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Warmworld FFC 30/60, Installation & Service Instructions Manual

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Warmworld FFC 30/60 Installation & Service Instructions Manual Download Page 25

Condensing Boiler

   

24

           6/03/00

Major Components

Condensate
Trap

 

Air Pressure Switch

Gas Valve

Gas Cock

Rubber ‘O’ Ring

( 3 Places )

Flue Thermostat

Fan Assembly

 

Secondary Heat

Exchanger

 

Fibre Washer

( 2 Places )

Flow Pipe

Control
Sensor

 O/H Stat

 

Primary Heat

Exchanger

Gas Manifold

HT Lead

Pilot Assembly

 Main Injector

Electrode

Pilot Injector

 

 Ceramic Board

Set

Burner

Condensate
Outlet

 

Inspection Cover

Flue Gas
Sampling Point

 

Flue Hood Gasket

Fig.10

Summary of Contents for FFC 30/60

Page 1: ...NSING BOILERS Natural Gas Only GC No 41 555 15 41 555 16 Serial Number 0087 FFC 30 60 FFC 65 80 Installation Service Instruc tions Note to the Installer Please leave these Instructions adjacent to the meter ...

Page 2: ... 113 33 B S P 20 kg 28 kg 1 4 litres 3 bar 1 m 30 82ºC 10 12 litres m 5 litres m 22mm Copper 230V 50Hz 40W 1 Amp 20mm 3 Amp 790 High 400 Wide 330 Deep 450 Front 30 Above 25 Below 30 Left Right Concentric 160 High 160 Wide 55 Deep Twin 260 High 150 Wide 100 Deep Concentric 110 Twin 80 Concentric 100 2000 Twin overall 200 30000 FFC 65 80 min max Condensing Boiler 1 06 06 01 Pressure Loss All Models ...

Page 3: ...s an open circuit for water to flow between the flow and return In some system designs this may require the addition of a bypass an automatic bypass is preferred The boilers also contain integral frost protection the boiler will fire if the temperature within it approaches 4 to 5 degrees Centigrade It will do this even when turned to Off and can only be inhibited by removing the Permanent Live sup...

Page 4: ...board or compartment may be used provided it is modified for the purpose Details of essential features of cupboard compartment design including airing cupboard installations are given in BS 6798 In siting the boiler the following limitations MUST be observed 1 The position selected for installation MUST allow adequate space for servicing in front of the boiler and for air circulation around the bo...

Page 5: ...ater system if applicable should be in accordance with the relevant recommendations of BS 5546 Copper tubing to BS 2871 1 is recommended for water carrying pipework The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper The hot water cylinder ancillary pipework not forming part of the useful heating surface should be lagged to prevent heat loss ...

Page 6: ... The boiler is supplied for 230V 50Hz Single phase Fuse rating is 3A The method of connection to the mains electricity supply MUST facilitate complete electrical isolation of the boiler preferably by the use of a fused double pole switch having a 3mm 1 8in contact separation in both poles and servicing only the boiler and system controls The point of connection to the mains should be readily acces...

Page 7: ... cut off during installation Right or Left Outlet 1 Secure the 50mm flue tube with ELBOW connec tor on the saddle using the Velcro strap See Fig 7 2 Measure carefully and saw off the 50mm tube to give required projection from wall See Fig 7 3 Measure carefully and saw off the 110mm Air duct tube to give required projection from wall The flue pipe must project more than the outer air duct when asse...

Page 8: ...Trim 3 With the bottom of the boiler away from the wall hang the top of the back panel onto the Mounting Box Now by gently lowering the bottom of the boiler against the wall the fan spigot should engage in the flue connector Observe the correct engagement of the fan spigot into the flue 4 For Twin Pipe Installations Remove the cap from the spare inlet on the condensate trap Offer up the silicone d...

Page 9: ...is preferred The boiler waterside is completely copper so all good corrosion inhibitors are suitable Designs The following designs are all acceptable 1 Sealed system to BS 6798 and BS 5449 1 2 Combined Feed and Vent systems 3 Separate Cold Feed and Vent systems The pump may be on the flow or return but careful note of its position relative to the feed and vent MUST be made to avoid pumping over or...

Page 10: ...mpletely normal It is recommended that the gas cock is turned off during this early stage Because of a built in delay the boiler is always held off for a minimum of 120 seconds However for commissioning purposes switch off using the System Isolating Switch will avoid the delay It is strongly suggested that the following stages of commissioning are followed and not an immediate connection of all se...

Page 11: ...t check again for water sound ness Refit the case to the boiler Add remainder of corrosion inhibitor Balance the system in the normal way to obtain even heating of all radiators If fitted set the cylinder thermostat to 60oC or lower if preferred Complete the Logbook and pass to the user when explaining and demonstrate the operation of the system Their instructions are located under the Electrical ...

Page 12: ...efill system adding 3 4 of the inhibitor Do not light boiler Vent all radiator and air release points Run pump for 5 10 second bursts and revent Condensing Boiler 11 06 06 01 Do not light boiler Run pump for at least 30 minutes Stop at 5 minute intervals to vent Continue venting until no more air noise can be heard Light boiler and run at max thermostat setting Continue for 15 minutes venting ever...

Page 13: ...Condensing Boiler 12 06 06 01 Installation Dimensions Fig 2 Pipe Connections Locations Service Access ...

Page 14: ...Condensing Boiler 13 14 12 00 Schematic Wiring Fig 3 ...

Page 15: ...Condensing Boiler 14 06 06 01 Physical Wiring Diagram Fig 4 ...

Page 16: ...ler 15 06 06 01 Fixing Positions Fig 5 L C 17 kW 24 kW 24 kW 60 0 22 Wall Fixing Holes 2 Lower Wall Fixing Holes Core Drill 128mm Use 2 at the top and any other 2 below 6 6 17 kW For Concentric 270 or i ie Core Drill ...

Page 17: ...01 Boiler Panel Assembly Control Board Chassis Electrical Cover Top Trim Front Burner Baffle Side Trim Fig 6 Pressure Cover Concentric Flue Boiler Mounting Box Fan Protection Hoop Lower Burner Baffle Twin Pipe Boiler Mounting Box ...

Page 18: ...ue Positions Fig 7 Fig 8 Flue Duct Air Duct 100mm Condensate Drain Connection connects to drain point on Flue Spigot Adapter Flue Spigot Adapter Drain Point Twin Pipe Boiler Mounting Box Assembly Connects to optional condensate drain point on Condensate Drain Trap ...

Page 19: ...ame is detected and the control board stops sparking and then energises the main gas valve and the burner lamp is illuminated The pilot flame lights the burner and it stays alight until turned off by the control thermostat system controls or in the case of a fault condition a safety thermostat The flue thermostat will trip if the flue exceeds a pre set temperature The overheat thermostat will trip...

Page 20: ...Condensing Boiler 19 Fault Diagnosis ...

Page 21: ...equired If in doubt drain the system and remove for inspection 2 Condensate Syphon With a suitable bowl to catch the water un screw the drain cap s on the underside of the Syphon trap and drain the water Remove any solids and replace cap s Fig 12 CHANGING COMPONENTS THERE ARE NO REPAIRABLE ITEMS IF NOT WORKING AN ITEM MUST BE REPLACED The boiler is in two major sections the Case and the Electrical...

Page 22: ...ANCE CASE COULD RESULT IN LEAKAGE OF COMBUSTION PRODUCTS INTO THE ROOM 3 Fan Assembly Lower the Electrical Tray Remove the Case Undo the wing nut holding the Fan Protec tion Hoop Pull the electrical connectors off the Fan Gently pull the pressure tubing off the tap pings on the Flue Hood Undo the two screws holding the Flue Hood and slide forward and away Re assembly is the reverse 4 Air Pressure ...

Page 23: ...o position Pull off the HT lead Pull the Burner forward off the two studs at the rear Remove the Pilot Assembly Re assembly is the reverse 11 Main Injector Lower the Electrical Tray Remove the Case Remove the Burner Undo the Main Injector from the manifold Re assembly is the reverse 12 Combustion Chamber Insulation Lower the Electrical Tray Remove the Case Remove the Front Baffle then undo the fou...

Page 24: ...d Set 24 kW M1089 106 404 Fan Assembly 17 kW M1095 Fan Assembly 24 kW M0910 106 435 Control Board M3752 Control Assembly M3915 Gas Valve Sigma 840 M3783 Air Pressure Switch Concentric Flues 7712 379 091 Air Pressure Switch Twin Pipe Flues M4176 Main Injector 3 4mm 17 kW M3806 Main Injector 4 1mm 24 kW M0919 106 386 Overheat Thermostat M3781 379 314 Pilot Injector 7709 386 673 Electrode 7710 386 74...

Page 25: ...aces Flue Thermostat Fan Assembly Secondary Heat Exchanger Fibre Washer 2 Places Flow Pipe Control Sensor O H Stat Primary Heat Exchanger Gas Manifold HT Lead Pilot Assembly Main Injector Electrode Pilot Injector Ceramic Board Set Burner Condensate Outlet Inspection Cover Flue Gas Sampling Point Flue Hood Gasket Fig 10 ...

Page 26: ...e Trap Air Gap Air Gap 110mm Soil Pipe or Drain Soakaway Insulate against freezing 150mm Land Drain Filled with Gravel 750mm deep Condensate Drain from Boiler Air Pressure Switch pipe connection Vent Syphon Connect To Waste Drain Cap Bypass Condensate Drain Trap Note Internal minimum 19mm pipe External minimum 32mm pipe Optional Condensate Drain for Twin Pipe Flue Applications Fig 12 ...

Page 27: ...8 1 Hanham Business Park Memorial Road Bristol BS15 3JE Telephone 0117 949 8800 Fax 0117 949 8888 The Company reserves the right to change specification without notice Your statutory rights are not affected ...

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