Boulter eco-system User Manual

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Page 1

Eco-System

Boiler

Boulter Boilers Ltd

Magnet House

30 White House Road

Ipswich

IP1 5JA

Tel: 01473 241555

Fax: 01473 241321

Manual Part No. PL 49021 Issue No 1 Date April 2002

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INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974, it is a requirement to provide information on substances hazardous to health (COSHH Regulations 1988).

The Company takes every reasonable care to ensure that these products are designed and constructed to meet these general safety requirements, when properly used and installed.

To fulfil this requirement products are comprehensively tested and examined before despatch.

This appliance may contain some of the materials below. When working on the appliance it is the Users/Engineers responsibility to ensure that

any necessary personal protective clothing or equipment is worn appropriate to parts that could be considered as being hazardous to health and safety.

INSULATION & SEALS Glass Rope, Mineral Wool, Insulation Pads, Ceramic Fibre, Fibre Glass Insulation. May be harmful if inhaled. May be irritating to the skin, eyes, nose or throat. When

handling avoid inhalation and contact with the skin or eyes. Use (disposable) gloves, face masks and eye protection.

After handling wash hands and other exposed parts. When disposing, reduce dust with water spray, ensure parts are securely wrapped.

GLUES, SEALANTS & PAINT Glues, Sealants and Paint are used in the product and present no known hazards when

used in the manner for which they are intended. KEROSENE & GAS OIL FUELS (MINERAL OILS)

1. The effect of mineral oils on the skin vary according to the duration of exposure.

2. The lighter fractions also remove the protective grease normally present on the surface of the skin rendering the skin dry, liable to crack and more prone to damage caused by cuts and abrasions.

3. Skin rashes (oil Acne). Seek immediate medical attention for any rash, wart or sore developing on any part of the body, particularly the scrotum.

4. Avoid as far as possible any skin contact with mineral oil or with clothing contami-

nated with mineral oil.

5. Never breath any mineral oil vapours. Do not fire the Burner in the open i.e. out of the Boiler as a miss fire will cause unburnt oil vapours.

6. Barrier cream containing lanolin such as Rosalex Antisolv, is highly recommended together with a strict routine of personal cleansing.

7. Under no circumstances should mineral oils be taken internally.

HEALTH AND SAFETY

Due to a policy of continual development Boulter Boilers reserves the right to alter or amend the design of its products without prior notice.

OFTEC Code of Practice OCP/1: 1995 For the Safe Installation, Commissioning, Maintenance and Fault Rectification of Oil Firing Equipment should be consulted.

BOULTER BOILERS

Boulter Boilers Limited Magnet House, 30 White House Road, Ipswich IP1 5JA Telephone: (01473) 241555 Fax: (01473) 241321 A member of the Bullough Group of Companies

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BOULTER BOILERS Eco-System PAGE 1

CONTENTS - Part 1

SECTION 1 - USER GUIDE

1:2 Safety Notices 1:5 Operating Instructions

1:5:1 Boiler Control Thermostat 1:5:2 Boiler Overheat/Limit Thermostat 1:5:4 Lockout Indicator 1:5:5 Starting your Boiler 1:5:6 Switching off Temporarily 1:5:7 Shutting Off for Summer 1:5:8 Sealed System Central Heating 1:5:9 Frost Protection 1:5:10 Oil Delivery 1:5:11 Maintenance/Troubleshooting Guide 1:5:12 Option Programmer

SECTION 2 - INTRODUCTION

2:1 Introduction 2:2 Flue Options 2:3 Commissioning 2:4 Safety

SECTION 3 - TECHNICAL DATA

3:1 Fuels 3:2 Boiler Technical Details 3:3 Burner Details 3:4 Electric’s 3:5 Dimensions 3:6 Commissioning Data

SECTION 4 - INSTALLATION

4:1 Standards and Regulations 4:2 The Heating System 4:3 Siting & Positioning 4:4 The Hearth 4:5 The Chimney 4:6 Air Supply 4:7 Oil Storage 4:8 Oil Supply 4:9 Oil Burner

SECTION 5 - BALANCED FLUES

5:1 Balanced Flue Boilers 5:2 Horizontal Balanced Flues 5:3 Vertical Balanced Flues 5:4 Positioning the Boiler 5:5 Terminal Guards 5:6 Horizontal Flue Terminal 5:7 Blanking Plates

SECTION 6 - BALANCED FLUE INSTALLATION

6:1 Notes on Installation 6:2 Low Level Horizontal Flue 6:3 High Level Horizontal Flue 6:4 Vertical Flues 6:5 High Level Flue Length Alteration 6:6 Quick Fit Flue Systems

SECTION 7 - COMMISSIONING

7:1 Commissioning 7:2 Responsibility 7:3 Reporting 7:4 Recommended Commissioning Check

List

7:5 Recommended Commissioning Tests

SECTION 8 - MAINTENANCE

8:1 Maintenance 8:2 Air Shutter Adjustment 8:3 Baffle Arrangement

SECTION 9 - SPARES & ACCESSORIES

9:2 Boiler Spare Parts, 12/19 & 19/26 9:4 Burner Parts

SECTION 10 - FAULT FINDING

10:1 Fault Finding 10:2 Fault Finding Chart

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BOULTER BOILERS Eco-System PAGE 2

1:2 IMPORTANT SAFETY NOTES

To obtain the best possible performance and trouble free operation from your Boiler, it is important that you read these instructions carefully. Your Eco Boiler has built-in safety features, which are detailed in the relevant section of this manual.

1:2.1

The heating system must comply with the latest editions of British Standard 5410 and The Building Regulations.

Please note: It is essential in the interest of the Boiler efficiency and reliable performance that once the Boiler has been installed it is first commissioned by a competent and preferably an O.F.T.E.C.* registered engineer. It is the responsibility of the installer to ensure that the Boiler is commissioned.

If an engineer is not known, Boulter Boilers will be pleased to provide details of commissioning and servicing engineers from their register.

*The Oil Firing Technical Association for the Petroleum Industry - Banstead, Surrey 01737

373311.

◆ If it is known or suspected that a fault exists on the Boiler, it MUST NOT be used until the fault has been corrected by a competent engineer (see Failure to Start).

◆ It is essential that the instructions in this booklet are strictly followed for safe and economic operation of the Boiler. Failure to observe these instructions may invalidate your right to free breakdown cover during the guarantee period.

We recommend that you keep these instructions in a place near your appliance for easy reference.

1:2.2 Air Supply to Boiler Conventional Flue

Where your Boiler is used on an open conventional flue system, a permanent air supply is required for combustion. Clearances provided at the sides and rear of the appliance for air entry must be kept free of obstruction. For further explanation please refer to section 4.6 of this installation manual.

Your Eco Boiler should be connected to an electrical supply complying with the Electrical Wiring Regulations (BS7671): as well as an oil supply complying with BS5410 Pt.1; and an appropriate flue system.

◆ ALWAYS SWITCH OFF THE ELECTRICAL SUPPLY before removing any of the covers for cleaning.

◆ If any part of the Boiler or its flue is modified, then the guarantee/warranty will be invalidated.

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1:5 OPERATING INSTRUCTIONS

1:5.1 BOILER CONTROL THERMOSTAT

The Boiler Control Thermostat is also the ON/OFF switch for the Boiler. To Switch the Boiler off, turn the Thermostat to the ‘OFF’ position and isolate at the mains isolating switch.

The Boiler Control Thermostat also controls the water temperature within the Boiler.

The recommended Control Thermostat settings are as follows:

WINTER HEATING & HOT WATER No. 4 SUMMER HOT WATER ONLY No. 2 The Boiler Control Thermostat automatically

switches the Burner ON and OFF to maintain the selected temperature. The Burner is lit by an automatic ignition system and therefore there is no pilot flame.

The Boiler should not be operated below 60°C as this will cause corrosion which will reduce the life of the Boiler (Summer position).

1:5.2 BOILER OVERHEAT/LIMIT THERMOSTAT

The Boiler is fitted with a safety overheat/limit thermostat. This will interrupt the power supply to the Boiler and shut it down completely in the unlikely event of overheating.

Should this occur, wait for the Boiler to cool, and then reset the thermostat by pressing the limit thermostat reset button located at the rear of the Control Panel.

If this problem still persists, turn off the Boiler and consult your installer.

BOULTER BOILERS Eco-System PAGE 3

Page 6

1:5.4 LOCKOUT INDICATOR

In the unlikely event of a Burner malfunction, it will automatically shutdown, and the red lockout indicator on the Control Panel will be lit.

To restart the Burner, wait for a period of at least 45 seconds. Remove the front door panel (as illustrated) and press the lockout reset button located on the front of the Burner (see fig 2). If the Burner immediately goes to lockout again, wait three minutes and then repeat the procedure, once more only, by pressing the reset button again.

If this problem still persists, turn off the Boiler and consult your engineer.

1:5.5 STARTING THE BOILER

1. Ensure that all external controls, e.g. programmer, timer, room thermostat etc., are turned on and calling for heat.

2. Make sure the Boiler Control Thermostat is set within the recommended range 2 to 4 and that the mains electricity and oil are turned on.

1:5.6 SWITCHING THE BOILER OFF TEMPORARILY

The Boiler may be stopped by turning the boiler control thermostat to the OFF position on the standard Control Panel, or the programme switch to the OFF position on the optional programmer. Alternatively, the Boiler may be stopped by:

1. Turning off the mains switch controlling the Boiler, or

2. Turning the programmer (if fitted to the heating

system) to its off position.

1:5.7 SHUTTING OFF FOR THE SUMMER

If the Boiler is to be shut off for the summer, it is advisable to have it thoroughly serviced. Thorough cleaning will minimise corrosion during the idle period. Remember, when the Boiler is required, to ensure that the oil supply is open before switching on.

1:5.8 SEALED SYSTEM CENTRAL HEATING

It is important that the correct operating system pressure is maintained. Your Installer should give guidance on this.

1:5.9 FROST PROTECTION

If there is any danger that your Boiler may freeze up during severe weather conditions, it is recommended that you consult your installer who will be able to advise you on an appropriate course of action, either by installing a frost thermostat or the addition of system anti-freeze.

1:5.10 OIL DELIVERY

Where possible, it is advisable to temporarily switch the Boiler off when your oil supply is being replenished. This is to allow any sediment to settle and not be drawn into the Boiler. If not this could result in an inconvenient break down.

We advise that you keep your Boiler off for one hour after the oil is delivered to your tank. Please ask your supplier, or the driver to notify you before the oil is discharged.

1:5.11 MAINTENANCE AND TROUBLE SHOOTING GUIDE

1:5.11.1 MAINTENANCE

For normal cleaning of the outside casing, simply wipe with a dry cloth. To remove stubborn marks and stains, wipe with a damp cloth and finish off with a dry cloth. DO NOT use abrasive cleaning materials.

The Boiler must be serviced at regular intervals by a qualified service engineer. Failure to have the Boiler serviced at the recommended intervals will

BOULTER BOILERS Eco-System PAGE 4

Fig. 2

REMOVING

FRONT

DOOR

LOCKOUT

RESET

Page 7

invalidate the guarantee/warranty. Using Kerosine Class C2 fuel, the Boiler should be

serviced at twelve monthly intervals to ensure that the efficiency and performance of your boiler is maintained.

Please also note that on conventional flue models, it is possible for the air intake at the rear of the Boiler casing to become blocked with household debris.This air intake must remain clear at all times and so it is advisable to inspect and clean this area regularly. Please refer to section 1:2.2 in this booklet.

Flue Terminal Pluming

Due to the high efficiency of the Eco range white water vapour from the flue discharge - called pluming may be observed from time to time under certain weather conditions. This is perfectly normal and should be no cause for concern.

1:5.11.2 FAILURE TO START

If the Burner fails to start, adopt the following procedure:

1. Check that there is oil in the tank and that the supply valve is open.

2. Check the programmer or time switch to ensure that it is operating and set to the correct time to be “ON”.

3. Check that the Boiler Control Thermostat is set high enough to be “ON” or calling for heat.

4. Check whether the limit thermostat has tripped. Press the reset button once the temperature has dropped sufficiently.

5. Check whether the burner has gone to lockout and the indicator lamp on the control box is lit.

Press the reset button on the Control box, when released, the lights will go out and the Burner will again attempt to start. If the Burner does not run and again goes to lockout with red indicators glowing:

◆ Wait three minutes.

◆ Repeat the procedure by pressing the button.

◆ Failure to start on the second attempt indicates

a fault requiring attention.

◆ Switch off the mains supply and call your service engineer.

BOULTER BOILERS Eco-System PAGE 5

Page 8

2:1 INTRODUCTION

This Manual covers Installation, Commissioning and Maintenance of the Eco Boilers.

The Eco boiler is:

1. Designed for Central Heating and Hot Water.

2. Not suitable for open vented systems.

3. Suitable for sealed Central Heating systems

which are within the maximum permitted working pressure. All Boilers are supplied with a manual reset limit thermostat.

4. Suitable for new installations and for replacing

existing boilers. Eco Boilers offer greater freedom to select the

most suitable position for siting and the opportunity to install the boiler in a suitable outbuilding if required.

All models are supplied as standard with low level horizontal firing Oil Burner, they are suitable for connection to a conventional chimney or any of the Camray 5 Balanced Flue options. Note: The nozzle on this appliance is only covered by a 1 year guarantee.

2:2 FLUE OPTIONS

Eco Boilers are designed to operate with high efficiency, clean combustion and low noise level. They offer unique versatility and can be used in the following modes:

1. Low level rear outlet balanced flue.

2. High level rear outlet balanced flue.

3. Vertical outlet balanced flue. (Insulated balanced draught chimney).

4. High level side outlet balanced flue.

5. For connection to a conventional chimney (via conventional Flue Kit, 12/26 Part No. FC4CF).

6. Other options ma

y be available. Please contact

Boulter Boilers.

The tested balanced flue terminals and connections afford an adequate supply of air for combustion and equalisation of pressure between exhaust and intake as required for operation under unfavourable wind conditions.

Balanced flues are supplied in a carton which includes ALL parts for balanced flue installation.

The horizontal terminals are designed to avoid the possibility of staining outer walls through which they pass.

2:3 COMMISSIONING

It is essential in the interest of boiler efficiency and reliable performance that once the boiler has been installed it is first commissioned by a qualified engineer.

If an engineer is not known, Boulter Boilers will be pleased to provide details of commissioning and servicing engineers from their register.

See Section 7 for Commissioning Procedure.

It is the responsibility of the installer

to ensure that the boiler is

commissioned by a competent engineer,

preferably an OFTEC* Registered

Commissioning Engineer.

*The Oil Firing Technical Association for the Petroleum Industry, Banstead, Surrey

☎ (01737) 373311.

2:4 SAFETY READ HEALTH AND SAFETY INFORMATION

ON INSIDE FRONT COVER OF THIS MANUAL.

IMPORTANT

Should you wish to remove or

dismantle any covers or parts of the

boiler for cleaning or maintenance

ALWAYS FIRST SWITCH OFF THE

ELECTRICITY SUPPLY.

1. On no account should any part of the Boiler or its Flue be modified with the exception of flues which require adjusting to length to suit site conditions, as detailed in this manual.

2. The wiring of the control panel should be as the wiring diagrams included in this Manual. Wiring should not be tampered with, modified or changed for any reason.

3. Only use Boulter replacement parts. Non compliance with the above will invalidate the

Guarantee.

BOULTER BOILERS Eco-System PAGE 6

IMPORTANT

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BOULTER BOILERS Eco-System PAGE 7

3:1 LIQUID FUELS

Eco Boilers will burn liquid fuels complying with BS2869 Part 2 1988 Class C2 as specified in the Code of Practice for Oil Firing BS5410 Part 1.

Class C2 (Kerosine)

This fuel is suitable for all Eco models. Burners are supplied with the appropriate nozzle and pump pressure as standard for this fuel. They are set for mid-range output. Details of all nozzle sizes and pump pressure for all outputs are shown on section 3.6.

3:2 BOILER TECHNICAL DETAILS

Maximum Boiler working pressure 3 Bar - 30.6m Water Head Minimum recommended return water temperature 60°C Maximum hearth temperature less than 85°C. Maximum side panel temperature less than 35°C above room temperature. Minimum Conventional flue draught at boiler flue outlet 0.035”w.g. (8.75N/m

Maximum Conventional flue draught at boiler flue outlet 0.15”w.g. (37.5N/m

Water Resistance Less than 300 m.m.w.g.

with 11°C temperature rise across the boiler.

3:3 BURNER DETAILS

Burner type - RIELLO 484T50, 483T50 or 487T50 Pressure Jet - supplied as standard. Manually

adjustable air regulator. The burner must be set to details given in section

3.6.

For further details of the burner, refer to the burner data sheets supplied in the literature envelope.

3:4 ELECTRIC’S

Electrical Supply 230v., 1 Ph., 50Hz.

The Electrical Installation of this

appliance must be performed by a

suitably qualified electrical

engineer/installer.

All wiring to supply and all system components external to boiler must comply with the latest edition of BS7671:1992 formerly IEE Wiring Regulations.

This appliance must be effectively earthed and connection to the supply must be through a double pole isolating switch fused 5 amp.

The isolating switch must have all pole contact separations at least 3mm

IMPORTANT

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BOULTER BOILERS Eco-System PAGE 8

3:5 DIMENSIONS

Model

12/19

19/26

Output

Btu/h

x 1000

11.7/ 19

40/65

19/

26.4

65/90

ABCDEFGHJ

Flue

mm mm mm mm mm mm mm mm mm

insøins

860 596 446 130 121 540 55 65 92 4"

BSP

860 596 446 130 121 540 55 65 92 4"

BSP

Weight

Empty

Kgs

112

114

Water

Content

Filled

Weight

Kgs

130

135

Litres

17.5

21.0

* Conventional Flue Size

FLOW CONNECTION

RETURN CONNECTION

FLOW CONNECTION

*15.00

50.00

50.00 50.00

20mm ET KNOCKOUT

Page 11

BOULTER BOILERS Eco-System PAGE 9

3:6 COMMISSIONING DATA

12/19 19/26

Maximum Temperature of Adjustable Controls Control Stat 85

C +/- 2oC

Limit Stat 110

C +0/-6oC

Maximum Emissions Limit (Class 1) NOx 250 mg/kWh-CO 125 mg/kWh

Range of Temperature Control Control Stat 0 - 85

Exit Flue Gas Mass Flow Kg/Sec x 10

-3

Heat Input (Full Load) kW (based on Net 22.1 29.0

efficiency of 91%)

Heat Output (Full Load) kW 19 26.4

1. There are two columns in the table for combustion gas temperature:FLUE EXIT temperature, and BOILER TEST POINT temperature.

2. Where possible CO2, smoke and flue gas temperatures should be sampled from the FLUE EXIT (i.e. external balanced flue discharge, or from the test point provided in the conventional flue adaptor)

3. These figures may be used to calculate combustion efficiency.

4. Alternatively (where the forgoing is impractical such as vertical BF) gases can be sampled at the BOILER TEST POINT inside the casing. Because the gas temperatures at this point are significantly higher it should not be used to calculate or measure efficiency.

5. If the BOILER TEST POINT temperature agrees with the data in Table 3:6.1, then use the appropriate FLUE EXIT temperature from the table to calculate the combustion efficiency.

6. On conventional flue only - flue draught should be measured at the flue exit test point.

3:6.1 Class C2, Kerosene Oil RIELLO BURNER

Model

12/19

19/26

Output

Riello RDB TYPE

Nozzle Danfoss Delevan

US/GPH

Pump

Pressure

Btu/h

x1000

11.7

16.1

23.4

26.4

0.4x60oES

0.5x60

0.6x60

0.75x60oW

0.85x60

7.0

8.0

7.6

7.2

8.0

100

115

110

105

115

BAR psi

Boiler

Test Point

Temp oC

215-245

260-285

295-320

280

304

335

Flue Exit

Temp

Gross

165-195

180-225

180-245

180

200

204

Smoke

No.

C02

483T50

484T50

101.08

111.49

121.76

101.76

112.17

122.41

0-1

Fuel Rate Kg/h

LOW 6.69 9.61 MID 8.46 11.84 HIGH 9.24 12.79

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BOULTER BOILERS Eco-System PAGE 10

4:1 STANDARDS & REGULATIONS

The installation of the Boiler must comply with the latest edition of :

BS 5410 Oil Installations

Pt 1 up to 44kW;

Pt 2 and over 44kW BS 5449 Forced circulation hot water central heating systems for domestic premises. BS 4543 Pt. 1 & 3 Factory made insulated

chimneys.

BS 7593 Code of practice for the treatment of

water in domestic hot water central heating systems.

BS 7671 (1992) Electrical Wiring Regulations.

BUILDING REGULATIONS.

Part J&L England and Wales

Part F Section III Scotland

Part L Northern Ireland

The Control of Pollution (Oil) Regulations

Oil boilers should be installed in accordance with good practice as recommended by OFTEC (Ref. 2:3 Commissioning page 6).

4:2 THE HEATING SYSTEM

This should be installed in accordance with current good practice as advised by HVCA. It is not the purpose of the manual, nor is it possible, to adequately deal with the subject in this manual.

When designing and installing the controls of the heating system, it must be remembered that if the control system is such that the water circulation through the boiler can be totally or substantially reduced whilst the oil burner can still fire, the water in the boiler will reach very high or boiling temperature before the boiler thermostat can sense it and switch off the Burner.

If this condition is likely wire the controls so that the electrical supply to the burner is switched off simultaneously with the stopping of circulating pumps or the closing of motorised valves.

On existing heating systems where a Boiler is replaced, ensure that the system is chemically cleaned.

The system should contain clean water and be free from leaks. Suitable inhibitors against limescale and corrosion should be added to the system. Refer to BS 7593.

Kettling and system noises can be avoided by suitable pre-treatment (i.e. Chemical Cleaning) at the onset.This is essential when fitting a new boiler to an existing system.

4:3 SITING & POSITIONING

The noise level from Eco boilers is quite low and kitchen installations have not given rise to complaints. Consideration must be given however, to the following points.

1. Noise may be accentuated by the installation in small rooms or recesses with hard or hollow stud wall surfaces. Due consideration to the siting of boilers should be given.

Further advice from BOULTER BOILERS should be sought where any doubt exists.

2. Some individuals may be particularly sensitive to even low noise levels and this should be discussed before installation.

3. The type of chimney, position relative to the boiler and whether a draught stabiliser is to be fitted may affect sound level in the room.

4. The 12/19 & 19/26 Boiler models are serviced from the front. A space of 450mm (18”) in front should be available.

4:4 THE HEARTH

The Eco boilers have a Hearth Temperature of less than 85°C. The boiler requires a level hearth on which to stand which should comply with the Building Regulations.

If the Boiler is to stand on a floor made of combustible material then protection between the Boiler and the floor should be provided by means of non combustible material.

Consideration should be given to the Weight of the Boiler and the Building Regulations regarding floor loading.

The filled Boiler weight can be found in 3:5.

Advice should be sought from your local Building Control Office if there are any doubts regarding the floor supporting the Boiler.

Page 13

BOULTER BOILERS Eco-System PAGE 11

4:5 THE CHIMNEY - (FLUE Ø 4” OR 5”)

CONVENTIONAL CHIMNEY INSTALLATION ONLY.

VERY IMPORTANT All Eco boilers are supplied in Balanced Flue

Form. To connect either size of boiler to a

conventional chimney you must use The Conventional Flue adaptor FC4CF.

This includes all parts necessary to make the connection to the boiler. A test point is also provided for ease of installation and commissioning. Secure the air duct in the clip provided.

The use of this adaptor is essential for safe performance and is a condition of the guarantee that this must be fitted.

The boiler requires a minimum stable draught of

0.1 mbar (0.04w.g.). If the chimney exceeds 6m (20 feet) in length, it

may produce a draught exceeding 0.37 mbar (0.15” w.g.) and a draught stabiliser should be fitted.

The chimney should comply with the latest edition of the Building Regulations and BS 5410: Part 1.

Factory built chimneys must comply with the Building Regulations and BS 4543 Parts 1 and 3.

Compliance with the Building Regulations does not indicate that the chimney is satisfactory in respect of draught conditions, or is positioned so that ‘down draughts’ will not occur.

Special pots and cowls which might restrict the flow

of gases must not be fitted and should be removed. A brick chimney must be fitted with a suitable

stainless steel liner. Insulation between the liner and an exposed chimney may be necessary to avoid condensation.

A flexible liner should be the same diameter as the Flue Offtake size of the boiler - 4”(100mm) or 5” (125mm). (see page 8)

The Flue pipe, connecting the boiler to the chimney adaptor should be the same diameter as the Boiler Flue Offtake and should not be more than 1.8m (6’-0”) long. Flue Pipes when fitted should satisfy or be ‘deemed to satisfy’ the Building Regulations.

Flue pipe bends - 90° bends must not be used use 135° bends. Bends with soot doors should be used where necessary

FOR BALANCED FLUE INSTALLATIONS SEE SECTION 6.

4:6 AIR SUPPLY

CONVENTIONAL CHIMNEY INSTALLATION ONLY A permanent adequate supply of air is required for

combustion and correct operation of a draught stabiliser, if fitted.

This air enters the Boiler through the back panel. At least 15mm clearance is required at the rear of all boilers.

When the boiler is situated in a confined space or chamber a permanent adequate supply of air is required for ventilation to prevent over heating.

4:6.1 Opening Sizes

The clear opening required for combustion only should be based on a requirement of 550mm

/kW,

(or 1in

per 4000 Btu/h) above 5kW

When a draught stabiliser is fitted to the flue pipe or chimney in the room in which the boiler is situated the clear air intake should be 1100mm

/kW.

When the boiler is situated in a confined space with Combustion or Ventilation air from outside - Allow 550mm

/kW at low level and in addition

550mm

/kW at high level;

When Combustion and Ventilation air is taken from a heated adjoining space the allowance should be 1650mm

/kW at low level and in addition

1100mm

/kW at high level. Ensure that the heated adjoining space itself has an adequate supply of air.

When the Boiler is installed in a basement or low level boiler house where air can enter only from high level, the incoming air supply for Combustion and Ventilation should be ducted to low level. A high level outlet should be provided for ventilation.

Gasket

(foil face

up)

Test Point

Air Duct

Securing Clip

Nuts

Conventional Flue Adaptor

Fig 3

Page 14

BOULTER BOILERS Eco-System PAGE 12

4:7 OIL STORAGE

4:7.1 Oil Tank

Consideration to the access by fuel delivery lorries should be given when positioning the oil tank.

Tank positioning should be in accordance with BS 5410 Part 1 and OFTEC Technical Book 3.

In the interest of most economical deliveries the Oil Tank should be of 3,000 litres (600 gallons) capacity.

It should be complete with the following:

1. Sludge Cock - on steel tanks.

2. Outlet Valve.

3. Contents Indicator.

4. Screw fill connection and independent vent. The Fill and Vent should be suitably capped to prevent ingress of water or fitted with return bends.

4:7.2 Steel Tanks

Tanks should be mounted on suitable supports, if these are of brick or blocks, a damp proof membrane should be inserted between the tank and its supports.

Tanks should slope 20mm per 1m of length downwards from the Oil Outlet to the Sludge Cock situated at the opposite end.

4:7.3 Plastic Oil Tanks

Tanks made from plastic are now available. These should be UV stabilised for protection against sunlight, and coloured green. Plastic tanks do not need to stand on piers, but should be supported across the entire base area, ideally on 50mm thick garden slabs or a concrete base. As there is only one tapped outlet they are more suited to single pipe feed as gravity supply or with a Boulter 3K Oil Loop Deaerator where suction lift is required. (Part No. BS 03060)

4:8 OIL SUPPLY

The oil entry holes in the boiler casing are shown in the diagram in Section 3:5 of this manual. Flexible Hoses supplied with the Boiler MUST NOT pass through these holes.

All joints in the Oil Lines must be oil tight and the Oil Line should be flushed clean before connecting to the burner.

Note that no soldered joints are permissible in the oil line.

4:8.1 Oil Filter

An Oil Filter is supplied with the Boiler.

Connections are 1/4 BSP Female, see fig. 4:8c.

It is essential for reliable operation that the Oil Filter is fitted in the Oil Pipe supplying Oil from the Tank to the Burner. It should be fitted as close to the Boiler as practicable, but NOT inside the Boiler casing.

It is a condition of the guarantees that the Filter is fitted correctly.

4:8.2 Fire Check Valve (Not Supplied)

A Remote acting FIRE VALVE* must be fitted in the suction line at the time of installation - see BS 5410: Part 1.

The valve must be fitted external to the Boiler, preferably at point where the Oil Pipe enters the building. The sensor should be located above the Burner in the clip provided, see figs. 4:8b, 4:8d & 4:8f.

The entry point for the Fire Valve Sensor should be through any of the 20mm ET knockouts located at the top of the rear casing, or side panels.

To prevent damage to the capillary always pass the sensor through the blind grommet (supplied), it will be necessary to cut across the diaphragm.

*Remote Acting Fire Valves are available from Boulter, through your merchant or installer e.g.

Ref: Operating Capillary

Temperature Length

RAF9015C 90

C 1.5m

RAF9030C 90

C 3.0m

RAF9060C 90

C 6.0m

RAF9090C 90

C 9.0m

4:8.3 Single Pipe System

Fig. 4:8b If the bottom of the Oil Tank is above the oil Burner,

install a 10mm copper supply pipe to the Burner incorporating the correct Filter, Shut Off Valve and Fire Check Valve.

Ensure that the Burner Oil Pump is correctly set for ‘Single Pipe’ operation. (See 4:9.2).

4:8.4 Two Pipe System

Fig. 4:8d When the bottom of the Oil Tank is below the level

of the Oil Pump on the Burner it is necessary to install an additional 10mm return pipe.

The Oil Filter, Shut Off Valve, spring loaded NonReturn Valve and Fire Check Valve are always in the suction line supplying oil from the Tank to the Burner.

The Non-Return Valve must be fitted to allow the

Page 15

BOULTER BOILERS Eco-System PAGE 13

Fig. 4.8a

Flexible Oil Pipes and Fire Check Valve

Flexible Hose

Ball Valve Burner

flow in the correct direction and prevent drain back to the Tank, see fig. 4:8e.

Ensure that Valves are NOT fitted in the Return Line. The Return Line must be unobstructed at all times.

Ensure that the Burner Oil Pump is correctly set for ‘two Pipe’ operation. (See 4:9.1)

4:8.5 Deaerator Oil Pipe System

Fig. 4:8f An alternative two pipe arrangement can be

achieved using a 3K-Oil Loop Deaerator which removes the air from the oil feed on a single pipe lift. The Burner Pump is piped to the Deaerator, which should be positioned close to the burner, but NOT inside the Boiler Case. A Non-Return Valve

is not required in the return line.

The advantage of this system is gained where a two pipe run from the oil supply tank is long or difficult to achieve.

Boulter 3K Deaerators are available as an optional extra from your merchant (Part No. BS 03060).

4:8.6 Water Separator Oil Filter

For changeover applications, the use of a Water Separator Oil Filter, available from BOULTER BOILERS is recommended (BS03052).

4:8.7 Flexible Oil Pipes

The Flexible Oil Pipes are fitted inside the Boiler casing and are of adequate length to enable the Burner to be removed without disconnecting.When fitted correctly the pipes should be curved round the Burner as shown in Fig.4:8a.

Page 16

BOULTER BOILERS Eco-System PAGE 14

OIL CONNECTIONS SEE BELOW

FIRE CHECK VALVE

ALTERNATIVE FILTER POSITION

TOTAL PIPE LENGTH ‘L’

FIRE CHECK VALV E SENSOR

FILTER

SLUDGE COCK

OIL TANK

SCREW FILL

20mm / metre FALL

INDEPENDENT VENT

4 Metres MAXIMUM

SINGLE PIPE OIL SYSTEM - TANK OUTLET ABOVE BURNER

DO NOT FIT PUMP BYPASS SCREW TO BURNER - SEE 4.9.2

H METRES 0.5 1.0 1.5

2.0

Burner to supply 20 40 80 100

KEROSENE

10mm OD

PIPE

TABLE GIVING MAXIMUM PIPE LENGTH 'L' METRES

Fig. 4:8b Single Pipe Oil System.

RIELLO BURNER PUMP

NO BYPASS SCREW

FITTED

SINGLE PIPE OIL SYSTEM - OIL CONNECTIONS

Items 1 - 5 NOTsupplied with Boiler

ITEM PART QTY CODE

1 Filter 25I 1 BS 00496

2 Ball Valve 1 BS 03041

31/4'' BSP x 10mm Coupling 1 FS 00151

4 Longlife Hose 900mm 1 BS 03101

5 Grommet 3 RP00610

BOILER CASE

10MM DIAMETER SUPPLY TUBE

LH & RH FUEL ENTRY AVAILABLE (LH SHOWN) SCHEMATIC DIAGRAM FIT HOSE AS SHOWN IN FIG. 4:8a

PLUG

Fig. 4:8c Schematic Oil Pipe Connectors

Camray 5

Camray 5 Utility

Page 17

BOULTER BOILERS Eco-System PAGE 15

RETURN PIPE

NON RETURN VALVE

ALTERNATIVE FILTER POSITION

SUCTION PIPE ‘L’ MAX

FIRE CHECK VALV E SENSOR

FILTER

OIL TANK

SCREW FILL

INDEPENDENT VENT

TWO PIPE OIL SYSTEM - TANK OUTLET BELOW BURNER

FIT PUMP BYPASS SCREW TO BURNER

FIRE CHECK VALV E

SAW CUT OR SMALL HOLE IN RETURN PIPE INSIDE TANK TO PREVENT SYPHON

H METRES 0.5 1.0 1.5

2.0

Burner to 100 100 90 70

supply

KEROSENE

10mm OD

PIPE

TABLE GIVING MAXIMUM PIPE LENGTH 'L' METRES

Fig. 4:8d Two Pipe Oil System.

RIELLO BURNER PUMP

WITH BYPASS SCREW

FITTED

TWO PIPE OIL SYSTEM - OIL CONNECTIONS

Items 1 -5 are supplied with the Boiler. See Fig 4:8c.

BOILER CASE

10MM DIAMETER SUPPLY TUBE

LH & RH FUEL ENTRY AVAILABLE (LH SHOWN) SCHEMATIC DIAGRAM FIT BOTH HOSE AS SHOWN IN FIG 4:8a

10MM

DIAMETER

RETURN

TUBE

Fig. 4:8e Schematic Oil Pipe Connectors

Items 6 -10 NOT supplied with boiler.

ITEM PART QTY CODE

6 Non Return Valve 1 BS 00538

8 Longlife Hose 900mm 1 BS 03103

9 Washers 2 FS 00159

/8'' BSP x 10mm Coupling 3 FS 00157

Camray 5

Camray 5 Utility

100

Page 18

BOULTER BOILERS Eco-System PAGE 16

3K OIL DEAERATOR MUST BE INSTALLED UPRIGHT OUTSIDE BUILDING

DO NOT FIT NON-RETURN VALVE

TOTAL PIPE LENGTH

FIRE CHECK VALVE SENSOR

FILTER

OIL TANK

SCREW FILL

INDEPENDENT VENT

DEAERATOR OIL SYSTEM - TANK OUTLET BELOW BURNER

FIT PUMP BYPASS SCREW TO BURNER

FIRE CHECK VALV E

Fig. 4:8f. Deaerator Oil Systems

DEAERATOR PIPE OIL SYSTEM - OIL CONNECTIONS

LH & RH FUEL ENTRY AVAILABLE (LH SHOWN) SCHEMATIC DIAGRAM FIT BOTH HOSE AS SHOWN IN FIG 4:8c

Fig. 4:8g Schematic Oil Pipe Connections.

ITEMS 7, 8, & 10 ARE AVAILABLE AS A KIT NO. BS 03058C.

The table right shows total Pipe Length ‘L’ metres

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 6 242119161311 8 6 8 100 100 93 84 71 59 46 33

10 100 100 100 100 100 100 100 100

Pipe Size

mm O/D

Lift - H metres (3.5m Max)

3K OIL DEAERATOR

ITEM PART QTY CODE

6 3K Oil Loop 1 BS 03060

/4'' BSP x 10mm Coupling 3 FS 00151

8 Longlife Hose 900mm 1 BS 03103

'' x 10mm Coupling 1 FS 00157

Camray 5

Camray 5 Utility

Page 19

BOULTER BOILERS Eco-System PAGE 17

4:9 OIL BURNER

The Burner makers’ technical leaflet is supplied with this manual and provides supplementary information not included in this manual.

4:9.1 Burner Pump for Two Pipe and Deaerator System

For two pipe oil systems the Burner Oil Pump has to be fitted with the Bypass Screw supplied. Boilers are despatched with the Bypass Screw in a labelled envelope attached to the Burner. This socket screw is inserted into the return port as shown in Fig. 4:9a.

4:9.2 Burner Pump for Single Pipe System

The burner is supplied set for single pipe operation. The return port is plugged and the Bypass Screw is not fitted. See Fig. 4:9b.

Fig. 4.9a Burner Pump for Two Pipe Operation

Fig. 4.9b Burner Pump for Single Pipe Operation

ONLY USE BYPASS SCREW FOR ALLEN KEY (2.5MM).

DO NOT USE SLOTTED SCREW

ALLEN KEY

BYPASS

SCREW

FLOW

RETURN

FLOW

BYPASS SCREW

NOT REQUIRED

RETURN PLUGGED

Page 20

BOULTER BOILERS Eco-System PAGE 18

5:1 BALANCED FLUE BOILERS

A range of Balanced Flue Kits are available as optional extras.

Balanced Flues permit considerable choice of siting of the Boiler. Boilers may be installed in situations where no chimney exists, where the chimney is unsatisfactory or in outhouses.

It is important that care is exercised in choosing a suitable location for the Boiler and Flues. It is to be expected that with the help of this manual and the application of caring engineering experience and common sense unreasonable liberties will not be taken.

It is a mandatory requirement that:-

1. The terminals of balanced flues which can be touched are to be fitted with a guard.

Any proposed installation which deviates from the details provided or gives rise to any doubt should be referred to BOULTER BOILERS LTD. who will be pleased to consider and discuss it.

5:1.1 Balanced Flue Types

Three types are available

1. Low Level Horizontal - Rear & Side

- Discharge L/R

2. High Level Horizontal - Rear & Side

- Discharge L/R

3. Vertical (Flat or Pitched Roof) Only Kerosine fuel may be used when the Low

level Horizontal flues are installed.

5:2 HORIZONTAL BALANCED FLUES

The Terminals of Horizontal Balanced Flues should be installed on a plain surface of wall preferably not less than 900mm from internal corners of the building and away from any recesses and any projections on the wall face that could affect wind flow across it.

Listed are the general restrictions as to the positioning of Horizontal Balanced Flue Terminals. Refer to Fig 5:4a

1. Positions should be avoided where the exhaust of combustion products could cause nuisance.

2. Terminals must be situated more than 600mm distance from any opening in the building.

3. Avoid close proximity to internal corners where products of combustion may not freely disperse and may enter the air intake to the boiler.

4. Avoid positions such as narrow passageways, especially with a closed end, where easy dispersion could be adversely affected.

5. Avoid positions where the terminal may be discharging close to and in the direction of a near

neighbouring dwelling or exhausting immediately over adjoining property.

6. Avoid positioning immediately under openable windows.

7. Care should be taken to ensure that there is clearance between the outer surface of the flue and any combustible material.

8. Positioning the Flue terminal within a CAR PORT is not recommended.

5:3 VERTICAL BALANCED FLUES

Vertical Balanced Flues enables boilers to be installed in single storey outhouses or utility rooms where it may not be convenient for it to be sited near an outer wall. It may also be employed to exhaust vertically to avoid nearby windows or doors.

Vertical Balanced Flues may also be preferred in cases where close proximity to adjoining houses or property dictates minimum exhaust noises.

5:3.1 Positioning of Vertical Flues

Listed are general restrictions as to the positioning of Vertical Balanced Flues. Refer to Fig. 5:4a.

1. Avoid positions where Vertical Flues will exhaust adjacent to a higher wall.The minimum distance for operation from a higher vertical wall must be 600mm.

2. Ensure Vertical Flues do not exhaust below the level of any openable window less than 2300mm horizontally from the terminal (see BS 5410:1).

3. Care should be taken to ensure that there is clearance between the outer surface of the flue and any combustible material.

Page 21

BOULTER BOILERS Eco-System PAGE 19

5:4 POSITIONING THE BOILER

Read Sections 5:2 & 5:3 Some combustion noise occurs at the Exhaust Terminal of Balanced Flues and care should be exercised

to ensure that the position of the exhaust is not near doors or opening windows of the house it serves, or doors or windows of any neighbouring house. See Fig. 5:4a.

Fig. 5.4a Balanced Flue Terminal Positions

REF DESCRIPTION DISTANCE IN MM

A Directly below an Opening, Air Brick or Window 600 B Below a Gutter, Sanitary Pipework or Eaves 75 (600*) C From any Internal Corner 300 (900) D Above Ground 300 (600) E From a surface facing the Terminal 600 (1200) F From a Terminal facing a Terminal 1200 G Vertically between Two Terminals on the same wall 1500 H Horizontally between Two Terminals on the same wall 750 (1200)

J From any External Corner 300 (600)

Horizontally from any Opening, Air Brick, Window or Door

600

L Vertical Flue from Wall (Flat or Pitched Roof) 750

Table to above Flue Terminal Positions - MINIMUM dimensions

*Where the terminal is within 1m of any plastic material, such material should be shielded from the effects of the combustion products of the flues

NOTE:- Whilst the dimensions in BS 5410 are shown in the table, it is stressed that possible variances

in local site conditions may not always be obvious and that if in any doubt the dimensions in brackets

should be observed.

BOULTER BOILERS would be pleased to advise on any difficult positioning

RECOMMENDED FLUE TERMINAL POSITION

Terminals should be so positioned as to avoid products of combustion entering opening into buildings or other flues or vents.

Page 22

BOULTER BOILERS Eco-System PAGE 20

5:5 TERMINAL GUARDS

When the terminal is positioned where there is the possibility of accidental contact by persons, or of damage to the terminal, an approved guard is necessary (Boulter Code FL26160).

Generally, exhaust 2 metres above ground level alleviates the necessity for a guard.

A suitable guard is available from BOULTER BOILERS as shown below.

5:6 HORIZONTAL FLUE TERMINAL

The Terminal for Horizontal Balanced Flue is secured to the wall by means of four screws. The indexing plate should have its four edges siliconed to the outside wall to provide a weather seal.

5:7 BLANKING PLATES

The Boiler is supplied in Balanced Flue form. With 2 full side/rear Blanking plate and one top blanking plate.

The Blanking plates should be fitted to prevent access to hot surfaces and to maintain the efficiency of the boiler.

Fig. 5.5a

Fig. 5.6a Wall plate FL47108

Fig. 5.7a Side Panel Blanking Plate

300

265

330

160

140

185

160

Page 23

BOULTER BOILERS Eco-System PAGE 21

6:1 NOTES ON INSTALLATION

LOW LEVEL AND HIGH LEVEL BALANCED FLUES

1. The Terminal must be slightly angled down to ensure correct operation of the boiler. Due to the efficiency levels of Eco - System pluming from the terminals may occur under certain conditions. Any condensation may be acidic due to the fuel characteristics and it is advisable not to install the flue in any position where the condensation could cause damage to paint surfaces etc.

2. The Terminal index plate should be sealed to the external wall using silicon sealant or other impervious material to prevent water ingress.

3. Ensure that the outlet of the Terminal points downward (TOP upper-most and Boulter correct way up).

4. Ensure that the boiler to offtake gasket is fitted (foil face upwards) and the clamp is made with four nuts and washers securely fixed.

5. Ensure that the ‘Sealing Rings’ are fitted in the correct groove. Use a mild detergent as a lubricant to ease assembly.

6. The Flue is telescopic and no cutting

of the flue

pipes is necessary.

7. 500mm and 1000mm flue extension kits are available. Do not exceed the maximum flue lengths stated in this manual.

8. The flexible air duct is an integral part of the appliance and must be used on all balanced flue kits. Ensure that it is not damaged and that either end is connected via the jubilee clip provided to ensure correct boiler operation.

Page 24

BOULTER BOILERS Eco-System PAGE 22

6:2 LOW LEVEL HORIZONTAL FLUE

6:2.1 Rear

6:2.2 Side - Right or Left Hand

Fig. 6:2a Low Level Horizontal Rear

Fig. 6:2b Low Level Horizontal Side

Model 12/19 19/26 Dim A 770mm 770mm

160

185

See attached colour

leaflet for dimensions

Page 25

BOULTER BOILERSEco-System PAGE 23

Fig. 6:2c Low Level Horizontal Flue Assembly

LOW LEVEL FLUE INSTALLATION Site conditions will dictate to a certain extent the

best method of assembling low level balanced flues.

The illustration shows a typical rear outlet flue. Assemble the flue generally as follows:

1. Position boiler check that water connections and flue proposed is according to clearances specified.

2. Mark flue position.

3. Move boiler away from the wall and using a diamond tipped core drill drill a 6” (150mm) hole, ensuring the hole is horizontal.

4. Remove rear top panel of boiler and identify flue outlet (rear, LH or RH side). Move blanking plate to appropriate position using nuts and washers.

5. Ensure flue exhaust seal is in position and in good condition, ie undamaged. Lubricate with a mild detergent.

6. Place boiler offtake gasket in position on top of boiler (foil face upwards).

7. Lay internal flue in appropriate position in boiler and offer up to hole in wall.

8. Secure internal flue to boiler via four nuts and washers as supplied.

9. Remove outer terminal 4 screws and put terminal to one side.

10. Taking outer air duct ensure Seal is fitted and in good condition. Lubricate with a mild detergent.

11. Ensuring that there is no wall debris present in either ducts slide outer air duct into inner air duct.

12. Using the four holes on the external wall plate as a guide drill four fixing holes into the external wall.

13. Replace the outer air duct and pushing firmly home screw into position (4 screws).Weather seal all edges.

14. Taking the terminal end keeping it square to the external flange push home over the internal flue exhaust pipe until the four holes on the flange align. NB Ensure that TOP is on the upper most surface of the terminal and ‘Boulter’ is upright.

15. Secure the terminal to the flange using the four screws.

16.Fit an approved terminal guard if in an accessible position. Available from Boulter Boilers.

17. Inside: Using the clips supplied fix the flexible air duct

to the burner spigot and flue offtake securely.

Continue on with the rest of the installation.

TOP

INNER SEAL

OUTER SEAL

Page 26

BOULTER BOILERS Eco-System PAGE 24

6:3 HIGH LEVEL HORIZONTAL FLUE

6:3.1 Rear

Fig. 6:3a High Level Horizontal Rear

66.5mm

See

attached

colour

leaflet for

details

DIM ‘A’ 135mm

See attached colour

leaflet for details

Page 27

BOULTER BOILERS Eco-System PAGE 25

Fig. 6:3b High Level Horizontal Flue Assembly

HIGH LEVEL SIDE & REAR INSTALLATION Assemble the flue generally as follows:

1. Position boiler check that all water connections and proposed flue position are according to clearances specified.

2. Mark the flue position on the wall.

3. Move the boiler away from the wall and using a diamond tipped core drill drill a 6” 150mm hole in the wall ensuring the hole is level.

4. Remove the top panels of the boiler and fit the appropriate blanking plate to rear panel using the nuts and washers provided.

5. Fit the boiler offtake gasket to the four studs and fit offtake spigot with the four nuts and washers provided.

6. Ensure the flue exhaust seal is in position and undamaged. Lubricate with a mild detergent.

7. Fit the vertical flue offtake plate to the rear top panel of the boiler and fit the assembly into position over the vertical offtake spigot.

8. Take the 1000mm vertical extension and fit an O Ring seal to the outer duct, lubricate with a mild detergent and ensure that the flue exhaust seal is fitted to the inner duct undamaged and in the correct orientation.

9. With the seals fitted slide the extension into the offtake

socket external O Ring end first.

10. Take High Level elbow fit larger O Ring seal to short arm,

lubricate with a mild detergent and ensure flue exhaust seal is fitted to the inner duct undamaged and in the correct orientation.

11. Ensuring there is no debris in the wall place longer arm

through drilled hole and slide into second extension being careful not to scratch metal work.

The high level elbow must be slightly sloped downwards.

12. Using the drill provided drill 6 holes as indicated on the

drawing and secure with the self tapping screws supplied.

13. FROM OUTSIDE Remove the outer terminal four screws and put terminal to

one side.

14. Taking outer air duct ensure Seal is fitted and in good

condition.

15. Check wall cavity for debris and remove if necessary. Slide

the outer air duct into the inner air duct until home.

16. Using the four holes on the external wall plate as a guide

drill four fixing holes into the external wall to suit those supplied.

17. Replace the outer air duct and pushing firmly home screw

into position (4 screws). Weather seal all edges.

18. Taking the terminal end, keeping it square to the external

flange push home over the internal flue exhaust pipe until the four holes on the flange align.

NB. Ensure that TOP is on the upper-most surface of the

terminal and BOULTER is upright.

19. Secure the terminal to the flange using the four screws.

20. Fit an approved terminal guard if in accessible position.

Available from Boulter Boilers.

21. INSIDE Use the clips supplied to fix the air duct to the burner spigot

and vertical flue offtake spigot

Continue with the rest of the installation.

drill

Page 28

BOULTER BOILERS Eco-System PAGE 26

Fig. 6:3d High Level Horizontal Flue Side

6:3.2 Side - Right or Left Hand

See attached colour

leaflet for details

See attached colour

leaflet for details

323mm

66.5mm

Page 29

BOULTER BOILERS Eco-System PAGE 27

6:4 VERTICAL FLUE INSTALLATIONS

6:4.1 Notes on installation

Site conditions will dictate the best method of assembling the vertical balanced flue.

Illustrations fig 6:4a & b show typical flat roof installations and illustrations fig 6:4c & d show typical pitched roof installations.

Refer to 6:6 for details of extensions required. The flue system is telescopic and the extensions fit between the vertical offtake spigot and the flue terminal.

Ensure at least 50mm overlap. Remove the rear top casing panel and fit the

vertical offtake spigot to the boiler using the four nuts and washers - sandwiching the gasket supplied between the boiler and spigot.

Where a flue system passes through a joist frame it is essential that the integrity of the ceiling fire barrier is retained. The optional extras - joist sleeve and support plate are recommended.

Alternatively this can be achieved by following the Building Regulations.

Joints in the flue must not be situated within the joist space.

Joints must be a minimum of 150mm below ceiling height.

Flue parts are assembled by sliding them together. The seals must be lubricated with the mild detergent supplied to assist fitting and sliding of parts. When flue parts have been set the desired length they should be drilled and self tapping screws used to fix them.

When preparing the ceiling/roof for the flue above the boiler it is advised to place the boiler in position, check locations of flow and return connections, oil supplies and general clearances. When satisfied mark the ceiling for cutting appropriate hole/s. Cover or move the boiler during the ceiling/roof preparation. Holes should be cut close to the size of the flue, say 10mm clearance.

A ceiling trim is provided which is slid onto the extensions during assembly and installation and is screwed to the ceiling. When the installation of flue extensions is complete finish off flashing, fit the cravat and seal between the cravat and flue with a suitable weather proof sealant. Slide on the terminal and secure with screws.

Using the clips provided connect the flexible air duct to the burner spigot and the other end to the flue offtake spigot.

Page 30

BOULTER BOILERS Eco-System PAGE 28

6:4 VERTICAL FLUE FLAT ROOF INSTALLATION

Fig. 6:4a Vertical Flue - Flat Roof

Page 31

BOULTER BOILERS Eco-System PAGE 29

Fig. 6:4b Vertical Flue - Flat Roof Assembly

Rain Cap

Air Entry Shield

Vertical Terminal Body

Ceiling Trim

Page 32

BOULTER BOILERS Eco-System PAGE 30

6:4 VERTICAL FLUE PITCHED ROOF INSTALLATION

Fig. 6:4c Vertical Flue - Pitched Roof

Page 33

BOULTER BOILERS Eco-System PAGE 31

Fig. 6:4dVertical Flue - Pitched Roof Assembly

Rain Cap

Air Entry Rain Shield

Vertical Terminal Body

Flue Support Quadrant Kit

Page 34

BOULTER BOILERS Eco-System PAGE 32

6:5 HIGH LEVEL FLUE LENGTH ALTERATION

There is a certain amount of adjustment available on the vertical height and horizontal length. This is attained by pushing two telescopic flues together until the desired dimension is obtained. Secure

any vertical lengths by using a drill and 4 self tapping screws supplied.

6:6 QUICK FIT FLUE SYSTEMS

Page 35

BOULTER BOILERS Eco-System PAGE 33

7:1 COMMISSIONING

It is essential in the interest of boiler efficiency and reliable performance that once the boiler has been installed it is first commissioned by a competent engineer, preferably an OFTEC commissioning engineer.

If an engineer is not known Boulter Boilers will be pleased to provide details of commissioning and servicing engineers from their register.

Commissioning must be carried out at the point of first firing.

Incorrect emissions can cause premature fouling of the flue ways.

7:2 RESPONSIBILITY

It is the responsibility of the installer to ensure that the boiler is properly commissioned. It is essential that the commissioning procedures detailed in this manual are carried out by a qualified engineer using recognised test equipment.

It is recommended that the relevant section of BS 5410: Part 1: latest edition is carefully read.

7:3 REPORTING

It is recommended that you use a report sheet and check list. Make comments on the report where necessary, and give a copy to whoever has engaged your services, and retain and file your own copy. A suggested layout is shown over.

It is the responsibility of the installer

to ensure that the boiler is

commissioned by a competent engineer,

preferably an OFTEC* Registered

Commissioning Engineer.

IMPORTANT

Page 36

Tick off each item

OIL TANK

❐ Is there sufficient oil, and of the correct grade for the appliance?

❐ Is the tank adequately supported? ❐ Is a damp-proof membrane inserted between

the tank and support? (Non plastic tanks). ❐ Does the tank slope at least 20mm per metre

of length downwards towards the sludge cock? (Non plastic tanks).

❐ Is the tank painted or suitably protected externally?

Is the tank fitted with the following:

❐ Contents gauges ❐ Screw fill and indepentant vent cover or

capped fill and vent pipes.

❐ Outer valve ❐ Filter ❐ Sludge cock (Non plastic tanks).

HEIGHT OF TANK

❐ Is the bottom of the tank above the oil pump if a single pipe system is installed?

OIL SUPPLY LINE

❐ Ensure that galvanised iron has not been used. ❐ If black iron has been used, is it protected

against corrosion? ❐ Ensure that soldered connections on copper

pipes have not been used. ❐ Is the size of the pipe adequate for the boiler

rating?

❐ Are all joints leak proof? ❐ Is a fire valve fitted? ❐ Is a filter fitted? (correct way round) ❐ Is the oil line connected to the correct inlet

connection of the pump?

❐ Is the oil supply clean and free of water or other contamination?

❐ Disconnect the oil supply as close to the burner as possible and drain approximately a gallon of oil into a very clear container. Inspect the oil for impurities and repeat the process if necessary.

Do not re-connect the oil line until water and all impurities have been removed from the oil supply.

IF NOT THIS MAY DAMAGE THE PUMP. ❐ Clear oil filters and de-sludge the tank if

necessary.

TWO PIPE OIL SYSTEMS

❐ Is a spring-loaded non-return oil valve fitted in the suction line? (or a 3K Oil Deaerator).

❐ Does the return oil line terminate in the take at the same level as the suction outlet?

❐ Has an anti-syphon cut been made in the return oil line (inside the tank)?

BOILER

❐ Is the boiler standing on a level incombustible hearth?

❐ Are the thermostat phials inserted in their pockets?

❐ Are the baffles and bottom insulation (where applicable) correctly located?

❐ Is the boiler set for the fuel being supplied? ❐ Has the system and boiler been filled with

water and inhibitor as required? ❐ Is the boiler flueway inspection cover screwed

down sufficiently firmly to form a seal?

BOULTER BOILERS Eco-System PAGE 34

7:4 BOULTER BOILERS RECOMMENDED COMMISSIONING CHECK LIST - SHEET 1 OF 2

Customer...............................................

Site Address ..........................................

...............................................................

Appliance Model....................................

Serial No................................................

Fuel........................................................

Page 37

BOULTER BOILERS Eco-System PAGE 35

CASING PANELS

❐ Have grommets been fitted to relevant oil supply entry points (knockouts)?

❐ Does electrical cabling pass through a grommet to prevent chaffing?

BURNER

❐ Is the oil pump by-pass screw fitted, if applicable?

❐ Remove the burner. Is the correct nozzle fitted?

NOTE:- Burner operating instructions can conflict because they are intended for general guidance. Since the burner has been specifically matched to the particular boiler, the information in the Boiler manual takes precedence.

FLUE AND CHIMNEY

❐ Is the flue adequately sized for the appliance rating?

❐ Is the flue free of any obstruction? ❐ Has the chimney been adequately lined and

insulated? NOTE:- Lining the flue and back filling will help

prevent condensate problems

BALANCED FLUE APPLIANCES

❐ Is the correct flue kit fitted? ❐ Is the Flue off take correctly secured to the

boiler by four nuts and washers. Is the gasket provided fitted correctly?

❐ Has the rear Air Entry Plate been fitted with Blanking Plates where necessary?

❐ Can leakage from flues tubes or air ducts occur? All seals fitted correctly?

❐ Is the sampling test point (on high level or vertical kits) resealed?

VENTILATION

CONVENTIONAL FLUED BOILERS ❐ Is the ventilation opening from the outside to

the boiler room adequate? ❐ Is there sufficient clearance for air to enter the

Boiler at the rear of appliance? ❐ Will any ventilation fans prevent adequate

supply of combustion air? ❐ Is the CF adaptor fitted correctly to the boiler

with all nuts and gaskets? ❐ Is the sampling test point resealed?

ELECTRICAL POWER SUPPLY

❐ Is the electrical supply to the appliance appropriate?

❐ Are the electrical input connections to the control panel correct?

❐ Is the supply fuse correct? ❐ Does the wiring comply with the latest IEE

regulations? ❐ Does the power supply cable enter the casing

through a grommet?

GENERAL

❐ Has the boiler been installed in accorandance with manufacturers instructions?

7:4 BOULTER BOILERS RECOMMENDED COMMISSIONING CHECK LIST - SHEET 2 OF 2

Page 38

BOULTER BOILERS Eco-System PAGE 36

7:5 BOULTER BOILERS RECOMMENDED COMMISSIONING TESTS

❐ Have the manufacturers on-site assembly instructions been followed?

COMMISSIONING TESTS

❐ BEFORE ATTEMPTING TO START THE BOILER PLEASE THOROUGHLY CHECK ALL ITEMS ON THE COMMISSIONING CHECK LIST. THIS WILL HELP TO AVOID UNNECESSARY CALL BACKS

❐ ENSURE THAT THE BOILER IS MATCHED MOST CLOSELY TO THE HEATING SYSTEM REQUIREMENTS BY FITTING THE CORRECTLY SIZED NOZZLE AND/OR CHOOSING THE CORRECT OIL PRESSURE.

❐ Fit combined air bleed manifold and 0-300psi (0-20 bar) pressure gauge to the appropriate oil pump connection, and replace burner.

❐ Set the boiler thermostat to between Summer and Winter positions, see fig. 1.

❐ Switch on the electrical supply to the boiler, checking that programmers are switched to the ‘ON’ position, and that the room thermostats are calling for heat. When the burner motor starts, on one pipe

systems it may be necessary to temporarily open the air bleed screw on the test manifold.

If the burner locks out during the ignition attempt, wait 45 seconds before pressing the reset button on the control box. Several attempts on first firing may be necessary.

❐ Once the burner is firing check and if necessary adjust the oil pressure.

❐ CARRY OUT COMBUSTION CHECKS BY INSERTING PROBES INTO SAMPLING POINTS PROVIDED: Low level balanced flue, rear or side - end of

terminal. High level balanced flue, rear or side - end of

terminal, or TEST POINT in boiler. Vertical balanced flue - TEST POINT in boiler.

Conventional flue - hole provided via screw in vertical offtake section.

❐ Check the Smoke No., if clean wait 10 minutes and measure CO

❐ Adjust the air shutter if necessary, open to reduce CO

2, close to increase CO2.

If the air shutter is adjusted, re-check the Smoke No.

❐ Check the flue gas temperature. The figures should agree with the Boiler

Commissioning Data.

❐ Check lockout function, either cover the photocell or remove solenoid coil, to simulate flame failure. Reinstate components and press lockout button.

❐ Check the operation of the limit thermostat

❐ Complete commissioning report and enter the

details on to the guarantee form which should be returned to BOULTER BOILERS in the envelope provided.

❐ Instruct the user on the operation of the appliance and leave this manual with the customer.

Page 39

BOULTER BOILERSEco-System PAGE 37

8:1 MAINTENANCE

A boiler fired with Class C Oil should only require attentions once each year.

8:1.1 General Inspection

With the Boiler operating, inspect for signs of unsatisfactory operation, i.e. leakage of combustion products, leakage of oil, or unusual noises from the pump or motor.

Check the commissioning list if it is your attendance to the appliance. Is there a reason why the Boiler might fail after you leave?

It is useful to measure the combustion date, i.e. CO2, Smoke No. and flue gas temperature, and a check on the oil pressure, prior to carrying out maintenance work.

8:1.2 Maintenance Procedure Switch off electrical supply at the MAINS

ISOLATING SWITCH.

OIL TANK De-sludge oil tank (if necessary), and draw of any

accumulated water. Check the correct grade of oil is being used. FILTERS Inspect and clean all oil filters. Change paper

elements for new. BURNER Turn off the oil cock and disconnect the flexible oil

hose from the oil cock. Remove burner and clean thoroughly, the burner

draught tube, the electrodes and generally the head assembly. CHANGE the nozzle for one with the specified make, oil rate, spray pattern and angle.

Inspect the ignition electrodes for crazing in the porcelain. Replace if there are signs of deterioration.

A dirty fan impeller can impair the performance of a burner, inspect and clean if necessary.

Inspect photocell, if badly discoloured, change it. Inspect the flexible oil hose for leaks or

discolouration. Use only replacement flexible oil hoses that are detailed in the spare parts section of this manual.

BOILER The Boilers are serviced from the front. Remove flue inspection cover/s, and baffles, and

clean all heat transfer surfaces and baffles. Replace any damaged or unserviceable parts with manufacturers proprietary parts.

Inspect flue and air ducts for deterioration of seals, and repair if necessary. Re-lubricate with a mild detergent when refitting.

Refit parts and inspect seals etc. which should be replaced if required.

COMBUSTION TESTS Fit combined air bleed manifold and 0-300psi (0-20

bar) pressure gauge to the appropriate oil pump connection, and replace burner.

Switch on the electric supply to the boiler. When the burner motor starts, on one pipe

systems, it may be necessary to temporarily open the air bleed screw on the test manifold.

Once the burner is firing check and if necessary adjust the oil pressure.

Carry out combustion checks by inserting probes into sampling points provided or at the flue outlet.

Check the Smoke No., if clean wait 10 minutes and measure CO

Adjust the air shutter (see fig 8.2a), if necessary, open to reduce CO

2, close to increase CO2.

If the air shutter is adjusted, re-check the Smoke No.

Check the flue gas temperature. The figures should agree with data in Boiler

Commissioning Data, Section 3. FINAL CHECKS Check lockout function, either remove photocell

and cover it, or remove solenoid coil, to simulate flame failure. Reinstate components and press lockout reset button.

Check that the control thermostat is operating when the set temperature is reached.

Check the operation of the limit thermostat if possible.

Reset Limit thermostat once appliance temperature has dropped sufficiently.

Complete a maintenance report and give the customer a copy, retaining a copy for your records.

Page 40

BOULTER BOILERS Eco-System PAGE 38

8:2 AIR SHUTTER ADJUSTMENT

The Burner has a fixed Air Shutter with manual adjustment.

To adjust the CO

2 at the Air Shutter use a 3mm

allen key as shown.To increase the setting turn the airshutter clockwise (+) and to decrease turn anticlockwise (-).

8:3 BAFFLE ARRANGEMENT

To ensure correct placement of baffles ensure that castellated edges are positioned towards the heat exchanger and:

1. All baffles are horizontal

2. All baffle handles are in the forward position.

12/19

TOP

FRONT

TOP

FRONT

Fig. 8:2a Air Shutter Adjustment

Fig. 8.3a Baffle Arrangement

19/26

Page 41

BOULTER BOILERS Eco-System PAGE 39

9:2 BOILER SPARE PARTS 12/19 & 19/26 BOILERS

Fig. 12/19

Fig. 19/26

SAMPLE

POINT

SAMPLE

POINT

Page 42

9:2 BOILER SPARE PARTS 12/19 & 19/26 BOILERS

BOULTER BOILERS Eco-System PAGE 40

Heat Exchanger (Short Boiler only)

1st Baffle Top

2nd Baffle

3rd Baffle

Combustion Chamber Base Insulation

Inspection Cover complete

Inspection Cover Insulation (Ceraboard)

Base Tray

Heat Exchanger Insulation Set

Heat Shield

Door Panel

Rear Casing Panel

Left Side Casing Panel

Right Side Casing Panel

Top Front Panel

Top Rear Panel

Side Panel Blanking Plate

Blanking Plate

Control Panel Complete

Riello Burner Complete Type

Part No.

Burner Airduct

Side Panel Bracer

Side Flue Plate

SB40/65

HE47021C

HE47022C

HE47023C

IN47103

HE47218C

IN47201

PN47201C

IN49200C

PN23116

PN47235C

PN49202

PN47223C

PN47224C

PN31206C

PN49207C

PN49117

PN49108

PN57050C

484T50

3748455

RP47001

PN47214C

PN47118C

Item Description

Eco

SB65/95

HE47022C

HE47073C

N/A

HE47218C

IN47201

PN47201C

IN49200C

PN23116

PN47235C

PN49202

PN47223C

PN47224C

PN31206C

PN49207C

PN49117

PN49108

PN57050C

483T50

3748355

RP47001

PN47214C

PN47118C

12/19 19/26

Note: Items 22-26 not shown.

Page 43

9:4 BURNER PARTS - TYPE 483T50 & 484T50

BOULTER BOILERS Eco-System PAGE 41

Item

1 2 3 4 5 6 7 8 9

10A

11A

12 13

13A

14 15

15A

Part No. 3008652 3007162 3008653 3007582 3008651 3000439 3008649 3005787 3006384 3008768 3008859 3007513 3008860 3006552 3008642 3008861 3007178 3008543 3008862

Description Control Box 535RSE/LD O Ring Filter O Ring Needle Valve Regulator Pump Seal Protection Cover Gasket Flange Blast Tube Blast Tube (484T50) Electrode Assembly Electrode Assembly (484T50) Electrode Bracket Nozzle Holder Nozzle Holder (484T50) O Ring Collar (Includes O Rings) Collar (484T50)

Item

16 17 18 19 20 21 22 23 24 25 26 27 28 29 29 29 31 32 33

Part No. 3008648 3008650 3000443 3008654 3008644 3008647 3008794 3005708 3008646 3007479 3008863 3008879 3008877 3008878 3008878 3008878 3008876 3008875

Description Coil Motor Joint Pump Tube Air Damper Assembly High Voltage Lead Fan Photo Electric Cell Capacitor 4µF Burner Lead Burner Cover Solenoid Lead Air Box Seal Fan Box Seal KIT O Ring Seal Pressure Gauge Extension Electrode Clamp (484T50)

12 / 19 Blast Tube

end view

19 / 26 Blast Tube

end view



Page 44

BOULTER BOILERS Eco-System PAGE 42

10:1 FAULT FINDING

If the Boiler fails to start, make the following checks before calling a service engineer:-

1. Is there sufficient fuel in the storage tank?

2. Are all fuel supply valves open (turned fully anti-clockwise) and ball valves open?

3. Is the mains electricity supply switched on?

4. Is the programmer (or Boiler Operating Switch) set to call for heat?

5. Is the Boiler Thermostat set to the desired temperature?

6. Is the Lock-out Reset Button on the Control Box and Control Panel Neon illuminated? If so, press to reset Burner.

7. Check the fuse which should have been fitted to the mains electricity supply to the programmer/boiler operating switch. If the fuse has blown, replace it. If it blows again, call a Service Engineer.

IMPORTANT - Electrical Safety

IT IS ESSENTIAL THAT BEFORE ANY PANELS OR COMPONENTS ARE REMOVED FROM THE BOILER, THAT THE MAINS ISOLATOR IS SWITCHED OFF.

10:2 Fault Finding Chart

Trouble or Complaint Possible Cause Action

1. Suspect oil supply No oil in tank Check and arrange for tank to be filled if necessary

Supply valves closed Open all supply valves

Blockage in oil supply Shut off the burner isolating valve. Disconnect (Gravity head feed) the oil supply at the pump entry. Place receptacle

under the pipe. Slowly open the valve, not is the flow is unrestricted, restricted or blocked.

Wrong grade of oil Check for correct grade of fuel (see technical data)

Water contamination Open tank, drain valve and check

Tank vent blocked Check

Filter blocked Check for water or blockage

Air locks in supply pipe Check for high points in main oil supply

Air lock in pump Bleed pump, check flexible oil line.

2. Burner will not start Interruption or absence Check mains switch on. Check fuse in switched

of electrical supply at spur or plug. Check that time switch or programmer burner (Check this at contacts are closed. Check that the auxiliary stat Control Box mains is closed. Check boiler stat, cylinder stat, room terminal with test lamp) stat are calling for heat.

Control Box is locked out, Press reset button on the burner box refer to symptom 4

Photo-resistor receiving Check that the photo-resistor is fully home in its false light housing. Burner will not start with illuminated cell.

Faulty control box Replace.

3. Burner lights up but locks No oil supply Check oil in the tank.

out after 15 seconds

Photo-electric cell not Check that photo-electric cell is clean and fully receiving light from flame home in housing

Photo-electric cell Check and tighten if necessary. connections loose

Control box photo- Replace control box. electric cell circuit faulty

Flame instability Check combustion setting out and reset if

necessary.

Page 45

BOULTER BOILERS Eco-System PAGE 43

4. Burner starts but will not This can be due either light up to absence of oil of

ignition.

Oil pump air locked Pump should be self-venting with two pipe system (repeat air locking only. If a one pipe gravity feed is employed it must may be due to poor be purged through the vent port. pipe joints or defective gland packings)

Motor not driving Check that flexible drive is functioning correctly pump shaft and not slipping.

Blocked atomiser Remove and replace nozzle. nozzle

Oil pressure Check oil pressure on gauge and set to the correct abnormally low pressure (see technical data).

Solenoid valve faulty Break union at outlet to check presence of oil.

Check that seat is clear. Check coil for continuity. Inspect coil feed wiring to control box.

Pump rotation Check. incorrect

Ignition failure:

Electrodes dirty Inspect and clean if necessary.

Electrodes mis-set Inspect and reset gap 3 to 4mm between tips.

2mm in front of nozzle face.

Cracked electrode Check and replace if cracked or crazed. insulator.

Electrode leads Check for proper connections

5. Burner lights up, runs Air shutter closed Reset to correct position. continuously and emits visible smoke or shows Wrong nozzle Check make, type and spray angle. excess smoke on combustion check Worn atomiser nozzle Replace if necessary.

Oversize nozzle fitted Check size and replace with correct size of in error necessary.

Nozzle incorrectly Replace with correct nozzle. stamped

Burner air supply Inspect air intake and fan for fouling of impeller inadequate with dirt.

Burner oil pressure Check pressure and reset to correct pressure (see excessive Technical Data).

6. Burner lights up, runs Air in nozzle Should self-correct; if air repeatedly present; normally but flame cuts for leaks on oil line and flexible. off slowly on shut down (possibly with smoke or Magnetic valve not Inspecting and replace if necessary. pulsation) operating correctly

Shut off piston in Replace pump. pump sticking

7. Burner Pulsates Air shutter setting Inspect and reset or remove blockage. (a) continuously incorrect or fan inlet

blocked

Grossly oversized Checked and replace with correct size and type nozzle (see Technical Data)

Air supply inadequate Check fan operation and cleanliness.

Page 46

BOULTER BOILERS Eco-System PAGE 44

7. Burner pulsates Worn nozzle with Replace with nozzle of correct type and size (see (a) continuously excess throughout or Technical Data).

uneven spray pattern

(b) at initial firing Air in supply line Purge at pump to remove.

Blocked flue ways Clean boiler and flue.

8. Burner locks out on Localised low voltage Check with local Electricity Board to fit recorder. morning starts then runs supply in early Enlist aid of the Board. perfectly for rest of day morning

Air present in oil Restart burner several times - press lockout reset supply button repeat 7(b) above.

Bottom of oil tank Raise tank or install a two pipe oil supply from below level of oil tank. pump

Non-return valve Renew non-return valve. Rectify air leak faulty or air leak in two pipe oil supply system.

9. Burner fails due to blown Short circuit in wiring Inspect wiring, sheathing and inter-component fuse. connections for broken or damaged leads.

Replace if necessary.

Motor seized Check by hand and replace if necessary.

Breakdown of Replace motor. insulation of motor windings

10. Burner runs normally but Oil throughput Check nozzle size and pressure against rating will not reach desired insufficient temperature

Boiler has become Check with heating installer. undersized due to heating system expansion

Low efficiency and Check combustion readings, reset air. CO

Low efficiency due to Clean heat exchanger surfaces high flue gas temperature

Faulty boilerstat. Replace, check and clean. Partially blocked filter

11. Poor combustion Low CO

Check: CO2, oil pressure, nozzle size (see

readings Technical Data

High CO

Check: CO2, oil pressure, nozzle size (see Technical Data

High smoke Check: CO2, oil pressure, nozzle size (see

Technical Data

Check all Baffles are in place and correctly located.

High flue gas Check: air shutter, nozzle size (see Technical temperature Data), clean heat exchanger surfaces.

12. Oil odour Leaking joints Break all leaking joints and re-make

Page 47

BOULTER BOILERS Eco-System PAGE 45

13. High operating Control stat failed and Replace control stat and reset Limit Thermostat temperature operating on limit stat

14. Fumes in Boiler Room Inadequate draught Take necessary corrective action

due to unsatisfactory chimney or blockage of boiler flue ways or flue pipe

15. Unstable flame, some Air damper on burner Set up burner as for commissioning using oil puffing, ignition cuts in improperly adjusted pressure gauge, smoke pump, CO2 indicator and intermittently or faulty nozzle or draught gauge, adjust settings as necessary,

unsatisfactory draught replace nozzle if necessary. conditions or fault in See Commissioning Check List and Servicing oil supply Notes.

Page 48

1:1 Introduction 1:2 Regulations 1:3 Boiler Arrangement 1:4 Sealed System Components

2:1 Wiring Diagrams 2:2 Service Connection Dimensions 2:3 Tundish Position 2:4 Pipe Connection Details 2:5 Control Panel 2:6 Filling the System 2:7 Pressure Relief Valve 2:8 Expansion Vessel Pressure

3:1 Access 3:2 Water System 3:3 Additional Servicing

4:1 Sealed System 12/19 & 19/26

SECTION 1 - INTRODUCTION

SECTION 2 - INSTALLATION

SECTION 3 - SERVICING

SECTION 4 - SPARE PARTS

SECTION 5 - PUMP PERFORMANCE

BOULTER BOILERS Eco-System PAGE 46

CONTENTS - Part 2

Page 49

1:1 INTRODUCTION

1:2 REGULATIONS

Boulter Eco Sealed System Boilers are designed for use in sealed water systems. The Boilers are supplied with an expansion vessel and associated components arranged to minimise installation time.

Sealed System Boilers can be used for Conventional Flue or with any of the Boulter Balanced Flue options available for the Camray 5, except side low level.

Fig. 1:1 Typical Sealed System Arrangement

Components Supplied with Boiler - Fig 1:1

The installation must comply with the requirements of the latest editions of:

BS5449 Part 1 Forced Circulation Hot Water System;

BS7074 Part 1 Codes of Practice for Sealed Systems;

The Building Regulations Part G3: I.E.E. Wiring Regulations In addition to the standards and regulations

listed in this Manual.

1 Double Check Valve/Isolating Valve

2 Filling Loop - Flexible Hose

3 Mains Water Shut Off Valve

4 Circulating Pump - 3 Speed

5 Automatic Air Vent (Not supplied by Boulter)

6 Pressure Gauge - 0.4 bar range

7 Pressure Relief Valve - 3 bar

8 Tundish

9 Expansion Vessel Charged to 0 .5 bar

Item Description

Item 7

A facility to fit the PRV

inside the casing is

provided, or fit as shown.

BOULTER BOILERS Eco-System PAGE 47

Page 50

1:3 BOILER ARRANGEMENT

Fig. 1:3 Boulter Eco System Boiler Arrangement (12/19 shown)

TRANSIT BRACKET

4. CIRCULATING PUMP

9. EXPANSION VESSEL

1-3. FILLING LOOP

7. PRESSURE RELIEF VALVE

6. PRESSURE GAUGE

PUMP

ISOLATING VALVES

BOULTER BOILERS Eco-System PAGE 48

Page 51

Vessel Charge and bar 0.5 1 .0 1.5

Initial System

Pressure psi 7.3 14.5 21.8

Expansion

Vessel Total water content of system

size using expansion vessel supplied.

supplied

litres 125 90 62

gallons 27 19.7 13.6

litres 150 109 75

gallons 32.7 23.8 16.5

For systems having a larger

capacity multiply the total

system capacity by the factor to

obtain the total minimum

expansion vessel capacity

required.

1:4 SEALED SYSTEM COMPONENTS

1. Double Check Valve

Fitted to Cold Fill to prevent ‘back feed’ when Filling Loop is connected.

2. Filling Loop

A flexible hose which should ONLY be connected when filling or topping up the system.

THE FILLING LOOP HOSE MUST BE DISCONNECTED AND MAY BE LEFT HANGING FROM ONE OF THE FITTINGS WHEN NOT IN USE.

3. Mains Water Shut Off Valve

Supplied to isolate mains supply.

4. Circulating Pump

The pump is fitted to the Flow Pipe as a circulating pump for the Heating System.

5. Automatic Air Vent

The Vent automatically vents air from the system.

The bleed screw should be loosened one turn.

Routine venting of radiators is still advised.

6. Pressure Gauge

The Gauge (mounted behind the front door) is provided as a visual indication of the water pressure within the system.

When the system is initially filled (cold) and all radiators full and vented, the Pressure Gauge will show the Cold Fill Pressure. Set the Red pointer to this setting.

Cold Fill Pressure ✎

A pressure below the set Cold Fill Pressure indicates the system requires “topping up”.

7. Pressure Relief Valve

(fitted inside casing) This can be fitted to one of the top sockets

of the Boiler. The remaining top socket must be plugged.

8. Tundish

Supplied to provide a visual indication of water flowing from the Relief Pressure Valve (7). Refer to 2:3.

It is a requirement of G3 of the Building Regulations that the Tundish is fitted in a safe position visible to the householder.

9. Expansion Vessel

The Expansion Vessel is suitable for systems with a static head of up to 5 metres (16.5ft) i.e. the vertical distance between expansion vessel and highest point of system, usually the top of bedroom radiators. If the static head is greater than 5 metres, then the charge in the vessel must be increased to equal this higher static pressure. The pressure can be increased if required by simply pumping up the vessel with a standard type pump and checking the pressure with a tyre gauge with the system at zero pressure. A schraider type valve is provided on the vessel for this purpose (see note below). During air charge, leave the PRV open.

NOTE: The air charge should not exceed a pressure of 1.5 bar (22 p.s.i.)

10. Expansion Vessel Requirements

Boiler

12/19

10 litres

19/26

12 litres

0.08 0.11 0.16

BOULTER BOILERS Eco-System PAGE 49

Page 52

BOULTER BOILERS Eco-System PAGE 50

2:1 WIRING DIAGRAMS

IMPORTANT

ENSURE GOOD EARTH

ECO SEALED SYSTEM - CONTROL PANEL

SCHEMATIC WIRING DIAGRAM

Page 53

2:3 TUNDISH POSITION

2:2 SERVICE CONNECTIONS DIMENSIONS

A Tundish is supplied to provide a visual indication of water flowing from the Pressure Relief Valve of the Boiler.

The Tundish must be located in a position clearly visible to the Householder.

Installation of the Tundish must comply with Part G3 of The Building Regulations typically as fig. 2:3

FIG. 2:3 Tundish Installation

FIG. 2:2 Service Connections Dimensions

Model

12/19 19/26

ABC

815 354 317

BOULTER BOILERS Eco-System PAGE 51

Page 54

2:4 PIPE CONNECTION DETAILS

FIG. 2:4 Pipe Connection Details (12/19 shown)

NB Alternative locations for the PRV are shown in Figure 2.2 (Blank off existing position)

BOULTER BOILERS Eco-System PAGE 52

Page 55

9. When the system is completely full and vented close both Mains Isolating Valve and Double Check Valve and disconnect flexible Filling Loop Hose, catching water.

THE FILLING LOOP MUST BE DISCONNECTED WHEN NOT IN USE.

10. Set the red pointer of the Pressure Gauge to the Cold Fill pressure. Refer to 1:4.6.

1. Check that the black screw on the Automatic Air Vent is loosened 1 turn.

2. Check spare sockets in Boiler have been plugged.

3. Check drain cock/s are off.

4. Connect the Filling Loop Hose from the incoming mains supply to the Double Check Valve and open the Double Check Valve fully.

5. Open the Mains Isolating Valve partway to fill the system SLOWLY.

6. Flush system thoroughly and refill.

7. Vent radiator and any other manual Air Release Vents.

8. Check for leaks particularly on an older system which may have operated on a lower pressure.

2:5 CONTROL PANEL

2:6 FILLING THE SYSTEM

IMPORTANT

Do not allow water in Filling Loop to

spill over the Burner.

FIG. 2:5 Control Panel

BOULTER BOILERS Eco-System PAGE 53

Page 56

During routine servicing, the water should be “topped up” if necessary using the Filling Loop when the system is cold. Refer to 2:6 Filling the System.

In addition to the General Boiler Maintenance Manual, the following items should be checked on an annual basis at the very least.

1. System Pressure

The System Pressure should be checked periodically and increased as necessary using the Filling Loop or other approved method.

Filling should be carried out on a cold system so that the pressure can be increased to the original cold fill design pressure (indicated by the red pointer on the system Pressure Gauge).

The Pressure Gauge should be watched carefully during filling and the Mains Isolating Valve opened slowly.

2. System Draining

The Boiler as well as the system, is under pressure and before disconnecting any components, the system pressure must be reduced. It is recommended that a suitable drain be situated in one of the Boilers’ lower sockets to facilitate this.

After replacing the relevant parts refill the system as described in Section 2:6.

3. Pressure Relief Valve

This should be checked for operation during annual servicing by increasing the system pressure outlined in Section 2:7.

4. Expansion Vessel Pressure

Should be checked to be in accordance with the cold design pressure of the system.

This is checked by allowing the water pressure to increase until the valve operates - this should be between 2.7 and 3.3 bar.

Reduce the system pressure to achieve the initial cold fill pressure.

When the system water is heated, the pressure will rise above the Cold Fill setting. If the pressure reaches 2.5 bar when the Boiler is operated at its highest temperature with all radiators in circulation, then an additional expansion vessel must be fitted in the system. Refer to Section 1 :4.9 and BS 7074 Part 1 for information on sizing of the additional expansion vessel.

The design of the Sealed System Boiler enables the Pressure Vessel to be lifted and laid on the floor whilst still connected to the Boiler, enabling full access to the Burner and Heat Exchanger.

Any work top must be removable for service access to system components beneath the top casing lid.

2:7 CHECK PRESSURE RELIEF VALVE OPERATION

3:2 WATER SYSTEM

3:3 ADDITIONAL SERVICING

2:8 EXPANSION VESSEL PRESSURE

3:1 ACCESS

FIG. 3:1 Removing Expansion Vessel

BOULTER BOILERS Eco-System PAGE 54

Page 57

4:1 SEALED SYSTEM SPARE PARTS 12/19 & 19/26 BOILERS

Item

Double Check Valve

Filling Loop

Mains Water Shut Off Valve

Circulating Pump

Pressure Gauge

Pressure Relief Valve

Expansion Vessel (10l.)

207291

26775

BS 31004

EL 49012

206381

Part No.QtyDescription

Item

Expansion Vessel (12l.)

Flexible Hose c/w Washers

Expansion Vessel Bracket

Isolating Valve

1st Flow Pipe Assy.

2nd Flow Pipe Assy.

Tundish

BS 49010

99537

BS 49052C

BS 49051C

EL 49022

HE 49001C

207292

Part No.QtyDescription

1212



BOULTER BOILERS Eco-System PAGE 55

Page 58

5:1 PUMP PERFORMANCE

Pump Performance on Eco Sealed System Boilers

The graphs below show the pump performance curves as defined by the pump manufacturer.

1. Set the speed selector switch to maximum (Speed 111) and switch on the electricity supply and start the heating system.

2. Turn the switch to minimum (Speed 1) and if after a suitable time all the radiators are not hot, increase the speed of the pump by switching to Speed 11. Repeat this process until adequate circulation is achieved.

Remember, if the speed setting is too high, noise may be caused in the system and the power consumption will be unnecessarily high.

BOULTER BOILERS Eco-System PAGE 56

Page 59

Indicates changes

from previous issue

Due to a policy of continual development Boulter Boilers reserves the right to alter or amend the design of its products without prior notice.