Halstead BFF40 Operating manual

2000225095B.10.02
Balanced Fanned Flue Boiler
This is a Cat I2H Appliance
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. The instructions are an integral part of the appliance 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 beleftwiththeuser
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 Estate, Halstead, Essex CO9 2EX
Tel: [phone]. Sales Direct Line: 01787 475557. Fax: [phone]. Service Helpline: 01926 834834.
e-mail: [email protected] or [email protected] Website: www.halsteadboilers.co.uk

2
2000225095B
TESTING AND CERTIFICATION
This boiler is tested and certificated for for safety and performance. It is therefore important that no alteration is made to the boiler,
without permission, in writing, from Halstead Boilers Ltd.
Any alteration not approved by Halstead Boilers Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.3.
CE MARK
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed
tomeettherequirementsofDirective92/42/EEContheefficiencyrequirementsfornewhotwaterboilersfiredwithliquidorgaseous
fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed
for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.
Under Section 6 of The Health and Safety at Work Act 1974, we are required 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 before eating, drinking or going to the lavatory. If you do suffer irritation of the eyes or severe
irritation to the skin seek medical attention.
SPARE PARTS
REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performancespecificationthatwerequire. Donotusereconditioned orcopypartsthathavenot beenclearlyauthorisedbyHalstead
Boilers Ltd.
MANUAL HANDLING GUIDANCE
During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance
whilst lifting as the appliance or component exceeds the recommended weight for a one man lift.
In certain situations it may be required to use a mechanical handling aid.
Take care to avoid trip hazards, slippery or wet surfaces.
Important Information
Introduction 3
Lighting the Boiler 4
General Data 1 5
Water Systems 2 8
Flue and Ventilation 3 9
Installation 4 10
Electrical Wiring 5 17
Commissioning 6 18
Instructions to User 7 20
Servicing 8 20
Fault Finding 9 23
Replacement Parts 10 26
Spare Parts 11 28
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

32000225095B
Instructions for Use
Introduction
Pleasereadthese instructions and followthemcarefully for the
safe and economical use of your boiler.
The Halstead Buckingham 4 BFF series are balanced fanned
flue boilers. They provide heating and if required, an indirect
domestic hot water supply.
The boiler is automatic in operation, having only one user
control, the boiler temperature control.
Gas Safety (Installation and Use) Regulations
Inyourowninterestsandthatofsafety,itisthelawthatALLgas
appliances are installed by a competent person in accordance
with the current issue of the above regulations.
WARNINGS
Gas Leak or Fault
If a gas leak fault exists or is suspected the boiler must be
turned off, including the electrical supply and must not be
used until the fault has been put right. Advice/help should
beobtainedfromthelocalgasundertakingoryourinstallation/
servicing company.
Clearances
Make sure that nothing obstructs the ventilation grills or
clearances.
Minimum clearances must be left around the boiler as
shown in diagrams 1.6, 1.7 & 1.8.
Sheet Metal Parts
This boiler contains metal parts (components) and care
shouldbetakenwhenhandlingandcleaning,withparticular
regard to edges.
Cleaning
Keep the casing clean by wiping it occasionally with a damp
soapy cloth and dry with a polishing cloth.
Do not use abrasive cleaners.
Boilers Installed in a Compartment
If the boiler is fitted in a compartment, cupboard etc., do not
obstruct the purpose built compartment vents or the grill on the
boiler.
Do not use the compartment for storage purposes.
Maintenance
Toensurethecontinuedefficientandsafeoperationoftheboiler
itisrecommended that it ischeckedand serviced asnecessary
atregularintervals. Thefrequencyofservicingwilldependupon
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 call your installer or Halstead Boilers
Ltd.using the telephone number givenon theinside of the front
panel.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on :- 01256 372300.
Boiler Electrical Supply
THIS BOILER MUST BE EARTHED.
The boiler must only be connected to a 230V~50Hz supply
protected by a 3A fuse, maximum.
All wiring must be in accordance with the current issue of
BS7671.
Heatresistantflexiblecablehavingaconductorsizeof0.75mm2,
to the current issue of BS6500 Table 16 must be used.
To Connect an Electrical Plug
The standard colours of three core flexible cable are,
Brown - live, Blue - neutral, Green and Yellow - earth.
As the markings on your plug may not correspond with these
colours, continue as follows:
The Blue cable must be connected to the terminal marked “N”
or “Black”.
TheBrown cable must be connectedto the terminal marked “L”
or “Red”.
The Green and yellow cable must be connected to the terminal
marked “E” or “Green” or the earth symbol .
Protection Against Freezing
Iftheboileristobeoutofuseforanyperiodoftimeduringsevere
weatherconditionswerecommendthewholesystem,including
the boiler, be drained off to avoid the risk of freezing up. If an
immersion heater is fitted to the hot water cylinder make sure it
is switched off.

4
2000225095B
To Turn the Appliance On
Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat.
Turn the boiler temperature control clockwise to any position
between “0” and "Max", see diagram 1.
"Max" is approximately 82°C (180°F).
The boiler lighting operation is now automatic as follows:
The fan operates and after a short period of time, the spark
ignition operates, the solenoid opens, then the burner will light
shown by the burner ON neon (green) on the control panel
lighting up.
The burner will remain alight until switched off by the control
thermostat or any remote control.
Note: If the boiler is turned OFF at the boiler temperature
control, 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.
Iftheresetneonlights,turntheboilertemperaturecontrolto"0"
(off), wait 30 seconds, then repeat the lighting instructions.
To Turn the Appliance Off
For short periods, turn the boiler temperature control fully anti-
clockwise to “0” (off).
To relight, turn the boiler temperature control to any position
between “0” and “Max”.
Forlongerperiods,turntheboilertemperaturecontrolfullyanti-
clockwise to “0” (off) and switch off the electrical supply to the
boiler.
To relight follow the lighting sequence given above.
Instructions for Use
Diagram 1
BOILER
TEMPERATURE
CONTROL
10169
"BURNER ON"
NEON
RESET
NEON
"OFF"
POSITION

52000225095B
1 General Data
Important Notice
This boiler is for use only on G20 gas.
The boiler is delivered in one pack and the flue pack is supplied
separately.
Whereverpossible,allmaterials,appliancesandcomponentsto
beusedshallcomplywith the requirements ofapplicableBritish
Standards.
Where no British Standard exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Refer to Manual Handling Operations, 1992 Regulations.
Sheet Metal Parts
WARNING. Wheninstallingorservicingthisboiler, care should
betakentoavoidanypossibilityofpersonalinjurywhenhandling
the edges of sheet metal parts.
1.1 Technical Data
See diagrams 1.1, 1.2, 1.3 & 1.4
All dimensions are given in millimetres (except as noted) .
Approximate weight of complete boiler : 84kg (185lb)
Water content : 5.76 litre (1.27gallons)
Gas connection : Rc1/2(1/2in 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 CONNECTIONS Rc1 reduced
with DISTRIBUTOR TUBE to
Rc 3/4(3/4in. B.S.P.T.) (pumped return)
GAS CONNECTION
Rc 1/2(1/2in. B.S.P.T.)
The Seasonal Efficiency Domestic Boilers UK (SEDBUK)
is 'D' BFF40 = 78.3%, BFF50 = 78.2% & BFF60 = 78.5%.
ThevalueisusedintheUKGovernment’sStandardAssessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
1.2 Range Rating
See diagrams 1.2, 1.3 & 1.4 for boiler ratings.
A
CD H
B
F
G
E
J
K
L
NOTE: The boiler casing can be
set at two heights,
MAX. and MIN.
M
Diagram 1.2
10166

6
2000225095B
1.3 Statutory Requirements
The installation of this appliance must be carried out by a
competentpersonandmustbeinaccordancewiththerelevant
requirements of the current issue of:
Manufacturer’s instructions supplied.
The Gas Safety (Installation and Use) Regulations, Building
Regulations, Local Water Company Bye-laws, The Building
Standards (Scotland) Regulations, (applicable in Scotland),
HealthandSafetyatWorkAct,ControlofSubstancesHazardous
to Health, Electricity at Work Regulations and any applicable
local regulations.
Detailedrecommendationsarecontainedinthecurrentissueof
the following British Standards and Codes of Practice,
BS6891, BS5440 Part 1 and 2, BS6798, BS5449, BS5546,
BS6700, BS7478, BS7593, BS7671.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
1.4 B.S.I Certification
This boiler is certificated by B.S.I., for safety and performance.
Itis, therefore,important thatno alterationis made to the boiler
unless agreed, in writing, by Halstead Boilers Ltd.
Any alteration not approved by Halstead Boilers Ltd., could
invalidate the B.S.I. certification, boiler warranty and could
infringe the current issue of the Statutory Requirements.
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
toprovideasteadyinletworkingpressureof20mbar(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.
1.6 Electrical
WARNING. This boiler must be earthed.
The electrical installation must be carried out by a competent
person. All external components shall be of the approved type
and shall be connected in accordance with the current issue of
BS7671 and any local regulations which apply.
Connection of the boiler and any system controls to the mains
supply through an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363.
Alternatively, a 3A fused double pole isolating switch may be
used, having a minimum double pole contact separation of
3mm, serving only the boiler and system controls.
Heat resistant cable of at least 0.75mm2(24/0.20mm), to the
current issue of BS6500 Table 16, must be used for all
connections within the boiler casing, to the control box, pump
etc.
BOILER CASING HEIGHT(S) Diagram 1.5
BOILER CASING
ALTERNATIVE
HEIGHT
POSITIONS
MIN.
MAX.
To
floor
level
FLOOR LEVEL
9710
1 General Data
MAX.900
MIN. 860
Diagram 1.3
Diagram 1.4
10168 10167

72000225095B
1 General Data
1.7 Boiler Location
This boiler is not suitable for outside installation.
The boiler casing can be fitted at two heights. Refer to
diagram 1.5.
The boiler is assembled at the factory with the control box and
heat shield fitted in the lower position.
The boiler must stand on a level floor, conforming with local
authority requirements and building regulations.
The base temperature is within the requirements of the current
issue of BS5258. The boiler may stand on a wooden floor but
ametal baseplate isrequired toprotect plastictiles andsimilar
floor coverings.
Suitable installation clearance needs to be available at the
sidesoftheboilertofacilitatedirectconnectionofpipeworkand
making good around the flue assembly. The actual clearance
required will vary with site conditions.
When the boiler is to be installed level with work surfaces and
the like, minimum clearances should be provided as shown in
diagram 1.6. Work tops which overhang the cupboard sides,
almost in contact with the casing top, require a larger minimum
air gap. Flush sided fixtures require the same overall minimum
space but can have a reduced air gap on one side.
Boilers to be installed under work tops or fixtures, should be
positionedtoprovideminimumclearancesasshownindiagram
1.7. To facilitate minimum clearances it may be necessary to
modify kitchen units and fixtures.
A front access clearance for servicing of 700mm, should be
provided from a permanent wall or fixture.
The boiler may be installed in a cupboard, refer to minimum
ventilation and clearances as shown in diagram 1.8.
If the boiler is to be installed in a cupboard or compartment,
make sure that nothing will obstruct the openings/vents in the
compartment.
A compartment 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. Detailsofessentialfeaturesofcupboardorcompartment
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 installation of a boiler in a room containing a bath or
shower. Any electrical switch should be so positioned that it
cannot be touched by a person using the bath or shower. The
electrical provisions of the Building Standards (Scotland)
Regulations apply to such installations in Scotland.
Wheretheinstallationoftheboilerwillbeinanunusuallocation,
special procedures are necessary the current issue of BS6798
gives detailed guidance on this aspect.
1.8 Heating System Controls
The heating system should have installed: a programmer and
room thermostat controlling the boiler.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Note: For further information, see the current issue of the
Building Regulations, approved document L1, and the
references:
1)GIL 59, 2000: Central heating system specification (CheSS)
and
2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
Diagram 1.6
Diagram 1.7
MINIMUM CLEARANCES
LEVEL WITH WORKTOP
MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES
9711
320 MIN.
320 MIN.
CUPBOARDS
WORKTOP
9712
10 10
10 10
CUPBOARD
CUPBOARD 10
WORKTOP OR FIXTURE
BOILER
BOILER
5
CUPBOARD MINIMUM
VENTILATION & CLEARANCE Diagram 1.8
11626
10 10
10
DOOR
205cm2FREE AREA
FOR VENTILATION
205cm2FREE AREA FOR
VENTILATION
NOTE :
A clearance of 10mm
is required between
the front of the boiler
and fitted door.
Ventillation slots in the
front of the boiler must
be kept clear.
The free area for
ventilation must not be
reduced if a grille is
fitted.

8
2000225095B
Diagram 2.2
FULLY PUMPED SYSTEM
(DIAGRAMMATIC)
2 Water Systems
0870
1 metre
MIN.
27metres
MAX.
PUMP
Heating
Circuit
TO INDIRECT
CYLINDER
22mm VENT
15mm
COLD FEED
Distributor tube in
pumped return
connection
BOILER
C
L
DRAIN OFF
COCK
2.1 Water Pressure Head
Theboilershallonlybeconnectedtoacisternwatersupplywith
a minimum head of 1metre (3ft3in) and a maximum head of
27metres (90ft) which has an open vent in the system.
Theworkingpressuremustbewithintherange0.1barto2.7bar
(1.3 to 39lbftin2).
TheboilerMUST NOT beconnected to asealedwater system.
2.2 Inhibitor
Attention is drawn to the current issue of BS5449 and BS7593
on the use of inhibitors in central heating systems.
If an inhibitor is to be used in the system, contact should be
made with the inhibitor manufacturers so that they can
recommend their most suitable product.
Whenusing in anexisting system takespecial care todrain the
entiresystem,includingtheradiators,thenthoroughlycleanout
before fitting the boiler whether or not adding an inhibitor.
2.3 Gravity Domestic and Pumped Heating
Itisrecommendedthatacylinder thermostat is used to prevent
the stored water temperature becoming unnecessarily high
when the central heating pump is off.
The domestic primary flow and return must be 28mm o.d. The
installation must comply with the current issue of BS5546 and
BS6700, see diagram 2.1.
Iftheaboveconditionscannotbemet,itissuggestedthatafully
pumped system be used.
2.4 Pumped Heating and Hot Water
Where a single flow and return is 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
of11oC(20oF)acrosstheboiler. Attheappropriatepumpedflow
rate the pressure loss through the boiler can be found from the
graph, diagram 2.3.
Use a pump with integral valves or fit isolating valves as close
to the pump as possible.
2.6. Cylinder
Forall systems supplying domestic hotwater the cylinder must
be indirect.
2.7 Safety Valve
A safety valve need not be fitted to an open vented system.
2.8 Draining Tap
A draining tap must be provided at the lowest points of the
system which will allow the draining of the entire system,
including the boiler and hot water cylinder.
Draining taps should be to the current issue of BS2879.
2.9 Thermostatic Radiator Valves
If thermostatic radiator valves are fitted care must be taken to
ensure that there is an adequate flow rate through the boiler
when they close, refer to the current issue of BS7478 for
guidance. If fitted to all radiators ensure a bypass is fitted and
adjusttoachieveatemperaturedifferencenogreaterthan20oC
between flow and return with the thermostatic valves closed.
Diagram 2.1
0869
27metres
Max.
PUMP
Heating
Circuit
INDIRECT
CYLINDER
(Shown with
recommended
thermostat and valve).
22mm VENT
15mm COLD FEED
REFER TO BS 5546
28mm
Distributor tube in
pumped return
connection
BOILER
C
L
DRAIN OFF
COCK
Diagram 2.3
0872
600
500
400
300
200
100
0
12
8
4
0
0481216 20 24 28
FLOW RATE (LITRES/MINUTE)
WATER PRESSURE LOSS (mm HEAD OF WATER)
WATER PRESSURE LOSS (INCHES HEAD OF WATER)
24
16
800 32
28
20
700
0123456
FLOW RATE (GALLON/MINUTE)

92000225095B
3 Flue andVentilation
FROM
OUTSIDE
COMPARTMENT AIR VENT TABLE
COMPARTMENT
VENTILATION
REQUIREMENTS
VENTILATION
FROM ROOM
OR SPACE
BFF40 130cm220in2130cm220in2
HIGH LEVEL LOW LEVEL
VENT AREA VENT AREA
The flue must be installed in accordance with the rules in force
in the countries of destination.
3.1 Terminal Position
The minimum acceptable siting dimensions for the terminal
from obstruction, other terminals and ventilation openings are
shown in diagram 3.1.
The terminal must be exposed to the external air, the position
allowing free passage of air across it at all times.
BFF50 162cm226in2162cm226in2
BFF60 188cm229in2188cm229in2
BFF40 65cm210in265cm210in2
BFF50 81cm213in281cm213in2
BFF60 94cm215in294cm215in2
Car ports or similar extensions of a roof only, or a roof and one
wall,requirespecialconsiderationwithrespecttoanyopenings,
doors, vents or windows under the roof. Care is required to
protect the roof if it is made of plastic sheeting. If the car port
consists of a roof and two or more walls, seek advice from the
local gas company before installing the boiler.
If the terminal is fitted within 600mm below plastic guttering or
paintedsoffitanaluminiumshield1500mmlongshouldbefitted
immediately beneath the guttering or eaves. If the terminal is
fittedwithin450mmbelowpaintedeavesorapaintedgutter,an
aluminium shield 750mm long should be fitted immediately
beneath the guttering or eaves.
3.2 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
documentIGE/UP/7/1998.Ifindoubtseekadvicefromthelocal
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
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal.
A suitable guard, reference Type “K3”, can be obtained from:
Tower Flue Components Ltd.,
Morley Road, Tonbridge,
Kent. TN9 1RA
3.4 Room Ventilation
The boiler is room sealed and does not require the room or
space containing it to have permanent air vents.
3.5 Ventilation for Boilers Installed in a
Cupboard
Forminimumventilationandclearancesforcupboardinstallation
refer to section 1.7 and diagram 1.8.
3.6 Compartment Ventilation
Where the boiler is fitted in a compartment, the high and low
level permanent air vents must have effective areas, see
“Compartment Air Vent Table” .
Both the high and level air vents must communicate with the
same room or must both be on the same wall to outside air.
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS POSITION MM
HORIZONTAL FLUES
ADIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING, AIR BRICK,
OPENING WINDOW, AIR VENT, OR ANY
OTHER VENTILATION OPENING 300
BBELOW GUTTER, DRAIN/SOIL PIPE 25
CBELOW EAVES 25
DBELOW A BALCONY OR CAR PORT 25
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25
FFROM INTERNAL/EXTERNAL CORNERS
OR TO A BOUNDARY ALONGSIDE THE
TERMINAL 25
GABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
HFROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300
Diagram 3.1
A
A
E
G
G
B,C B,C
F
K
C
UNDER CAR PORT etc.
H,I
JD
F
K
FL
11508

10
2000225095B
Diagram 4.2
General Installation Notes
The appliance pack contains :-
Boiler.
Fan connector.
Casing panels, packed seperately.
Loose items fittings pack, see list in pack.
The flue is supplied seperately.
NOTE: The rear flue option kit Part. No. 425861 is available,
whichconsistsofwallcoverplates, for replacementBuckingham
balanced flue appliances.
Before installation of the boiler make sure that the location
selectedis in accordancewith therequirements of Section1.7.
4.1 Unpacking
Theboiler casingpanelsarepackedseparatelywithin themain
carton and are designed to enable gas and water connections
to be made before fitting the casing panels.
The casing brackets, flue restrictor, distributor tube and other
loose items, are in the fittings pack.
NOTE:
To make a neat finish to the flue outlet a flue collar kit, part No.
900850, with instructions, is available, see diagram 4.4.
Ifrequiredanoptionalwalllinerkit,partno.900862,isavailable
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
Selecttheboilerlocation,withdueregardtothefluelengthand
terminal position, see diagrams 3.1 and 4.1.
For a wall thickness up to 300mm, provided that the optional
wall liner kit is used, the flue can be fully installed from the
inside.
For a wall thickness of over 300mm the external flue hole will
needto be madegood from the outside, thisalso applies if you
use the flue kit without the optional wall liner kit, irrespective of
wall thickness.
4 Installation
REAR STD.
REAR 75 95 510
MINIMUM
WALL
THICKNESS
MINIMUM
FLUE
LENGTH
MAXIMUM
FLUE
LENGTH
FLUE
PACKS
NOTE :
IF IT IS NECESSARY TO CUT THE DUCTS
TO ACHIEVE THE "FLUE LENGTH" MAKE SURE
THAT THE OVERLAPS ARE AS FOLLOWS :-
THE OVERLAP FOR AIR DUCT = 25mm
THE OVERLAP FOR FLUE DUCT = 50mm
FLUE & AIR DUCT LENGTH = A + 15 + 3
10062
300
42
700
Ø115
FRONT VIEW
BOILER
OUTLINE
*INCREASE TO 30mm IF A FLUE COLLAR IS ADDED
*