IDEAL Henrad WH LX 30 FF Installation And Servicing Manual Download | Manualshive

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Summary of Contents for Henrad WH LX 30 FF

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Page 2: ...Henrad WH LXFF 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 components ...

Page 3: ...7 1 76 0 76 4 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 copper 28mm copper FEMALE Return connection 22mm copper 28mm copper FEMALE Maximum static water head m ft 30 5 100 Minimum static water head m ft 0 45 1 5 Electrical supply 230 V 50 Hz Boiler power consumption 100W Fuse rating External 3A Internal F1A to ...

Page 4: ...onnection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is down stream of the combustion chamber I2H An appliance designed for use on 2nd Family gas Group H only B G Certified P I No 87 AP 107 Destination Countries GB and IE Natural Gas only Appl...

Page 5: ...lations bylaws of the local water authority the Building Regulations and Building Standards Scotland and any relevant requirements of the local authority Detailed recommendations are contained in the following British Standard Codes of Practice BS 6891 Low pressure installation pipes BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 60 kW BS 5449 Forced circulation h...

Page 6: ...ce in which the boiler is to be installed must be at least wide enough to accommodate the tool Pelmet restrictions If the ability to fit or remove the casing during installation and subsequent servicing is impaired by pelmets etc this operation can be made easier by first removing the controls pod casing in line with the following instructions a Release the controls pod casing fixing screws a 3 fu...

Page 7: ...installed so that the terminal is exposed to external air 2 It is important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to whi...

Page 8: ...r internal space in which the boiler is installed 2 If the boiler is to be installed in a cupboard or compartment permanent air vents are required for cooling purposes in the cupboard compartment at both high and low levels The air vents must either communicate with room internal space or be direct to outside air The minimum effective areas of the permanent air vents required in the cupboard compa...

Page 9: ...ic circulator capable of providing an 11 C 20 F temperature differential e g Grundfos UPS 15 50 or equivalent The vertical distance between the pump and feed expansion cistern MUST comply with the pump manufacturers minimum requirements to avoid cavitation Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Caradon Plumbi...

Page 10: ...llector hood assembly 2 Inter panel 3 Pumped return pipe 4 Rubber sealing grommets 5 Pumped flow pipe 6 Wall mounting plate 7 Sealing plates 3 off 9 Back panel 10 Controls support 11 Control box 12 Timer optional 13 Heat exchanger 14 Combustion chamber 15 Main burner 16 Boiler drain point 17 Flue baffles 18 Pressure switch ...

Page 11: ... grille assy 1 off z Polyurethane foam seal 400 lg 1 off z No 8 x 8 lg Pozi pan hd screws 3 off 6 UNPACKING Boiler Pack Contents z The complete boiler z Installation Servicing Instructions z User s Instructions z Hardware Pack listed below z Wall mounting template z Wall mounting plate z Side outlet terminal mounting plate z Flue extension tube 1 off z Boiler sealing plate 1 off Hardware Pack Cont...

Page 12: ...m 39 should be supported with the bracket provided If the stand off brackets have been used it is necessary in order to keep the flue aligned to use the spacer bracket with the support bracket It is MOST IMPORTANT that the boiler is installed in a vertical position a Casing retaining screws 2 off Packing base Controls pod casing DELUXE MODEL LX 1 Unpack the boiler 2 Remove the casing as follows an...

Page 13: ...pe the templates into the selected position 3 Ensure squareness by hanging a plumb line as shown 4 Mark onto the wall if required the following a The wall mounting plate screw positions choose one from each group Note Mark the centre of the flue hole as well as the circumference b The position of the flue duct hole c Downward pipe routing bracket screw positions 5 Remove the templates from the wal...

Page 14: ...uct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the groove on the outer flue duct This ensures correct alignment of the flue terminal 4 Stick the self adhesive foam strip provided in the hardware pack onto the flue immediately behind the boiler sealing ring 15 WALL MOUNTING PLATE 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 If downward r...

Page 15: ...nting plate hooks as shown Do not use the burner controls for lifting 2 Fit the M8 screw washer and rectangular plate to retain the boiler Note Before fully tightening the M8 screw check the boiler alignment using a spirit level and adjust as necessary with the jacking screw 17 CONNECTING THE FLUE TO THE BOILER 18 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the r...

Page 16: ...then making good the wall faces is not essential as seals are provided at both ends of the flue However both wall faces immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the 2 wall faces 2 Drill 4 holes with an 8mm 5 16 masonry drill and insert the plastic plugs provided for the wall mounting plate 3 Drill 4...

Page 17: ...tube is cut square mark the flue all the way round 4 Insert the cardboard duct ring for support and cut to length 5 Remove cardboard duct ring and remove any burrs 24 FITTING BOILER SEALING RING TO THE FLUE 1 Fit the boiler sealing ring inside the outer flue duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the groove on the outer flue duct This ensures correct alig...

Page 18: ... is required then the downward routing pipe brackets and M8 spacer supplied in the Downward Piping Kit should be fitted to the wall mounting plate now 3 Fit the bottom 2 screws to secure the bracket s to the wall through the wall mounting plate 4 Check with a spirit level that the plate is vertical Notes 1 Have ready to hand the M8 screw washer and rectangular plate supplied in the hardware pack 2...

Page 19: ...o the fan 5 Pull the flue extension tube and engage onto the fan elbow and secure with the screw attached to the elbow Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal grille is correctly aligned 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 accur...

Page 20: ...l grille Boiler Extension tube Not for 100 FF model 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 Drill 3 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screws provide...

Page 21: ... must be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 41 3 If a proprietary system is used follow the instructions supplied by the manufacturer 4 System designs featuring controls or wiring arrangements which allow the boiler to fire when there is no pump circulation taking place should not be fitted Advice on required modifications to the wiring may be ...

Page 22: ... 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature LEGEND b blue bk black br brown r red w white y g yellow green or orange gy grey 38 PICTORIAL WIRING LEGEND b blue bk black br brown r red y yellow w white or orange v violet p pink gy grey y g yellow green 39 MID PO...

Page 23: ...or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the timer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with m...

Page 24: ...annel on the top of the boiler assembly Swing the bottom of the casing down and secure with the 2 captive 43 INITIAL LIGHTING screws To improve access to the gas valve remove the controls pod casing Release the controls pod front fixing screws 3 turns only Remove the pod by pulling it forward to disengage from the keyhole slots Refer to Frame 44 The casing must seat correctly and compress the seal...

Page 25: ...hem to the Householder 9 After installation commissioning and customer hand over instructions please complete the appliance log book and leave this with the customer 10 Stress the importance of regular servicing by a CORGI registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR After completing the installation and commissioning of the system the installer ...

Page 26: ...her servicing or replacement of components the boiler casing must be removed Refer to Frame 48 3 Pull the HT lead connection off the printed circuit board and pull the lead upwards through the bottom panel grommet 4 Remove the 4 screws retaining the air box pilot assembly to the vertical manifold and carefully remove the assembly 49 BURNER AND AIR BOX REMOVAL 1 Remove the screw retaining the front...

Page 27: ...connect 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 3b Side or top flue Slacken off two M4 screws securing the flue elbow and flue connector Disconnect the flue connector from the elbow and slide into the flue Remove the flue elbow 4 Disconnect the silicon rubber tube from the rear of the colle...

Page 28: ...rd model illustrated For the deluxe model LX slide the glass fascia out before removing the sightglass assembly Refit the glass fascia after refitting the new sightglass assembly PILOT The pilot is factory set to maximum and no further adjustment is possible If after removing and checking the injector as detailed in Frame 58 and ensuring that there is an inlet pressure of 20 mbar available the pil...

Page 29: ...e 2 side retaining clips and remove the switch 12 Re assemble in reverse order 57 THERMOSTAT CONTROL THERMISTOR SENSOR LEAD and ON OFF SWITCH REPLACEMENT 58 PILOT BURNER REPLACEMENT 1 Refer to Frame 54 2 Remove the burner and air box assembly Refer to Frame 49 3 Remove the electrode retaining nut and remove the pilot shield and electrode 4 Unscrew the central pilot fixing screw and lift the pilot ...

Page 30: ...se order 10 Replace the boiler casing 11 Check the gas valve operation 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 Refit the new electrode and lead in reverse order Ensure that the pilot shield is replaced 7 Check the spark gap Refer to Frame 58 8 Re...

Page 31: ...he barbs on the PCB stand offs to release the PCB from the box 9 Fit the new PCB and re assemble in reverse order ensuring the correct orientation of the switch 10 Refit the boiler casing 11 Check the operation of the boiler 1 Refer to Frame 54 2 Remove the APS fixing screw 3 Remove both sensing tubes from the APS 4 Remove the 3 electrical connections from the APS 5 Connect the new APS in reverse ...

Page 32: ...itted 15 Fully test all functions including water and gas soundness 66 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 5 Boiler assembly Exploded view for illustration of the procedure detailed below 1 Refer to Frame 54 2 Remove the burner air box assembly Refer to Frame 49 3 Drain the system 4 Disconnect the water connections If compression fittings are used then cut the pipes both above and below...

Page 33: ...sure switch Is the boiler casing correctly fitted Does the pilot light NO YES NO YES Does the spark stop after pilot is lit NO Is there a gas supply to the boiler Is the pilot injector blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polarity of the mains supply ...

Page 34: ...5002 30 FF 80 FF 1 004 982 Pilot burner injector HONEYWELL 4580 1075001 100 FF 1 16 308 358 Pilot burner head Q359A with Honeywell 4580 1075002 injector 30 FF 80 FF 1 079 599 Honeywell 4580 1075001 injector 100 FF 1 079 590 18 Gas valve kit VR 4601AA1036 230 V 1 075 698 19 308 549 Ignition electrode complete with lead and backnut 410 mm lg 1 111 881 20 E02 653 Control box assembly including thermo...

Page 35: ...and pilot assembly 13 Main burner 14 Main burner injector 69 BURNER ASSEMBLY Exploded View LEGEND Numbers up to 51 relate to the B G spares list 20 Control box 21 Thermostat potentiometer 24 Thermostat knob 25 Printed circuit board 26 Mains on off switch 17 Pilot shield 18 Gas control valve 42 Gas service cock 70 CONTROL BOX Exploded View ...

Page 36: ...36 Henrad WH LXFF FF Installation 71 BOILER CASING ASSEMBLY SHORT LIST OF PARTS Deluxe model LX Standard model 72 SHORT PARTS LIST ...

Page 37: ...Henrad WH LXFF FF Installation 37 ...

Page 38: ...3 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 p l c These appliances are designed for use with Natural Gas only They have been tested and conform with the provisions of BS 6332 and BS 5258 THIS SYMBOL IS YOUR ASSURANCE OF QUALITY The code of prac...

Page 39: ...our 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 using extra sheets if required and post it or fax it to us on 01482 498699 Boiler details Model Size details on control panel door Date of Installation Installer details Name Address Post Code Telep...

Page 40: ...eneral 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 required The Henrad Guide a specifier s and installer s introduction to the Henrad domestic boiler range The Henrad Householders Guide to assist the installer when presenting to his her customers ...

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