesses of 114 to 600mm Note. If the stand-off brackets are used it is essential that 30mm is added to the measured wall thickness when marking the flue (to allow for the thickness of the brackets). 1.

  • Page 14: Mounting The Boiler

    INSTALLATION 16 MOUNTING THE BOILER Note. Have ready to hand the M8 screw, washer and rectangular plate supplied in the hardware pack. For downward routing of pipes the M5 spacer supplied in the Downward Piping Kit, should now be fitted to the back of the boiler. 1.
  • Page 15 INSTALLATION 19 FLUE ASSEMBLY - Exploded view For wall thickness 114mm to 600mm 1. An optional flue duct extension kit is required for lengths (distance from the outside wall to the relevant side of the boiler casing) greater than 600mm (23 ") Refer to Frame 8.
  • Page 16 INSTALLATION 22 CUTTING THE FLUE 23 FITTING THE FOAM SEAL For flue lengths 114 to 600mm ONLY 1. To determine the position for the foam seal measure the 1. Measure the flue length required (i.e. the distance from wall thickness and mark it onto the flue, measuring from the groove near the terminal.

  • Page 17: Fitting The Side Outlet Plates

    INSTALLATION 26 FITTING THE SIDE OUTLET PLATES 27 WALL MOUNTING PLATE 1. Fix the mounting plate to the wall with the No.14 x 50mm Note. If the boiler is fitted closer than 25mm to the side wall wood screws. the side outlet plate must be fitted now. 2.

  • Page 18: Connecting The Flue To The Boiler

    INSTALLATION 29 CONNECTING THE FLUE TO THE BOILER 1. Pull the flue through the side outlet plate and locate the 3 studs in the hole in the side of the boiler. 2. Secure the flue to the boiler using the three M5 nuts provided.
  • Page 19 INSTALLATION 32 FLUE EXTENSION DUCTS - continued Flue length General arrangement Extension Extension duct Note. Side flue shown. tube 1. A maximum of 2 extension ducts (plus the standard flue duct) may be used together. 2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided.

  • Page 20: Gas Connection

    INSTALLATION 34 GAS CONNECTION 35 WATER CONNECTIONS Refer to 'Gas Supply ', page 6. 1. Remove the plastic plugs from the flow and return pipes. Refer to Frame 2 for gas inlet service dimensions. A minimum pressure of 20 mbar MUST be available at the 2.
  • Page 21 INSTALLATION 38 PICTORIAL WIRING LEGEND blue bk black brown yellow white orange violet pink grey y/g yellow/green 39 MID POSITION VALVE Pumped only Notes. 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring. 2. Numbering of terminals on thermostats is specific to the manufacturer.

  • Page 22: Frost Protection

    INSTALLATION 40 TWO SPRING CLOSED VALVE Pumped only Notes. 1. Some earth wires are omitted for clarity. Ensure proper earth continuity when wiring. 2. Numbering of terminals on thermostats is specific to the manufacturer. 3. This is a fully controlled system - set the boiler thermostat to maximum.

  • Page 23: Gas Installation

    INSTALLATION Gas Installation 42 COMMISSIONING AND TESTING (a) Electrical Installation 1. The whole of the gas installation, including the meter, MUST be inspected and tested for soundness, and purged in accordance with the recommendations of BS. 6891. 1. Checks to ensure electrical safety should be carried out by a competent person.

  • Page 24: Handing Over

    INSTALLATION 44 INITIAL LIGHTING - continued 45 GENERAL CHECKS d. Balance the system. Make the following checks for correct operation: 5. Finally, set the controls to the user's requirements. 1. Set the boiler thermostat knob to position 6 and operate the The temperatures quoted below are approximate and vary between mains on/off switch.

  • Page 25: Boiler Casing Removal

    The servicing procedures are covered more fully in Frames 48 to Caradon Ideal Services, details of which are outlined in the 52 and must be carried out in sequence.

  • Page 26: Cleaning The Fan Assembly / The Flueways

    SERVICING 50 CLEANING THE FAN ASSEMBLY / THE FLUEWAYS 1. Remove the 2 silicon rubber tubes from the fan sensing points. 2. Disconnect the fan leads. 3a. Rear flue Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue.

  • Page 27: Gas Pressure Adjustment

    SERVICING 53 GAS PRESSURE ADJUSTMENT MAIN BURNER PILOT After any servicing, reference should be made to Table 2 The pilot is factory set to maximum and no further which quotes details of the rated output with the related adjustment is possible. If, after removing and checking the burner setting pressure and the heat input.

  • Page 28: Pilot Burner Replacement

    SERVICING 57 THERMOSTAT CONTROL, THERMISTOR SENSOR LEAD and ON/OFF SWITCH REPLACEMENT Refer also to Frame 54. A. Remove the fixing screws B. Swing the control box down into the servicing position. Thermostat control 1. Pull the knob off the shaft. 2.

  • Page 29: Ignition Electrode And Lead Replacement

    SERVICING 59 IGNITION ELECTRODE AND LEAD REPLACEMENT 1. Refer to Frame 54. 2. Remove the burner and air box assembly. Refer to Frame 49. 3. Remove the electrode retaining nut. 4. Remove the pilot shield. 5. Remove the ignition electrode and integral lead. 6.
  • Page 30 SERVICING 62 FAN REPLACEMENT 1. Refer to Frame 54 2. Remove the 2 silicon rubber tubes from the fan sensing points. 3. Disconnect the fan leads. 4a. Rear flue. Slacken the M4 screw securing the flue connector to the fan. Disconnect the connector from the fan and slide into the flue. 4b.

  • Page 31: Heat Exchanger Replacement

    SERVICING 66 HEAT EXCHANGER REPLACEMENT 8. Slacken 3 turns only the 4 heat exchanger / inter-panel Note. Refer to Frame 5 (Boiler assembly - Exploded view) for retaining screws. illustration of the procedure detailed below. 9. Lift the heat exchanger / inter-panel assembly upward and 1.

  • Page 32: Fault Finding

    FAULT FINDING Check mains supply and fuses. Reset the overheat 'stat. Set control START Check timer and system thermostats 'stat to maximum. Allow the boiler to Check that the mains on neon are all ON. Check that boiler plug and reach temperature - if the overheat 'I3' is illuminated.

  • Page 33: Short List Of Parts

    When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Key No.

  • Page 34: Burner Assembly - Exploded View

    SHORT LIST OF PARTS 69 BURNER ASSEMBLY - Exploded View LEGEND 16. Pilot shield. 12. Main burner. 10. Burner manifold 17. Gas control valve. 13. Main burner injector. 11. Air box and pilot assembly. 42. Gas service cock. 70 CONTROL BOX - Exploded View LEGEND 19.
  • Page 35 SHORT LIST OF PARTS 71 BOILER CASING ASSEMBLY 72 SHORT PARTS LIST Henrad WH Installation...
  • Page 36 THIS SYMBOL IS YOUR ASSURANCE OF QUALITY The code of practice for the installation, commissioning & servicing of central heating systems Natural Gas These appliances are designed for use with Natural appliances are FF.87/AP/107 Gas only. They have been tested and conform with service listed by RS.87/AP/108 the provisions of BS.

This manual is also suitable for:

Henrad wh 50 ffHenrad wh 60 ffHenrad wh 70 ffHenrad wh 40 ffHenrad wh 80 ffHenrad wh 100 ff

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