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IDEAL Henrad SEC 80FF, Installation & Servicing Manual, Page: 62 / 64

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IDEAL Henrad SEC 80FF Installation & Servicing Manual Download Page 62

62

Henrad SEC FF - 

Installation

Caradon Plumbing Limited

 pursues

a policy of continuing improvement
in the design and performance of its
products. The right is therefore
reserved to vary specification without
notice.

Henrad Installer/Technical Helpline: 01482 498 663

Caradon Plumbing Limited 

P.O. Box 103, National

Ave, Kingston upon Hull, HU5 4JN. Telephone:
01482 492 251 Fax: 01482 448 858. Registration
No. London 322 137. Registered Office: National
Avenue, Kingston upon Hull, HU5 4JN.

A subsidiary of Caradon plc

October 2000

153 962 A05

The code of practice for the installation,

commissioning & servicing of central heating systems

Technical Training

The Caradon Plumbing Limited Technical Training Centre
offers a series of first class training courses for domestic,
commercial and industrial heating installers, engineers and
system specifiers.
For details of courses please ring: .........

01482 498432

Summary of Contents for Henrad SEC 80FF

Page 1: ......

Page 2: ...Henrad SEC FF Installation 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 component...

Page 3: ...or 34 9 MJ m3 935 Btu ft3 nett To obtain the gas consumption at a different calorific value a FOR L S divide the gross heat input kW by the gross C V of the gas MJ m3 b FOR FT 3 H divide the gross he...

Page 4: ...connection not available for HEES Flue Elbow Kits 90 degree 45 degree 2 per pack Refer to the separate fitting instructions supplied with each kit SEC FF Natural gas only G C Appliance No 47 348 10 De...

Page 5: ...is drawn off The full output from the boiler is then directed via the diverter valve to the calorifier to supply a maximum DHW draw off of 10 l min at 35 o C temperature rise 1 BOILER WATER CIRCUIT DI...

Page 6: ...ET The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and ins...

Page 7: ...icrobore systems BS 5449 The domestic hot water system should be in accordance with BS 5546 and BS 6700 Copper tubing to BS 2871 1 is recommended for water carrying pipework and MUST be used for pipew...

Page 8: ...1 It is most important that the correct concentration of the water treatment product is maintained in accordance with the manufacturers instruction 2 If the boiler is installed in an existing system a...

Page 9: ...stalled in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person...

Page 10: ...oss from the system either a From a manually filled make up vessel with a readily visible water level The vessel should be mounted at least 150mm above the highest point of the system and be connected...

Page 11: ...ent Guidance Notes for the Installation of Domestic Gas Condensing Boilers 1989 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and f...

Page 12: ...flexible hose 35 Heat exchanger 48 Prepiping frame 50 Control panel 72 Gas injection pipe 18 Automatic air vent 19 Fan pressure sensing pipe 22 CH return pipe 24 Pump inlet pipe 25 Boiler return pipe...

Page 13: ...ting template z These Installation and Servicing Instructions z User s Instructions z Stand off brackets optional use 1 pair z Concealment panels optional use 1 pair z Inner flue seal Stand off bracke...

Page 14: ...1 2 22 3 4 4 1 2 16 4 1 2 21 1 4 580 1530 mm 410 1360 mm 540 1490 mm Pack B2 1 off 22 3 4 60 1 4 16 53 1 2 21 1 4 58 1 2 Extn Duct 1 off 1530 2480 mm 1360 2310 mm 1490 2440 mm Pack B2 1 off 60 1 4 97...

Page 15: ...2 Ensure squareness by hanging a plumbline as shown 3 Mark onto the wall the following a The 4 wall mounting plate screw positions b The position of the flue duct Mark the centre of the hole as well...

Page 16: ...tion masonry falling outside of the building does not cause damage or personal 14 FITTING THE PIPING FRAME Fit the wall mounting frame either A Directly to the wall z z z z z Insert wall plugs z z z z...

Page 17: ...king gas pressure of 20mbr 8 w g must be avilable at the boiler inlet with the boiler firing at full DHW output Note Do not subject any of the isolating valves to heat as the seals may be damaged 16 G...

Page 18: ...lift it from the boiler 18 CUTTING THE FLUE Rear Flue Length of 114 to 580mm Note If the optional standoff bracket kit is used it is essential that 80 mm is added to the measured wall thickness when...

Page 19: ...ate trap 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...

Page 20: ...The 4 wall mounting plate screw positions b The position of the flue duct Mark the centre of the hole as well as the circumference Note Allow for stand off brackets if being used Use the the table on...

Page 21: ...ed around the groove provided The terminal wall plate need not be fitted 24 FITTING THE PIPING FRAME Fit the wall mounting frame either a Directly to the wall z z z z z Insert wall plugs z z z z z Put...

Page 22: ...as supply pipe of not less than 22mm O D copper or 3 4 BSP iron to the boiler A working gas pressure of 20mbr 8 w g must be avilable at the boiler inlet with the boiler firing at full DHW output Botto...

Page 23: ...lculated as follows a Measure and note the wall thickness X b Add dimension H measured in Frame 22 c For right hand side flue add 188mm 7 3 8 d For left hand side flue add 61mm 2 3 8 i e X H 188mm 7 3...

Page 24: ...ert 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 2 Pull the flue back and locate the f...

Page 25: ...rainage pipework must be arranged so that obstruction e g through freezing of external drainage pipe does not give rise to spillage within the dwelling Excessive external pipe runs should be avoided i...

Page 26: ...afety valve discharge pipe should be such that any discharge of water or steam does not create a hazard 4 Use the 900 compression elbow so that the pipe is directied towards the rear 33 SAFETY VALVE D...

Page 27: ...the outer flue extension duct onto the outer air duct 5 Drill one 3 2mm 1 8 dia hole through the outer air duct Do not drill the inner flue duct 6 Insert the self tapping screw provided to fix the air...

Page 28: ...4 INSTALLATION INSTALLATION Front elevation layout of boiler components control panel open Legend A Boiler heat exchanger B Gas valve C Safety valve D DHW plate heat exchanger E Condensate safety dra...

Page 29: ...be a slight water leak from the vent therefore electrical connections should be protected c Ensure that the pump is free to rotate i Remove the vent plug ii Using a screwdriver rotate the shaft sever...

Page 30: ...t allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles or a plug and socket serving only the boiler and system controls The...

Page 31: ...ler otherwise the boiler can be left live even when the boiler isolating switch is off Using a two channel timer will disable the heating switch 3 Room Thermostat It is recommended to use a room therm...

Page 32: ...32 Henrad SEC FF Installation INSTALLATION 42 PICTORIAL WIRING DIAGRAM INSTALLATION...

Page 33: ...checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter B Gas Installation 1 The whole of the gas installation including the meter should be inspected a...

Page 34: ...heck cycle will take place whenever the RESET button on the control panel is pressed and also once every 24 hours without a call for heat to ensure movement of the components once a day LEGEND A Gas c...

Page 35: ...e all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate 3 Release the boiler bottom panel 4 Turn the DHW flow regulator clockwise to reduce the DHW flow...

Page 36: ...ame 6 7 Check the condensate drain for leaks and check that it is discharging correctly 8 Finally set the controls to the User s requirements 9 Refit the boiler bottom panel 10 If an optional timer ki...

Page 37: ...to the required value by pressing and buttons d Store the new value by pressing the STORE button The display should flash twice e To return the control to the normal running STANDBY mode press the RE...

Page 38: ...Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 5 Explain the function and t...

Page 39: ...propriate z Check the sealing panel is correctly refitted ensuring that a good seal is made 53 CASING REMOVAL 54 BOILER SEALING PANEL REMOVAL 1 Release the 2 retaining clips 2 Swing the panel open to...

Page 40: ...5 Depress the retaining clip and rotate the fan to the right to disengage the bayonet fixing on the fan outlet 6 Draw the fan forward and unplug the electrical lead from the motor 7 Withdraw the fan f...

Page 41: ...et or similar beneath the boiler and remove all visible loose deposits from the heat exchanger fins using a suitable brush 2 Take care to clean debris from the ledge inside the combustion chamber 1 Pu...

Page 42: ...BOILER MUST NOT BE OPERATED IF THE SEALING PANEL IS NOT FITTED Note In order to replace components in Frames 75 to 85 it is necessary to drain the boiler Refer to Frame 72 1 Refer to Frame 60 2 Remove...

Page 43: ...newing any damaged or deteriorating gasket SERVICING Legend A Venturi B Sensing pipe 63 BURNER REPLACEMENT Legend A Burner B Gasket C Burner mounting flange D O ring seal Note Check the spark and dete...

Page 44: ...ctrode 1 Refer to Frame 60 2 Remove the boiler casing Refer to Frame 53 3 Remove the boiler sealing panel Refer to Frame 54 4 Unscrew the injector from the injection pipe 5 Fit the new injector using...

Page 45: ...mplete with mounting brackets and gas inlet pipe 10 Transfer the mounting brackets and sensing pipes to the new valve renewing any damaged or deteriorating sealing gaskets 11 Transfer the gas inlet pi...

Page 46: ...display board Ensure that the control unit is the correct one for the boiler 7 Unplug the spark and detector leads 8 Undo the 4 securing screws and withdraw the control unit from the panel 9 Fit the...

Page 47: ...ody 6 Fit the new actuator and re assemble in reverse order 7 Check the operation of the new actuator 72 DRAINING THE BOILER IMPORTANT In order to replace the components in Frames 73 to 85 it is neces...

Page 48: ...cle 6 Pull off the trap from the bottom of the boiler 7 Withdraw the trap from the boiler 8 Fit the new trap and re assemble in reverse order 74 DHW THERMISTOR SENSOR REPLACEMENT 1 Refer to Frame 60 2...

Page 49: ...hers provided and re assemble in reverse order 9 Check the operation of the new valve 75 CH THERMISTOR SENSOR REPLACEMENT Note There are 2 control thermistors one on the boiler flow boss and one on th...

Page 50: ...y b The gauge is correctly orientated within the panel 1 Refer to Frame 60 2 Remove the boiler casing Refer to Frame 53 3 Drain the boiler Refer to Frame 72 4 Close the DHW inlet isolating valve and o...

Page 51: ...9 Fit the new pump and re assemble in reverse order ensuring that a The new seals provided are fitted b The electrical connections are correctly remade c The pump selector switch is set at position 3...

Page 52: ...omplete with O ring provided and re assemble in reverse order IMPORTANT Ensure that the vent cap is loose A 1 Refer to Frame 60 2 Remove the boiler casing Refer to Frame 53 3 Remove the boiler sealing...

Page 53: ...s with a waterproof sheet or plastic bag 1 Refer to Frame 60 2 Remove the boiler casing Refer to Frame 53 3 Remove the boiler sealing panel Refer to Frame 54 4 Drain the boiler Refer to Frame 72 5 Dra...

Page 54: ...the heat exchanger from below withdraw the bosses from the flow and return tappings Check the O ring seals for damage and replace if necessary 22 Lower the heat exchanger to disengage from the flue co...

Page 55: ...est 1 Fan pre purge 2 Ignition 3 Burner on CH 4 Burner on DHW 5 Airflow switch not correct not applicable 6 Burner off in CH mode flow temperature T1 5 o C above set flow temperature Tset 7 Pump overr...

Page 56: ...ut 4 05 4 06 4 4 07 4 10 4 11 4 13 4 14 4 15 4 16 4 17 4 24 Flow and return sensors NTC1 and NTC2 reversed 4 26 Minimum gas pressure 4 30 Maximum difference between T1 and T2 exceeded 4 31 NTC1 short...

Page 57: ...139 950 9 E00 050 Water pressure switch SIT 1 075 176 10 E02 848 CH flow and return thermistor sensors and DHW thermistor sensors CROSSLAND COMPONENTS 3 150 260 11 E00 055 Pressure gauge ALTECNIC 1 13...

Page 58: ...58 Henrad SEC FF Installation 89 SHORT PARTS LIST SHORT LIST OF PARTS...

Page 59: ...ion electrode 13 Fan 14 Fan inlet venturi 19 Fan pressure sensing pipe 42 O ring 43 O ring 44 O ring 45 Gasket rubber 46 Gasket Cork 54 EV1 solenoid 55 EV2 solenoid 60 O ring 61 Burner gasket 70 Gas v...

Page 60: ...d SEC FF Installation 91 CONTROL PANEL ASSEMBLY Exploded View Legend 6 Gasmodul control 7 Display board 8 Fan speed control board 11 CH pressure gauge 12 Rocker switch 50 Control panel 58 Relay LIST O...

Page 61: ...61 Henrad SEC FF Installation 92 BOILER CASING ASSEMBLY SHORT LIST OF PARTS...

Page 62: ...lephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Registered Office National Avenue Kingston upon Hull HU5 4JN A subsidiary of Caradon plc October 2000 153 962 A05 The code of pra...

Page 63: ...r suggestions for how to improve our boilers and our service We will be giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form...

Page 64: ...l information required Please send me details of Henrad Training Courses Please arrange for a technical representative to contact me Please arrange for me to join an Henrad factory tour Range guides r...

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