Halstead BFF40 Instructions For Use Installation And Servicing Download Page 15 | Manualshive

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15

2000225095B

4 Installation

Diagram 4.17

0886

WING NUT

SELF
TAPPING
SCREWS
(3)

Diagram 4.18

TOGGLE
LATCHES

FAN
ACCESS
DOOR

4.12 Flue / Boiler Connection

Remove the three self-tapping screws from the lower part of the
control box support bracket, see diagram 4.17.

Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram
4.17.

Release the two toggle latches that secure the fan access door
and remove, see diagram 4.18.

Remove the electrical connections from the fan by pulling the
insulation boots only and disconnect the two silicone tubes from
the fan and air pressure switch taking note of their positions,
see diagram 4.19.

Remove the fan assembly from the flue hood by removing the
securing screw, pull forward and lift up to release the 3 hooked
securing lugs underneath the fan, see diagram 4.20.

From the flue pack take the flue spigot,the gasket is supplied in
the fittings pack.

Connect the flue spigot and gasket to the rear flue outlet of the
boiler using the self tapping screws provided, see diagram 4.3.

IMPORTANT. With regards to the Manual Handling Operations,
1992 Regulations, the following operation, exceeds the
recommended weight for one man lift.

Place the boiler in position taking care not to damage the casing
panels.

With access to the flue system through the boiler, pull the flue
on to the spigot bayonet connection, twist anti-clockwise to lock
into position.

Take the flue duct extension from the boiler and slide on to the
fan duct until it will go no further, see diagram 4.21.

Fit fan and engage the flue duct extension into the flue duct,
secure fan, replace electrical connections and silicone tubes.

The polarity of the electrical connections is not important.

Make sure that the air pressure tubes are fitted as before, see
diagram 4.19 and that the fan duct engages fully into the flue
duct extension piece.

(3) SELF
TAPPING
SCREWS
(for height
adjustment
only)

"LOW"
position

"HIGH"
position

"LOW"
position

"HIGH"
position

Diagram 4.19

AIR PRESSURE
TUBE (RED)

AIR PRESSURE
SWITCH

ELECTRICAL
CONNECTORS

AIR PRESSURE
TUBE (CLEAR)

FAN
SECURING
SCREW

11340

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Summary of Contents for BFF40

Page 1: ...liance 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 To b e l e f t w i t h t h e u s e r Instructions for Use Installation and Servicing 9706 Model BFF40 G C No 41 333 88 Model BFF50 G C No 41 333 89 Model BFF60 G C No 41 333 90 Halstead Boilers Limited 20 22 First Avenue Bluebridge Industrial E...

Page 2: ...equired to provide information on substances hazardous to health Ceramic fibre Insulation Pads Glassyarn These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands...

Page 3: ...servicingwilldependupon the particular installation conditions and usage but in general once a year should be enough It is the law that servicing must be carried out by a competent person If this appliance is installed in a rented property there is a duty ofcareimposedontheownerofthepropertybythecurrentissue of the Gas Safety Installation and Use Regulations Section 35 To obtain service please cal...

Page 4: ...ntrol wait at least 30 seconds before switching on again When the boiler switches off the burner will go out The automatic lighting sequence will operate again when heat is required It should be noted that this is a fanned flue appliance and fan operation may be heard If the reset neon lights turn the boiler temperature control to 0 off wait 30 seconds then repeat the lighting instructions To Turn...

Page 5: ...pt as noted Approximate weight of complete boiler 84kg 185lb Water content 5 76 litre 1 27gallons Gas connection Rc1 2 1 2 in BSPT Water connection Rc1 1in BSPT Electrical supply 230V 50Hz fused 3A Burner Aeromatic A B C D E F G H J K L M 300 700 558 294 384 555 442 3 Max 900 300 108 32 Min 860 GENERAL DIMENSIONS given in millimetres Diagram 1 1 9707 WATER CONNECTIONS Rc1 1in B S P T WATER CONNECT...

Page 6: ...rements 1 5 Gas Supply The gas installation should be fitted in accordance with the current issue of BS6891 The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar 8in wg at the boiler On completion test the gas installation using the pressure drop method and suitable leak detection fluid purge in accordance with the current issue of BS6891 ...

Page 7: ...nt used to enclose the boiler must be designed and constructed specifically for this purpose An existing cupboard or compartment modified for the purpose may be used Details of essential features of cupboard or compartment design are given in the current issue of BS6798 The boiler may be installed in any room although particular attention is drawn to the requirements of BS7671 with respect to the ...

Page 8: ...s taken from the boiler a minimum static head of 1metre 3ft3in must be provided between the water line of the feed tank and the centre of the waterway see diagram 2 2 2 5 Circulation Pump Normallythepumpshouldbesettogiveatemperaturedifference of11o C 20o F acrosstheboiler Attheappropriatepumpedflow rate the pressure loss through the boiler can be found from the graph diagram 2 3 Use a pump with in...

Page 9: ...ment IGE UP 7 1998 If in doubt seek advice from the local gas undertaking or Halstead Boilers Ltd 3 3 Terminal Guard A terminal guard is required if persons come into contact with the terminal or the terminal could be subject to damage If a terminal guard is required it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and be central over the terminal A suitab...

Page 10: ...onal wall liner kit part no 900862 is available complete with instructions All flue assemblies are designed for internal installation Make sure that the ductings do not slope down towards the boiler Diagram 4 1 9867 9868 4 2 Flue Position and Length Select the boiler location with due regard to the flue length and terminal position see diagrams 3 1 and 4 1 For a wall thickness up to 300mm provided...

Page 11: ... terminal restrictor and secure with locking screw but do not tighten see diagram 4 5 Engage the terminal restrictor on the flue terminal by hooking it over the terminal end and engaging the clamping bracket behind the inner ring of the terminal securing it by tightening the locking screw see diagram 4 5 9869 SCREW 4 SPIGOT GASKET FLUE BAYONET CONNECTION Diagram 4 4 7148 OPTIONAL FLUE COLLAR 4 Ins...

Page 12: ... three remaining lower connections may be used for the gravity domestic hot water return Fit plugs into any unused boiler tappings 4 7 Water Connections Fully Pumped Systems Fit suitable fittings into the boiler tappings as required see diagram 4 9 Make sure that all pipes are taken backwards and will clear the casings It is important that all connections are made as shown in diagram 4 9 Fit the w...

Page 13: ...m the boiler see diagram 4 11 Do not route any pipework water or gas across the front of the combustion chamber cover The gas pipework must be along the left hand side of the boiler 4 Installation No 8 SCREW 4 4 9 Casing Brackets Loosen the side insulation blankets by removing the securing bracket see diagram 4 12 and fit the two upper and two front casing brackets shown in diagram 4 13 using the ...

Page 14: ... factory with the control box and heat shield fitted in the lower casing height position Diagram 4 14 Diagram 4 16 SCREW SIDE CASING R H SHOWN 9863 SIDE CASINGS FITTING Diagram 4 15 MAX SIDE CASING R H MIN BOILER PLINTH FRONT CASING BRACKET No 8 SCREW 4 LOCATING SLOTS 4 Installation UPPER CASING BRACKET 4 11 Side Casings Fit the side casings by locating their lugs into the appropriate slot in the ...

Page 15: ...he flue spigot and gasket to the rear flue outlet of the boiler using the self tapping screws provided see diagram 4 3 IMPORTANT WithregardstotheManual HandlingOperations 1992 Regulations the following operation exceeds the recommended weight for one man lift Place the boiler in position taking care not to damage the casing panels With access to the flue system through the boiler pull the flue on ...

Page 16: ...ck for any water leaks and put right Make the gas connection to the service cock at the lower left hand side of the boiler see diagram 1 1 The whole of the gas installation including the meter should be inspected tested for soundness and purged in accordance with the current issue of BS6891 4 14 Top Casing Refer to diagram 4 22 Fit two plastic pegs one on each side in the holes on the top casing T...

Page 17: ...p Make sure the cable is suitably secured When making connections make sure that the earth conductor ismadeofagreaterlength thanthecurrentcarryingconductors so that if the cable is strained the earth conductor would be the last to become disconnected 5 3 Pump Connection The pump must be connected to the external controls 5 4 Testing Electrical Checks to ensure electrical safety must be carried out...

Page 18: ...TS 10052 A CONTROL BOX B PHIAL POCKET C GAS SERVICE COCK D BURNER ON NEON E RESET NEON F TEMPERATURE CONTROL G BURNER PRESSURE TEST POINT H GAS PRESSURE ADJUSTMENT SCREW J DATA LABEL E D A G The ignition system will operate to light the boiler After a pre set time if ignition has not taken place the boiler will shutdown To re start the lighting sequence turn the boiler temperature control to O the...

Page 19: ... the boiler temperature control fully anti clockwise to 0 Isolate from the electrical supply Remove the pressure gauge from the test point and refit screw making sure a gas tight seal is made Whentheboilertemperaturecontrolisturnedtothe 0 position by hand wait at least 30 seconds before turning On again Theremaybeaninitialsmellgivenofffromtheboilerwhennew this is quite normal and it will disappear...

Page 20: ...e live Switch on the electrical supply and gas supply then operate the boiler On completion of the test switch off the electrical supply and gas supply remove analyser tube and replace sampling point cap Servicing Before servicing turn off the gas and isolate the electrical supply to the boiler After completing a service always test for gas soundness make electrical checks and carry out functional...

Page 21: ...k to disengage the retaining lugs then lift up see diagram 8 8 When replacing the flue hood ensure that it rests on the guides and that the rear of flue hood is located under the pegs at the rear and pushed down and back fully IMPORTANT When re fitting fan check that it fits fully into the flue duct extension piece COMBUSTION CHAMBER COVER IGNITION AND EARTH LEADS GROMMET Diagram 8 7 0886 WING NUT...

Page 22: ...lectrodeandcleanandreplaceasnecessary see diagram 8 13 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 Examine the flue hood and terminal to make sure they are clean and clear of obstructions Refit all parts Light the boiler and carry out functional tests as described in...

Page 23: ... water is cold If neon 6 is lit flame failure has occured Reset boiler by turning temperature control to Off waiting 30 seconds and then on If fault persists continue with fault finding below Before carrying out fault finding ensure that gas electricity and water are available at the boiler Is neon 1 lit NO Check power supply Is neon 2 lit NO YES YES Faulty thermistor Replace With electrical suppl...

Page 24: ...section 8 1 then remove the control box cover refer to section 5 1 Refer to Boiler Fault Finding see diagram 9 1 Fault Finding Wiring Diagram see diagram 9 3 Pictorial Wiring Diagram see diagram 9 4 9 2 Electrical Supply Failure Failure of the electrical supply will cause the burner to go out Operationwillnormallyresumeontherestorationoftheelectrical supply Iftheburnerdoesnotrelightafteranelectric...

Page 25: ...N 3 NEON 4 NEON 5 NEON 6 NEON KEY see P C B FAN P C B CONTROL BOARD GAS CONTROL VALVE TERMINAL BLOCK THERMISTOR AIR PRESSURE SWITCH NEON 1 NEON 5 NEON 4 NEON 6 NEON 2 NEON 3 F4A FUSE p y g p b bk bk bk bk b bk b r g y bk b LS LIVE Switched N LS N br r g y g y g y g y br b b br BROWN b BLUE g y GREEN YELLOW g GREY bk BLACK p PURPLE y YELLOW r RED KEY g y NEUTRAL EARTH MAIN KEY TO TERMINAL BLOCK br ...

Page 26: ... Board P C B Remove front panel to gain access see section 6 8 Remove control box lid by undoing the four securing screws two on control box two on the heat shield and lift off see diagram 10 1 CONTROL BOX COVER CONTROL BOX SECURING SCREWS TERMINAL BLOCK Diagram 10 1 9905 ELECTRICAL PLUGS Diagram 10 2 PCB Diagram 10 3 PHIAL POCKET THERMISTOR BOILER TEMPERATURE CONTROL Carefully pull the boiler tem...

Page 27: ...tch see diagram 10 5 When fitting the replacement make sure that the air pressure tubes are fitted as shown in diagram 10 5 and the electrical connections are made as shown in wiring diagram 9 4 10 9 Fan Remove front panel to gain access see section 6 8 Refer to the relevant paragraphs of the servicing section to remove the fan access door Remove the electrical connections and air pressure tube fr...

Page 28: ...l is positioned on the heat shield see diagram 6 1 1 2000461752 Multifunctional control 2 227131 Fan 3 227070 Air pressure switch BFF40 50 3 227097 Air pressure switch BFF60 4 2000461793 Electrical thermistor 5 202635 Spark electrode 6 2000461714 Boiler temperature control knob 7 K7218 Injector BFF40 7 205729 Injector BFF50 7 2000461837 Injector BFF60 8 227098 Fuse 9 227030 Control board 10 205658...

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