Halstead BFF80 Operating manual

9919
221992D.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
Model: BFF80
G.C. No. 41-333-91
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
221992D
TESTING AND CERTIFICATION
Thisboileristestedandcertificatedfor safetyandperformance. Itisthereforeimportantthatnoalterationismadetotheboiler,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. Donotusereconditionedorcopypartsthathavenotbeen clearlyauthorisedbyHalstead
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 7
Flue & 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

3221992D
Instructions for Use
Introduction
Pleasereadthese instructions and followthemcarefully for the
safe and economical use of your boiler.
The Halstead Buckingham 4 B FF 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 1.4, 1.5 & 1.6.
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 itischeckedand 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
weather conditions we recommend the whole system 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
221992D
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
10191
"BURNER ON"
NEON
RESET
NEON
"OFF"
POSITION

5221992D
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. Wheninstallingorservicing this boiler, careshould
betakentoavoidanypossibilityofpersonalinjurywhenhandling
the edges of sheet metal parts.
1.1 Technical Data
See diagrams 1.1 & 1.2.
All dimensions are given in millimetres (except as noted) .
Approximate weight of complete boiler : 131.5kg (290lb)
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
GENERAL DIMENSIONS - given in millimetres Diagram 1.1
9921
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' 78.6%.
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 diagram 1.2.
A
CDH
B
F
G
E
J
K
L
A B C D E F G H J K L M
387 700 558 294 364 555 442 3 Max 900/ 300 194 32
Min 860
M
NOTE: The boiler casing can be
set at two heights,
MAX. and MIN.
Diagram 1.2
10182

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221992D
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 madeto theboiler
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 1.3
BOILER
CASING
ALTERNATIVE
HEIGHT
POSITIONS
MIN.
MAX.
To
floor
level
FLOOR LEVEL
9922
1 General Data
Diagram 1.4
Diagram 1.5
MINIMUM CLEARANCES
LEVEL WITH WORKTOP
MINIMUM CLEARANCES
UNDER WORKTOP, FIXTURES
9923
407 MIN.
407 MIN.
CUPBOARDS
WORKTOP
10124
10 10
10 10
CUPBOARD
CUPBOARD
10
WORKTOP OR
FIXTURE
BOILER
BOILER
5
MAX.900
MIN. 860

7221992D
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 1.3.
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 1.4. 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
1.5. 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.
Theboilercan be installedwithin a cupboard,referto minimum
ventilation and clearances as shown in diagram 1.7.
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)GIL59, 2000: Centralheating system specification(CheSS)
and
2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.
CUPBOARD MINIMUM
VENTILATION & CLEARANCE Diagram 1.6
DOOR
272cm2FREE AREA
FOR VENTILATION
10mm
10mm
10mm
CUPBOARD CUPBOARD
272cm2FREE AREA
FOR VENTILATION
IMPORTANT
A CLEARANCE OF 10mm IS REQUIRED BETWEEN THE
FRONT OF THE APPLIANCE AND THE FITTED DOOR.
THE VENTILATION SLOTS ON THE FRONT
OF THE APPLIANCE MUST BE KEPT CLEAR.
THE FREE AREA FOR VENTILATION MUST
NOT BE REDUCED IF A GRILLE IS FITTED.

8
221992D
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 toprevent
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 2.3
1.50
1.25
1.00
0.75
0.50
0.25
0
30
20
10
0
0612 18 24 30 36 42
FLOW RATE (LITRES/MINUTE)
WATER PRESSURE LOSS (metre HEAD OF WATER)
WATER PRESSURE LOSS (INCHES HEAD OF WATER)
60
40
2.00 70
50
1.75
0123456789
FLOW RATE (GALLON/MINUTE)
1074
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

9221992D
3 Flue andVentilation
FROM
OUTSIDE
COMPARTMENT AIR VENT TABLE
COMPARTMENT
VENTILATION
REQUIREMENTS
VENTILATION
FROM ROOM
OR SPACE
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.
272cm242in2272cm242in2
136cm221in2272cm242in2
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
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 1.6.
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.

10
221992D
Diagram 4.2
10051
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,forreplacementBuckingham
balanced flue appliances.
Before installation of the boiler make sure that the location
selectedis in accordancewith therequirements of Section1.7.
4.1 Unpacking
Theboilercasingpanelsarepackedseparatelywithinthemain
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 fromthe 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
387
194
700
115
BOILER
OUTLINE
FRONT VIEW
*INCREASE TO 30mm IF A FLUE COLLAR IS ADDED
*

11 221992D
4.3 Flue Hole Cutting
Markoutthefluecentre,seediagram4.2,thencutaholeforthe
flue using, preferably, a 115mm minimum core drill.
4.4 Rear Flue Option Kit - 425861 (if applicable)
Fitthewallcoverplatesasdescribedintheinstructionssupplied
with the kit.
4.5 Flue Preparation
Note: If the flue collar kit, see diagram 4.4, is to be used
increase the 15mm projection to 30mm.
Extend the telescopic flue to the required length, making sure
thattheminimumoverlapisnolessthan25mm,andthattheflue
terminalprojects15mmminimumbeyondwallface,seediagram
4.1.
If it is necessary to cut the flue ensure that the overlap is as
stated in diagram 4.1.
Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 4.3.
Seal the joint with the tape provided.
Note: Should any one of the flue sections require cutting to
obtain desired flue system length make sure that the overlaps
are as follows:-
The overlap for air duct = 25mm
The overlap for flue duct = 50mm.
Take the terminal restrictor and position the clamping bracket
makingsuretheclampingbracketnibprotrudesintheslotofthe
terminal restrictor and secure with locking screw, but do not
tighten, see diagram 4.5.
Engagethe terminalrestrictor on the flue terminalby hookingit
over the terminal end and engaging the clamping bracket
behindtheinnerringoftheterminalsecuringitbytighteningthe
locking screw, see diagram 4.5.
9869
SCREW (4)
SPIGOT
GASKET
FLUE
BAYONET
CONNECTION
Diagram 4.4
7148
OPTIONAL
FLUE
COLLAR
4 Installation
Diagram 4.3 Diagram 4.5
7323
RESTRICTOR
CLAMPING
BRACKET
CLAMPING
BRACKET NIB
FLUE
TERMINAL
LOCKING
SCREW
TERMINAL RESTRICTOR
SHOWN FITTED
STANDARD 510mm REAR
7332
SCREW
AND TAPE
Fittheselfadhesivefoamsealprovidedinthefluepackaround
the air duct at the position shown in diagram 4.1.
Make sure that the ductings do not slope down towards the
boiler.
Makegoodaroundtheflueoutsideafterinstallationoftheboiler.
Important:Ifthewalllinerkitisused,theselfadhesivefoamseal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 4.6 for position of self
adhesive seal.
Push the flue assembly into and through the hole such that it is
withinthewall,anddoesnotstickoutintotheroom. Donotpush
theflueassemblytoofarintotheholeasithastobepulledback
into the boiler and secured.
Ifthe boiler isnot to befitted forsome time coverthe hole inthe
wall.

12
221992D
Diagram 4.7
WATER CONNECTIONS - GRAVITY
DOMESTIC, PUMPED HEATING
ALTERNATIVE
HEATING
RETURN
With distributor
tube (not shown)
ALTERNATIVE
HEATING OR
DOMESTIC
HOT WATER
FLOW
GRAVITY
DOMESTIC
RETURN TO
ANY OF THE
3 REMAINING
LOWER CONNECTIONS
9859
4.6 Water Connections - Gravity Domestic and
Pumped Heating
Fit suitable fittings into the boiler tappings, see diagram 4.7.
Make sure that all pipes are taken backwards and will clear the
casings, see diagram 1.1.
Heating flow: Any one of the four upper connections may be
used.
Domesticflow: Anyoneofthethreeremainingupperconnections
may be used.
Heating return: The water distributor tube must be fitted into
either of the front lower connections on all installations, see
diagram 4.8. This tube is in the fittings pack.
Domestic return: Any one of the 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
diagram4.9. Makesurethatallpipesaretakenbackwardsand
will clear the casings.
It is important that all connections are made as shown in
diagram 4.9.
Fit the water distributor tube into the return connection, see
diagram 4.8. This tube is in the fittings pack.
Fit plugs into any unused boiler tappings.
4 Installation
Diagram 4.6
FOAM SEAL
FOAM SEAL
WALL THICKNESS-
OVER 300mm
15mm
WALL THICKNESS-
UP TO 300mm
Q-35mm
Q
Q
7102
WITH WALL LINER KIT ONLY
Diagram 4.9
WATER CONNECTIONS FULLY
PUMPED SYSTEMS
9859
ALTERNATIVE
FLOW
POSITIONS
ALTERNATIVE
RETURN
POSITIONS
With distributor
tube (not shown)
DISTRIBUTOR TUBE Diagram 4.8
1076
UPPER
MARKER
DISTRIBUTOR
TUBE
must be in
pumped return
connection
UPPER MARKER
must lie between the
two outer NOTCHES

13 221992D
CASING BRACKETS FITTING Diagram 4.12
9858
FRONT
CASING
BRACKET
No.8
SCREW
(4)
CAPTIVE
NUT
UPPER CASING
BRACKET
CAPTIVE
NUT
4.8 Pipework
When the front tappings are used, it is essential that any
pipework or fittings do not project more than shown in diagram
4.10.
WhenusingareartappingwithRc(1inBSP)fittingfor28mmod
pipework, it is recommended that a short nipple and an Rc
thread(BSP)tocopperelbowisused.Ifthepipeworkisrequired
to run back to the wall, make sure that it will clear the boiler air
ductand,ifworkingtominimumclearance,doesnotprojecttoo
far from the boiler, see diagram 4.11.
Donot route anypipework, wateror gas, acrossthe front ofthe
combustion chamber cover.
Thegaspipeworkmustbealongthelefthandsideoftheboiler.
4 Installation
No.8
SCREW
(4)
4.9 Casing Brackets
Fit the two upper and two front casing brackets shown in
diagram 4.12, using the No.8 screws provided.
NOTE: The screws will already be fitted.
Pushthecaptivenuts,suppliedloose,ontothecasingbrackets
as shown in diagram 4.12.
Diagram 4.10
PIPEWORK CASING
CLEARANCES
Diagram 4.11
REAR CONNECTION
PIPEWORK (28mm)
9861
FOR MINIMUM
CLEARANCE
9860

14
221992D
4.10 Side In-fill Panel (if required)
Asidein-fillpanelissuppliedwiththeboiler,whichcanbefitted
at the rear of the left or right hand side casing but can be
discarded if the water connections are made on both sides of
theboileroriftheboilerisscreenedbyfixtures. Thein-fillpanel
will usually be fitted on the side where there no pipework
connections.
Insert the push fit plastic location peg, supplied, through the in-
fillpanelandsidecasingholesand securewiththespringclips,
see diagram 4.13.
NOTE
The boiler is assembled at the factory with the control box and
heat shield fitted in the lower casing height position.
9863
SIDE CASINGS FITTING Diagram 4.14
MAX.
SIDE
CASING
(R.H.)
MIN.
BOILER
PLINTH
FRONT
CASING
BRACKET
No. 8
SCREW
(4)
LOCATING
SLOTS
4 Installation
Diagram 4.13 Diagram 4.15
SCREW
SIDE CASING
(R.H. SHOWN)
UPPER
CASING
BRACKET
PLASTIC
PEG
PLASTIC
PEG
SPRING
CLIP
SIDE
CASING
(R.H.SHOWN)
UPPER VIEW
LOWER VIEW
SPRING
CLIP
SIDE
CASING
(R.H. SHOWN)
IN-FILL
PANEL
IN-FILL
PANEL
4.11 Side Casings
Fit the side casings by locating their lugs into the appropriate
slot in the boiler plinth, see diagram 4.13, depending on the
required height, there are two options, see section 1.7.
Secure the casing sides to the front and rear upper casing
brackets with self-tapping screws supplied, see diagrams 4.13
and 4.15.

15 221992D
4 Installation
Diagram 4.16
0886
WING NUT
SELF
TAPPING
SCREWS
(3)
Diagram 4.17
TOGGLE LATCHES
FAN ACCESS DOOR
4.12 Flue / Boiler Connection
Removethethreeself-tappingscrewsfromthelowerpartofthe
control box support bracket, see diagram 4.16.
Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram
4.16.
Release the two toggle latches that secure the boiler access
door and remove, see diagram 4.17.
Remove the electrical connections from the fan by pulling the
insulationbootsonlyanddisconnectthetwosiliconetubesfrom
the fan taking note of their positions, see diagram 4.18.
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 diagrams 4.18 & 4.19.
Fromthe flue packtake the fluespigot,the gasket issupplied 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.WithregardstotheManual HandlingOperations,
1992 Regulations, the following operation, exceeds the
recommended weight for one man lift.
Placetheboilerinpositiontakingcarenottodamagethecasing
panels.
With access to the flue system through the boiler, pull the flue
ontothespigotbayonetconnection,twistanti-clockwisetolock
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 4.20.
Fit fan and engage the flue duct extension into the flue duct,
secure fan, replace electrical connection 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 4.18 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 4.18
FRONT AIR PRESSURE
SWITCH TUBE (CLEAR)
FAN ELECTRICAL
CONNECTORS
AIR
PRESSURE
TUBES
(RED)
FAN SECURING SCREW
REAR AIR
PRESSURE
SWITCH TUBE (RED)
10259

16
221992D
4.13 Water & Gas connections
Replace fan access door, heat shield and control box.
Note: When replacing the fan access door make sure the lip at
thetopofdoorfits intoandbehindtheslottedbracketlocatedat
the top of the boiler.
As there are two casing height options, the control box height
and the heat shield may have to be adjusted to suit your
requirements.
Complete the water connections to the boiler.
Fill, vent and flush the system.
Check 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.
Thewholeofthegasinstallation,includingthemeter,shouldbe
inspected,testedforsoundnessandpurgedinaccordancewith
the current issue of BS6891.
4.14 Top Casing
Refer to diagram 4.21.
Fit two plastic pegs, one on each side, in the holes on the top
casing.Theplasticpegsareatightfitandarebestpushedhome
with a flat faced tool.
Secure front of top casing with the screws provided.
4 Installation
Diagram 4.21
TOP CASING
9865
SCREW (2)
PLASTIC
PEG (2)
10149
Diagram 4.20
FLUE DUCT
EXTENSION PIECE
FAN
Diagram 4.19
SECURING
LUGS

17 221992D
bk
5 ElectricalWiring
MAINS INLET
CONNECTOR Diagram 5.2
0000
0000
CABLE
CLAMP
SCREW
5.1 Control Box Access
Removecontrolboxcoverbyundoingthefoursecuringscrews
(two on control box, two on the heat shield) and lift off, see
diagram 5.1.
5.2 Electrical Connections
WARNING. This boiler must be earthed.
Take care not to damage any internal wiring.
Using heat resistant (85oC) cable of at least 0.75mm2(24/
0.2mm)andofasuitablelength,routeasshownindiagram5.3.
Thread through the grommet at the bottom rear of the control
box, through the cable clamp and connect to appropriate
terminals. Tighten cable clamp screws, see diagram 5.2.
Standard colours are, brown - live (L), blue - neutral (N) and
green/yellow - earth .
The mains cable outer insulation must not be cut back external
to the cable clamp.
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 by a
competent person.
After installation of the system, preliminary electrical system
checks as below should be carried out.
1. Test insulation resistance to earth.
2. Test earth continuity and short circuit of all cables.
3. Test the polarity of the mains.
The installer is requested to advise and give guidance to the
user of the controls scheme used with the boiler.
Replace the control box cover. Diagram 5.3
CABLE
CLAMP
CONTROL
BOX
COVER
CONTROL
BOX
SECURING
SCREWS
BOILER
TEMPERATURE
CONTROL
Diagram 5.1
9905
CABLE
CLIPS
CABLE
CLIPS
HEAT RESISTANT
CABLE
TERMINAL BLOCK
CONNECTIONS
TERMINAL
BLOCK

18
221992D
6 Commissioning
IMPORTANT NOTE
TheWARNINGNOTICE attached to thefrontcasing
must only
be removed by the user
Please ensure the “Benchmark” logbook is completed and left
with the user, and the magnetic lighting instruction label is
placed on the surface of the boiler casing.
6.1 All Systems
Commissioningshouldbecarriedoutbyacompetentpersonin
accordance with the current issue of BS6798.
UNDER ALL CIRCUMTANCES the case must be correctly
fitted and sealed, unless fault finding.
Makesurethatthesystemhasbeenthoroughlyflushedoutwith
cold water without the pump in place.
Refit the pump, fill the system with water, ensuring that all the
air is properly vented from the system and pump.
6.2 Initial Lighting and Testing
CAUTION. This work must be carried out by a competent
person, in accordance with the current issue of BS6798.
Makesurethatallnakedlightsandcigarettesareextinguished.
Refer to ‘Instructions for Use’ and identify the controls.
Check that the boiler is isolated from the electrical supply.
Turn the gas service cock “On” , see diagram 6.1.
Purge in accordance with the current issue of BS6891.
WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.
If programmer control is fitted, make sure it is in the ON mode.
Make sure that any remote controls are calling for heat.
Diagram 6.1
BOILER COMPONENTS
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
Turn the boiler temperature control clockwise to “Max”.
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”, then fully clockwise to “Max”.
"Max" is approximately 82°C (180°F).
Aftertheburnerhaslit,the“Burneron”neononthecontrolpanel
will come on.
Isolate the boiler from the electrical supply.
Loosen the burner pressure test point screw and connect a
suitable pressure gauge, see diagram 6.1.
Switch on the electrical supply to the boiler.
WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.
6.3 Testing - Electrical
Turn the boiler temperature control fully clockwise to the
maximum setting.
The lighting sequence is 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
shownbythe“BurnerOn”neononthecontrolpanellightingup.
The burner will remain alight until switched off, either by the
boilertemperaturecontrol,programmer(if fitted) or anyremote
system control.
To make sure that the flame supervision device is working
correctly the following should be done.
With the burner alight, turn the gas service cock “Off”, see
diagram 6.1.
F
B
C
H
A
0000
J

19 221992D
6 Commissioning
After a short period the burner will go out.
The correct working of the flame supervision is shown by the
“Burner On” neon going out and the ignition sequence starting
up.
After a short period the boiler will shut down.
If the lighting sequence described fails, refer to fault finding
section 9.
To carry on turn the gas service cock “On”, see diagram 6.1.
To re-start the lighting sequence, turn the burner temperature
control to “0” then fully clockwise to “Max.”.
During normal operation when the boiler switches “Off”, the
burner will go out. The automatic lighting sequence will work
again when heat is required.
Iftheresetneonlights,turntheboilertemperaturecontrolto"0"
(off), wait 30 seconds, then repeat the lighting instructions.
6.4 Testing - Gas
With the boiler on proceed as follows:
Test for gas soundness around the boiler gas components
using a suitable leak detection fluid, in accordance with the
current issue of BS6891.
Check the burner gas pressure at least 10 minutes after boiler
has lit, refer to Data Label, see diagram 1.2.
If necessary adjust the gas pressure to obtain the required
setting turning screw clockwise, to decrease pressure, see
diagram 6.1.
Should any doubt exist about the gas rate, check it using the
gasmeter test dial and stopwatch at least 10 minutesafter the
burnerhaslit,makingsurethatallothergasburningappliances
and pilot lights are off.
Gas rate: Buckingham 4 BFF80 : 2.8m3/h (79ft3/h)
is for guidance only, dependent on the heat setting.
Turn the boiler temperature control fully anti-clockwise to “0”.
Isolate from the electrical supply.
Removethepressuregaugefromthetestpointandrefitscrew,
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 after a short period of
time.
6.5 Testing - All Water Systems
Allow the system to reach maximum working temperature and
examine for water leaks.
There should be no undue noise in the system.
Theboilershouldthenbeturnedoffandthesystemdrainedoff
as rapidly as possible,whilst still hot.
Refill system.
6.6 Open Vented System
Ensure there is no pumping over of water or entry of air at the
open vent above the feed and expansion cistern.
Diagram 6.2
LOCATING
STUDS
LOCATE
UNDER LIP
FRONT
PANEL
Diagram 6.3
FRONT PANEL
SECURING SCREWS
BOTTOM PLINTH
PANEL
SECURING SCREWS
6.7 Adjustment - Fully Pumped Open Vented
System
Whencommissioning the system the boilershould first be fired
on full service, that is, central heating and domestic hot water.
Adjustthepump to thesystemdesign setting, thenbalance the
system, making adjustments as necessary.
6.8 Completion
Adjust the boiler temperature control and any system controls
to their required settings.
Fit the bottom plinth panel and secure with two dog point
screws, see diagram 6.2.
Finally fit the front panel by hooking under front of top panel
locating on the two studs, see diagram 6.2 and securing at the
bottom on to the bottom plinth panel with two screws, see
diagram 6.3.

20
221992D
7 Instructions to the User
Instruct and demonstrate the safe and efficient operation of the boiler, heating system and domestic hot water system.
Advise the user, that to ensure the continued efficient and safe operation of the boiler, it is recommended that it is checked and
serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once
a year should be enough.
Draw attention, if applicable to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes
a duty of care on all persons who let out any property containing a gas appliance.
It is the Law that servicing is carried out by a competent person.
Advisetheuseroftheprecautionsnecessarytopreventdamagetothesystemandbuildingintheeventoftheheatingsystembeing
out of use during frost and freezing conditions.
Reminder - Leave these instructions and the “Benchmark” logbook with the user.
8 Servicing
REMEMBER,Whenreplacingapartonthisappliance,useonly
spare parts that you can be assured conform to the safety and
performance specification that we require. Do not use
reconditionedorcopypartsthathavenotbeenclearlyauthorised
by Halstead Boilers Ltd.
Products of Combustion Check
Note: To obtain a products of combustion reading, remove the
front panel and remove the control box as descibed in the
relevantparagraphsofsection4.12. Next,removethecapfrom
thesamplingpoint,locatedonthetopofthelefthandsideofthe
inner casing, see diagram 8.1.
Connect the analyser tube on to the nipple.
WARNING. The multifunctional control and fan operate on
mains voltage, terminals will become live.
Switchontheelectricalsupplyandgassupplythenoperatethe
boiler.
Oncompletionofthetestswitchofftheelectricalsupplyandgas
supply, remove analyser tube and replace sampling point cap.
Servicing
Beforeservicingturnoffthegasandisolatetheelectricalsupply
to the boiler.
Aftercompletingaservicealwaystestforgassoundness,make
electrical checks and carry out functional check on controls.
Unless stated otherwise all parts are replaced in the reverse
order to removal.
8.1 Access
Remove the boiler front casing panel, refer to paragraph 6.8.
Remove the bottom plinth panel by unscrewing the two dog
pointscrewssecuringthepaneltotheboilerplinth,seediagram
8.4.
Disconnect gas valve from gas cock and unplug electrical plug
from gas valve, firstly removing electrical plug securing screw,
see diagram 8.2.
Unclip electrical wires from control box support bracket, see
diagram 8.3.
Undo the four self-tapping screws that secure the combustion
chamberfrontandcarefullywithdrawittogetherwiththeburner
and gas valve assembly, taking care not to strain the ignition
and earth wire, see diagram 8.5.
Note: When replacing burner in combustion chamber make
sure it fits correctly on the guides. Diagram 8.2
0000
GAS
SERVICE
COCK
UNION
ELECTRICAL
PLUG
Diagram 8.1
0000
SAMPLE POINT
Disconnect the ignition and earth leads from the burner and
removebydrawingtheleadsthoughthegrommet,seediagram
8.5.
Removethethreeself-tappingscrewsfromthelowerpartofthe
control box support bracket, see diagram 8.6.
Undo the wing nut that secures the top of the heat shield and
carefully hinge down control box and heat shield, see diagram
8.6.
Release the two toggle latches that secure the boiler access
door and remove, see diagram 8.7.
SECURING
SCREW