Grant 50/70, 70/90, 90/140, 140/160, 160/200 User, Installation And Servicing Instructions

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Page 1

USER, INSTALLATION

and

SERVICING INSTRUCTIONS

MULTI PASS

For use with Kerosene or Gas Oil

Kitchen and Boiler House Models

50/70, 70/90, 90/140, 140/160 and 160/200

This appliance is deemed a controlled service and specific regional statutory

requirements may be applicable

After installing the boiler leave these instructions with the User

For System boiler installation and wiring refer to separate Supplement

Part No. DOC 02 Rev.12 October 2004

Page 2

Multi Pass Oil Boilers

Subject PageSection

1 User instructions ...................................... 3

2 Technical information .............................. 6

3 General boiler information....................... 10

4 Boiler installation..................................... 26

5 Commissioning......................................... 33

6 Information for the user ........................... 35

7 Boiler servicing ........................................ 36

8 Wiring diagrams....................................... 43

9 Fault finding ............................................. 46

10 Burner spares ........................................... 48

11 Health and safety information.................. 50

12 EC declaration of conformity .................. 51

Date % CO2Net flue gas

temp.

Smoke No. Service engineer/Tel. No.

Date:..............................

Commissioning engineer:.............................................................................. Tel. No: ....................................

Boiler model/output: ........................................ Btu/h Fuel type: Kerosene or Gas oil

Nozzle size: .................................... Pump pressure: .................... Air setting: ...........................

Flue gas % CO2: ............................. Net flue gas temp:................ Smoke No:...........................

It is recommended that the boiler should be regularly serviced, at least once a year, and the details entered below by the service engineer.

COMMISSIONING REPORT

SERVICE LOG

LIST OF CONTENTS

Page 3

Multi Pass Oil Boilers

1 - USER INSTRUCTIONS

The boiler will provide domestic hot water and central heating and is fully automatic once switched on. Kitchen models have a 'boiler on' neon, see Fig. A, which lights when the boiler is switched on, but does not necessarily indicate the burner is firing.

If your Kitchen model has a programmer fitted, it will provide hot water and central heating during the periods set on the programmer.

To access the Kitchen model controls, open the front door from the right (may be altered to open from the left if required).

Controls for Multi Pass Kitchen models - Fig. A

°C

Boiler

thermostat

Overheat thermostat

reset button

(under plastic cap)

Controls for Boiler House models - Fig. B

1 Ensure that - There is sufficient fuel, of the

correct type, in the supply tank and all fuel supply valves are open. The water supply is on. The electricity supply to the boiler is off. The boiler On/Off switch is set to OFF (Kitchen models). The room thermostat (if fitted) is at the desired setting. The boiler thermostat is set to the required setting (see Section 1.7).

2 Switch on the electricity supply to the boiler.

Note: Boiler House models will light at this stage.

3 For Kitchen models, set the On/Off switch to ON

and, if fitted, the programmer (CH or HW) to ON. The boiler will now light automatically.

4 If you have a programmer fitted in the control panel

(Kitchen models only), refer to the Programmer Section and set the programmer. Set the HW and CH functions to TIMED. The boiler will now operate during the 'on' periods set on the programmer.

About your boiler

1.1

Boiler controls (see Fig. A or B)

1.2

Lighting your boiler (see Fig. A or B)

1.3

Page 4

Multi Pass Oil Boilers

Kitchen models for short periods - Set the On/Off to OFF. To restart, simply set the switch to ON.

Kitchen models for long periods: Set the On/Off switch to OFF and switch off the electricity supply to the boiler. If required, the fuel supply valve may be closed and the water and electricity supplies turned off at the mains. To restart, refer to the full lighting instructions above.

Boiler House models for short periods - Switch off the electricity supply to the boiler. To restart, switch on the electricity supply to the boiler.

Boiler House models for long periods - Switch off the electricity supply to the boiler. If required the fuel supply valve may be closed and the water and electricity supplies turned off at the mains. To restart, refer to the full lighting instructions given in Section 1.3.

1 Check that the boiler On/Off switch is ON. 2 Check that the programmer (if fitted) is working

and is in an 'on' period.

3 Check that all thermostats are set to the desired

setting and are calling for heat.

4 Check if the burner 'Lock-out' reset button is lit. If it

is, press it to start the burner. If the burner fails to light and goes to 'Lock-out' again, check that you have sufficient fuel in the storage tank and that the fuel supply valve is open.

5 Ensure that a fuse has not blown or that the

electricity supply has not failed.

6 Check to see if the safety thermostat has operated

(see Section 1.7).

If the burner still fails to light after carrying out these checks then a fault exists. Switch off the electricity supply to the boiler and contact your Service engineer.

Multi Pass boilers will operate on either Class C2 Kerosene or Class D Gas Oil to BS 2869:1998. Your Installer will have informed you of the type of fuel your boiler has been set to use and he will have marked this on the boiler data label. You should always quote the type of fuel you require when ordering from your supplier.

Note: Balanced flue models (flue terminal through the wall) must only be used with Kerosene, unless the flue terminal is more than 2.0 m above ground level.

Do not wait until the fuel runs out before you order some more. Sludge in the bottom of the tank may be drawn into the fuel lines. If it is possible, switch off the boiler when the new supply is delivered and leave the fuel to settle for an hour before restarting the boiler.

1 Boiler thermostat - This control allows the

temperature of the water leaving the boiler to heat the radiators and domestic hot water to be adjusted.

Note: If you have a cylinder thermostat on your hot water cylinder, this will control the temperature of your domestic hot water. The boiler thermostat setting must be equal to or above the cylinder thermostat setting to enable the cylinder thermostat to control the domestic hot water system.

The boiler thermostat has an operating range of 65 to 85°C. The following settings are recommended:a Heating and hot water in Winter 85°C b Hot water only in Summer 65°C

2 Burner Lock-out reset button - If there is a

burner malfunction, a built-in safety circuit switches the burner off and the Lock-out reset button will light. Usually such malfunctions are short lived and pressing the reset button will restore normal operation.

If the burner continually goes to 'Lock-out' a fault exists or the fuel supply is low. If you have sufficient fuel, you will need to call your Service engineer.

3 Safety thermostat - Your boiler is fitted with a

safety overheat thermostat which will automatically switch off the boiler in the case of a control malfunction causing overheating.

If your boiler goes off and you try to light it but nothing happens and the 'Lock-out' reset button on the burner is not lit, the overheat thermostat has probably operated. The boiler will not light until the thermostat is reset. To reset, unscrew the small plastic cap (see Fig. 23 or 24), press the button then replace the cap.

If this condition continually repeats, contact your Service engineer.

4 Programmer (if fitted) - Refer to the instructions

supplied with the Programmer.

1 - USER INSTRUCTIONS

Turning off your boiler (see Fig. A or B)

1.4

Points to check if burner fails to light

1.5

About your fuel

1.6

General notes and care of your system

1.7

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Multi Pass Oil Boilers

5 Ventilation - Always ensure that the boiler has

adequate ventilation. Any ventilation openings provided by the Installer must not be obstructed. Periodically check that they are clear.

Do not attempt to 'box in' the boiler or build a compartment around it before consulting your Installer.

Do not place any combustible material around or on the boiler or flue pipe.

6 Flue terminal - The flue terminal on the outside

wall must not be obstructed or damaged. In severe conditions check that the terminal does

not become blocked by snow.

7 Frost protection - Your Installer may have fitted a

frost thermostat. If not, and you are likely to be away for a short time, leave the boiler on with the boiler thermostat set at a low setting. For longer periods the boiler and system should be drained. Contact your Service engineer for draining and filling the system.

8 Cleaning and servicing - Lightly wipe over the

case with a damp cloth and a little detergent. Do not use abrasive pads or cleaners.

You should have your boiler serviced at least once a year to ensure safe and efficient operation. Contact your Service engineer for further details.

9 Failure of electricity supply - If the electricity

supply fails, the boiler will not operate. It should relight automatically when the supply is restored.

If a programmer is fitted (Kitchen models only) it will retain the time settings for up to 24 hours and will not have to be reset to the correct time of day when the supply is restored (the display remains for up to 1 hour, but will re-appear when the supply is restored).

The boiler requires a 230/240 V ~ 50 Hz supply. It must be protected by a 5 Amp fuse.

Warning: This appliance must be earthed.

If your boiler is operating on a sealed heating system, the installer will have pressurised the system and should have told you (or set it on the pressure gauge) the system pressure when cold (this is normally between 0.8 and 1.0 bar, which will increase slightly when hot). If the pressure (when cold) is below the set pressure mentioned above, you should contact your Installer or Service engineer to re-pressurise the system. If the system requires frequent re-pressuring, ask your Installer or Service engineer to check the heating system for leaks.

The boiler or system will be fitted with an automatic air vent to remove air from the system. Any air trapped in the radiators should be removed by venting the radiators using the vent screw at the top of each radiator. Only vent a radiator if the top is cool and the bottom is hot. Excessive venting will reduce the system pressure, so only vent when necessary and check the system pressure as mentioned above. Repressurise the system if necessary.

Note: Your system may incorporate a 'Top-Up' vessel, advice on how to use it should be obtained from your installer.

The boiler or system may be fitted with a safety valve to release excess pressure from the system. If water or steam is emitted from the end of the safety valve discharge pipe, switch off the boiler and contact your Installer or Service engineer.

The expansion vessel air charge must be checked annually. Failure to maintain an adequate air charge in the vessel may invalidate the warranty.

1 - USER INSTRUCTIONS

Electricity supply

1.8

Sealed central heating system

1.9

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Multi Pass Oil Boilers

Model

Water content litre

gal

** Weight (dry) kg

Max. heat input (Kerosene) kW

Btu/h Flow and return connections Flue diameter (conventional) Waterside resistance Flow/Return temp. diff. of 10°C Flow/Return temp. diff. of 20°C Maximum static head Minimum circulating head Boiler thermostat range Limit (safety) stat switch off temp. Max. hearth temperature Electricity supply Motor power Starting current Running current Oil connection Conventional flue

Max. operating press.

Sealed system Open system

28 m

65 to 85°C

111°C ± 3°C

Less than 50°C

230/240 V ~ 50 Hz Fused at 5 Amp

¼" BSP Male (on end of flexible fuel line)

Minimum flue draught - 8.7 N/m² (0.035 in wg)

Maximum flue draught - 37 N/m² (0.15 in wg)

2.5 bar 3 bar

* Boiler House model only **Weight includes burner but excludes flue

125 W max.

2.5 Amp

0.95 Amp

70/90

4.2

117 (98)*

258 (216)*

27.6

94 200

Boiler technical data

2.1

2 - BOILER TECHNICAL INFORMATION

37.5 mbar

6.1 mbar

1" BSP

100 mm (4 in)

8.7 mbar

2.7 mbar

125 mm (5 in)

11/4" BSP

50/70

4.2 115 253

21.4

73 000

160/200

36.0

7.9

210 (197)* 462 (433)*

62.5

212 000

150 mm (6 in)

90 W max.

2.6 Amp

0.85 Amp

90/140

5.7

148 (125)* 326 (275)*

43.7

149 140

140/160

36.0

7.9

210 (197)* 462 (433)*

49.4

169 600

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Multi Pass Oil Boilers

Kerosene Notes:

1 The data given above is approximate only and is based on the boiler being used with a low level balanced flue. 2 The above settings may have to be adjusted on site for the correct operation of the burner. 3 Gas Oil is not suitable for use with low level balanced flue models, unless the flue terminal is higher than 2.0 m above

outside ground level.

4 The installer must amend the boiler data label if the type of fuel or nozzle used is changed. 5 The 50/70, 70/90and 90/140 models use Riello burners. The 140/160 and 160/200 models use EOGB Sterling 90

burners. 6 * Indicates the factory set output. 7 ** Net thermal efficiency (BSRIA). 8 The net flue gas temperatures given above are ± 10%. 9 When commissioning, or when the output or fuel is changed, the air damper must be adjusted to obtain the correct

CO2 level and the installer must amend the data label. 10 When downrating the 50/70 model to 50 000 or 60 000 Btu/h, an LD2 head must be fitted. 11 *** Flue gas temperatures taken at combustion door test point will be approximately 25°C higher.

2 - BOILER TECHNICAL INFORMATION

Note: All boilers are despatched for use with kerosene.

Multi Pass oil boilers using Class C2 kerosene

2.2

(kW)

14.7

17.6

20.5

23.5

26.4

32.2

36.7

41.0

47.0

52.8

58.6

Model

(Btu/h)

50 000 60 000 70 000 70 000 80 000

90 000 110 000 125 000 140 000 140 000 160 000 160 000 180 000 200 000

95.4

95.2

96.0

95.7

95.8

94.5

94.1

93.8

(Btu/h)

52 400 63 000 73 000 73 000 83 780

94 200 116 400 132 800 149 140 149 140 169 600 169 600 190 800 212 000

(kW)

15.3

18.5

21.4

24.5

27.6

34.1

38.9

43.7

49.7

55.9

62.1

Nozzle

0.50/60°S

0.60/60°S

0.60/60°EH

0.75/60°EH

1.00/60°ES

1.10/80°EH

1.25/60°S

1.35/60°S

1.50/60°S

1.65/60°S

Oil

press.

(bar)

7.00

9.00

8.50

7.00

9.50

8.00

8.50

8.25

7.50

8.25

8.00

9.25

Smoke

No.

0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1

Fuel flow

rate

(kg/h)

1.33

1.60

1.87

2.13

2.40

3.18

3.24

3.80

4.34

4.76

5.39

Flue gas

temp.***

(°C)

168 166 167 167 166 168 180 185 184 185 195 195 195 195

(%)

12.0

Flue gas mass

flow rate

(kg/h)

21.5

25.5

29.6

30.0

34.4

38.7

47.4

54.0

60.5

60.4

68.3

77.3

86.4

Burner

head

LD2 LD2 LD3 LD3 LD3

LD3 LD3A LD3A LD3A K/KA K/KA C/KA C/KA C/KA

Heat Output Net Heat Input

Net

eff **

(%)

(Btu/h)

50/70

70/90

90/140

140/160

160/200

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Multi Pass Oil Boilers

2 - BOILER TECHNICAL INFORMATION

Gas Oil Notes:

1 The data given above is approximate only. 2 The above settings may have to be adjusted on site for the correct operation of the burner. 3 Gas Oil is not suitable for use with low level balanced flue models, unless the flue terminal is higher than 2.0 m above

outside ground level.

4 The installer must amend the boiler data label if the type of fuel or nozzle used is changed. 5 The net flue gas temperatures given above are ± 10%. 6 The 70/90 and 90/140 models use Riello RDB burners. The 140/160 and 160/200 models use EOGB Sterling 90 burners. 7 * Net thermal efficiency (BSRIA). 8 ** Flue gas temperatures taken at combustion door test point will be approximately 25°C higher.

(kW)

20.5

23.5

26.4

32.2

41.0

47.0

52.8

58.6

Model

(Btu/h)

70 000 80 000

90 000 110 000 140 000 140 000 160 000 160 000 180 000 200 000

94.6

94.7

94.6

94.1

94.3

(Btu/h)

76 900 87 900

98 900 116 745 148 470 148 768 170 606 170 606 191 079 212 575

(kW)

22.5

25.8

29.0

34.2

43.5

43.6

50.0

56.0

62.3

Nozzle

0.50/60°S

0.55/60°S

0.60/60°S

0.75/60°S

1.00/60°S

0.85/60°S

1.10/60°S

Oil

press.

(bar)

11.00

12.00

10.75

9.80

16.50

20.00

15.00

16.50

Smoke

No.

0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1 0 - 1

Fuel flow

rate

(kg/h)

1.57

1.80

1.97

2.30

2.97

3.48

3.95

4.47

4.98

Flue gas temp.**

(°C)

200 200 200 185 184 185 195 195 195 200

(%)

12.0

Flue gas mass

flow rate

(kg/h)

30.0

34.4

38.7

47.4

60.5

60.2

68.8

76.9

85.9

Burner

head

LD3 LD3

LD3 LD3A LD3A K/KA K/KA K/KA C/KA C/KA

Heat Output Net Heat Input

Net

eff * (%)

(Btu/h)

70/90

90/140

140/160

160/200

Multi Pass oil boilers using Class D gas oil

2.3

Page 9

Multi Pass Oil Boilers

70/90

90/140 140/160 160/200

50/70 70/90

140/160 160/200

Fig. 1

Boiler House models

1080

410

410 690

120

125

170

200

499

650

160

1803654

ABCDEFGH

Model

(Kitchen)

Dimension (mm)

860 605

ABC EFG

Model

(Boiler House)

Dimension (mm)

720 895

460 460

445 480

625 655

65 68

499 650

145 135

160 185

1000

550 580 765 145 700 240 70

1196

530 835 148 175 700 245 75

2 - BOILER TECHNICAL INFORMATION

Boiler dimensions

2.4

See Fig. 1

Kitchen models

90/140

Page 10

Multi Pass Oil Boilers

The Multi Pass range of automatic pressure jet oil boilers have been designed for use with a central heating system with indirect domestic hot water cylinder. They are not suitable for use with either a direct cylinder or a 'primatic' cylinder.

The boilers are suitable for use on sealed central heating systems.

Five Kitchen models are available and are listed below together with their maximum outputs.

50/70 20.5 kW (70 000 Btu/h) 70/90 26.4 kW (90 000 Btu/h) 90/140 41.0 kW (140 000 Btu/h) 140/160 46.6 kW (160 000 Btu/h) 160/200 59.0 kW (200 000 Btu/h)

Four blue cased Boiler House models are available and are listed below together with their maximum outputs.

70/90 26.4 kW (90 000 Btu/h) 90/140 41.0 kW (140 000 Btu/h) 140/160 46.6 kW (160 000 Btu/h) 160/200 59.0 kW (200 000 Btu/h)

All models (except the 70/90 and 90/140) are despatched pre-set at their maximum output and for use with kerosene. The 70/90 and 90/140 are pre-set to mid range output.

The boilers are supplied as Conventional flue models, if a Balanced flue version is ordered, a Balanced Flue Kit is required. The following flue kits are available from Grant UK. Refer to Sections 4.8 and 4.9 for further details.

Yellow system - Standard low level concentric balanced flue

Short low level concentric balanced flue 225 mm, 450 mm and 675 mm extensions 90° extension elbow 45° extension elbow 45° elbow

Green system - Standard external high level/vertical flue

starter kit (room sealed) Short external high level/vertical flue starter kit (room sealed) 150 mm, 250 mm 450 mm and 950 mm extensions 195 - 270 mm adjustable extension 45° elbow High level terminal Vertical terminal

White system - High level concentric balanced flue kit

225 mm, 450 mm and 950 mm extensions 275 - 450 mm adjustable extension 45° elbow Vertical concentric balanced flue kit 225 mm, 450 mm and 950 mm extensions 275 - 450 mm adjustable extension 45° elbow

3 - GENERAL BOILER INFORMATION

Boiler description

3.1

Kitchen boilers are supplied with the control panel and burner factory fitted. The burners for Boiler House models are supplied in a separate carton. A burner supply cable is supplied pre-wired to all burners.

All burners are pre-set for use with kerosene and are supplied ready to connect to a single pipe fuel supply system with a loose flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor supplied with the boiler. If required, an additional flexible fuel line (600 mm) and

/8" to 1/4" BSP male adaptor are available from Grant Engineering (UK) Limited, for two-pipe oil supply systems.

All models are suitable for use with Class C2 kerosene to BS 2869:1998.

All models, except the 50/70, are also suitable for use with Class D gas oil to BS 2869:1998.

Note: Only Kerosene may be used with low level balanced flues, unless the flue terminal is higher than 2.0 m above outside ground level.

If the fuel to be used is Gas Oil or the boiler output is to be changed, it may be necessary to change the burner nozzle, head and baffle settings. Refer to the Technical Information in Sections 2.2 and 2.3. To change the nozzle on Kitchen models, remove the burner from the boiler then remove the nozzle as described in Section 7.4. For Boiler House models, unpack the burner and remove the nozzle as described in Section 7.4. To remove the baffles refer to Sections

7.2 and 7.3, then refer to Figs. 30 to 34 for baffle settings. The installer must amend the boiler data label accordingly.

The temperature of the water leaving the boiler to heat the radiators and hot water cylinder is User adjustable from 65 to 85°C.

The boiler is fitted with an overheat thermostat (which allows it to be used on a sealed central heating system) which will automatically switch off the boiler if the heat exchanger exceeds a pre-set temperature of 111°C ± 3°C.

For Kitchen models the control panel is fitted with an ON/OFF switch, boiler thermostat control knob and the manual reset button for the overheat thermostat. An optional plug-in programmer is available which allows the User to set the operating times for central heating and hot water, (plug-in programmer not available for 140/160 and 160/200 models).

For Boiler House models a combined boiler and overheat thermostat is fitted with a boiler thermostat control knob and the manual reset button for the overheat thermostat.

Page 11

Multi Pass Oil Boilers

The boiler casing door is factory fitted with the hinges on the left hand side. If required, the door may be hinged on the right hand side as follows:Remove the hinge pin from the top of the door and the bottom hinge bracket. Refit them to the other side of the door and boiler casing. Adjust the bottom bracket until the door is correctly aligned.

Installation of a MultiPass boiler must be in accordance with the following recommendations:-

a Building Regulations for England and Wales,

and the Building Standards for Scotland issued by the Department of the Environment and any

local Byelaws etc. b Model and local Water Undertaking Byelaws. c Applicable Control of Pollution Regulations. d The following OFTEC requirements:-

OFST 100 Polythene oil storage tanks for

distillate fuels.

OFST 200 Fuel oil storage tanks and tank

bunds for use with distillate fuels, lubrication oils and waste oils.

Further information may be obtained from the

OFTEC Technical Information Book 3

(Installation requirements for oil fired boilers

and oil storage tanks).

3 - GENERAL BOILER INFORMATION

Regulations to comply with

3.2

Regional statutory requirements may deem this appliance to be a 'controlled service'.

Where this is the case, it is a legal requirement that the appliance is installed and

commissioned either under the remit of building control or by a 'Competent person' such

as a suitably qualified Oftec registered technician.

The installation should also be in accordance with the latest edition of the following British Standard Codes of Practice:-

BS 715 Metal flue pipes, fittings, terminals

and accessories. BS 799:5 Oil storage tanks. BS 1181 Clay flue linings and flue terminals. BS 4543:3 Factory made insulated chimneys for

oil fired appliances. BS 4876 Performance requirements for oil

burning appliances. BS 5410:1 Code of Practice for oil firing appliances. BS 5449 Forced circulation hot water systems. BS 7593 Code of Practice for treatment of

water in heating systems. BS 7671 Requirements for electrical

installations, IEE Wiring Regulations.

Failure to install and commission appliances correctly may invalidate the boiler warranty.

IMPORTANT

Before starting any work on the boiler, or fuel supply please read the health and safety information given in Section 11 on page 50.

Page 12

Multi Pass Oil Boilers

3.3.1 Fuel storage

A painted (outside only) storage tank must be constructed to BS 799:5:1987 and OFST 200 and should include the following:-

a A fuel level gauge (not a glass type). b A vent pipe incorporating a weatherproof

termination (bend or cap) of a diameter not less

than the filling pipe. c A sludge valve. d An outlet valve at the opposite end of the tank

to the sludge valve.

The tank should be positioned in accordance with the recommendations given in BS 5410:1:1997, which gives details of filling, maintenance and protection from fire.

The tank should be suitably supported so as to obtain a slope of 20 mm per metre towards the sludge valve.

A galvanised tank must not be used. A plastic tank may be used and must comply with

OFS T100. Note: Plastic tanks should be adequately and

uniformly supported on a smooth level surface, across their entire base area.

3.3.2 Fuel pipes

1 Fuel supply pipes should be of copper tubing with

an internal diameter of at least 8 mm. Galvanised pipe must not be used.

2 Flexible pipes must not be used outside the boiler

case.

3 A remote sensing fire valve must be installed in the

fuel supply line (outside) where it enters the building, with the sensing head located above the burner. Recommendations are given in BS 5410:1:1997.

4 A metal bowl type filter with a replaceable

micronic filter must be fitted in the fuel supply line. A shut-off valve should be fitted before the filter, to allow the filter to be serviced.

5 A flexible fuel line, adaptor and 1/4" BSP isolation

valve are supplied loose with the boiler for the final connection to the burner. If a two pipe system or Tiger Loop system is used, an additional flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor are available from Grant Engineering (UK) Limited.

3 - GENERAL BOILER INFORMATION

6 Flexible pipes should be inspected annually when

the boiler is serviced and replaced every two years.

7 The use of a 'Tankmaster' and Tiger Loop is an

ideal way of delivering an oil supply to the boiler. The Tankmaster unit, fitted to the storage tank, includes a filter, sight tube, shut-off valve and fire valve. A separate fire valve is required in the fuel line (outside) where it enters the building containing the boiler. See Fig. 4.

3.3.3 Single pipe system - (See Fig. 2)

1 Where the storage tank outlet is above the burner

the single pipe system should be used. The height of the tank above the burner limits the length of pipe run from the tank to the burner.

2 As supplied the burner is suitable for a single pipe

system.

3.3.4 Two pipe system - (See Fig. 3)

1 When the storage tank outlet is below the burner,

the two pipe system should be used. The pipe runs should be as shown in Fig. 3. The return pipe should be at the same level in the tank as the supply pipe, both being 75 to 100 mm above the base of the tank. The pipe ends should be a sufficient distance apart so as to prevent any sediment disturbed by the return entering the supply pipe.

2 Avoid the bottom of the tank being more than 3 m

below the burner.

3 A non-return valve should be fitted in the supply

pipe together with the filter and fire valve. A nonreturn valve should be fitted in the return pipe if the top of the tank is above the burner.

4 To be used with a two-pipe system, the burner

must be fitted with an additional flexible fuel line (a flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor are available from Grant Engineering (UK) Limited). See Section 3.3.6.

5 The pump vacuum should not exceed 0.4 bar.

Beyond this limit gas is released from the oil.

For guidance on installation of top outlet fuel tanks and suction oil supply sizing, see OFTEC booklet T1/139. Available at www.oftec.org.uk

Fuel supply

3.3

Page 13

Multi Pass Oil Boilers

3 - GENERAL BOILER INFORMATION

Fig. 3 - Two pipe system

Fig. 2 - Single pipe system

Page 14

Multi Pass Oil Boilers

3.3.5 Tiger Loop system - (See Figs. 4 and 5)

1 When The storage tank is below the burner, an

alternative to a two pipe system can be achieved using the Tiger Loop oil deaerator. This effectively removes the air from the oil supply on a single pipe lift.

2 The Tiger Loop is connected close to the boiler as

a two pipe system (omitting the non-return valve) as shown in Fig. 4. Refer to the manufacturers instructions supplied with the Tiger Loop. The Tiger Loop must be mounted vertically.

Note: To prevent any possibility of fuel fumes entering the building, the Tiger Loop must be fitted outside.

3 To be used with a Tiger Loop system, the burner

must be fitted with an additional flexible fuel line (a flexible fuel line (600 mm) and 3/8" to 1/4" BSP male adaptor are available from Grant Engineering (UK) Limited). See Section 3.3.6.

1/4" BSP female

connections

Tiger Loop

SUPPLY

TO PUMP

RETURN

FROM PUMP

SUPPLY

FROM TANK

Fig. 5 - Tiger loop

Fig. 4 - Tiger loop system

3 - GENERAL BOILER INFORMATION

Page 15

Multi Pass Oil Boilers

Fig. 6 - Riello RDB pump

1 Oil inlet connection

2 Return connection

3 By-pass screw

4 Pressure gauge connection

3.3.6 Two pipe oil supplies

Riello RDB burner - See Fig. 6

1 The fuel pump is supplied for use with a single

pipe fuel supply system. For use on a two pipe system, it is necessary to fit the By-pass screw (see Fig. 6) into the tapping in the return port.

2 The By-pass screw is supplied in the boiler

accessory pack.

3 Remove the plastic burner cover (two screws). To

gain access on Kitchen models, it may be necessary to remove the grey plinth - loosen the screw securing the right hand side of the plinth, then withdraw the plinth forward from the right and away from the case.

4 Remove and discard the blanking plug from the

return connection of the pump and fit the By-pass

screw using an hexagonal key. 5 Connect the return oil flexible fuel line to the pump. 6 Connect the 3/8" to 1/4" BSP adaptor to the flexible

fuel line. 7 Flexible fuel lines and adaptors are available from

Grant Engineering (UK) Ltd. 8 Boiler House models - Fit the burner as described

in Section 4.6.

Fig. 7 Danfoss pump

Pump end

cover

'U' shaped washer

Fig. 8 Danfoss BFP11 L3 pump

1 Supply to nozzle 2 Pressure gauge port 3 Pressure adjustment, 4 mm allen key 4 Vacuum gauge port

5 Return connection 6 Inlet connection 7 Changeover screw

EOGB Sterling 90 burner - See Figs. 7 and 8

1 Remove the four screws securing the pump end

cover and remove the filter.

2 Remove the lower cover plate fixing screw

(changeover screw) and discard the 'U' shaped washer (see Fig. 7). Replace the screw.

3 Replace the filter and pump end cover, ensure the

'O' ring is in position.

4 Remove and discard the return pipe connection

blanking plug from the pump (see Fig. 8) and connect the elbow of the flexible fuel pipe supplied with the burner.

5 Connect the flexible pipe to the rigid fuel return pipe.

3 - GENERAL BOILER INFORMATION

5 Pressure adjuster 6 Vacuum gauge connection 7 Solenoid 8 Supply to nozzle

Page 16

Multi Pass Oil Boilers

Air supply

3.5

Fig. 9 - Air supply for room sealed balanced flue boilers

3 - GENERAL BOILER INFORMATION

Electricity supply

3.4

1 A 230/240 V ~ 50 Hz mains supply is required.

The boiler must be earthed.

2 The supply must be fused at 5 Amp and there must

only be one common isolator for the boiler and control system, providing complete electrical isolation.

3 A fused double pole switch or a fused three pin

plug and shuttered outlet socket should be used for the connection.

4 The power supply cable should be at least 0.75 mm²

PVC as specified in BS 6500, Table 16.

5 All the wiring external to the boiler must be in

accordance with the current I.E.E. Wiring Regulations.

6 Any room thermostat or frost thermostat used must

be suitable for use on mains voltage.

7 In the event of an electrical fault after installation

of the boiler, the following electrical system checks must be carried out:- Short circuit, Polarity, Earth continuity and Resistance to earth.

See Figs. 9 and 10

A sufficient permanent air supply to the boiler should be provided:

a For proper combustion of fuel and effective

discharge of combustion products to the open air.

b For the ventilation of any confined space in

which the boiler is installed to prevent overheating of the boiler any equipment in and near the boiler.

c For the satisfactory operation of any draught

stabiliser which may be fitted.

It should be both the designer's and installer's concern that the air required for these functions be introduced so as to cause as little discomfort as possible to the building occupants and thus to offer them the least temptation to obstruct the ventilators.

Further details may be obtained from BS 5410:1:1997.

Notes:

For a boiler fitted in a compartment, which is ventilated as shown, no additional allowance is necessary.

Open flue - Extract fans, where needed, should be in accordance with Section 4.4.7 in BS 5410 Part 1 1997.

Page 17

Multi Pass Oil Boilers

3 - GENERAL BOILER INFORMATION

Note: If the boiler is in a compartment, this must be added to the areas required for ventilation.

Minimum size of air vents required - see Figs. 9 and 10

Vent A Vent B Vent C Vent D Vent E

50/70 113 cm² (18 in²) 226 cm² (36 in²)

85 cm² (13 in²) 226 cm² (35 in²) 338 cm² (52 in²)

70/90 145 cm² (23 in²) 290 cm² (46 in²) 118 cm² (18 in²) 290 cm² (45 in²) 436 cm² (68 in²)

90/140 226 cm² (35 in²) 452 cm² (70 in²) 198 cm² (31 in²) 451 cm² (70 in²)

677 cm² (105 in²)

140/160 256 cm² (40 in²) 512 cm² (80 in²) 231 cm² (36 in²) 517 cm² (80 in²)

776 cm² (120 in²)

160/200

325 cm² (50 in²)

650 cm² (100 in²)

295 cm² (46 in²) 645 cm² (100 in²) 967 cm² (150 in²)

Fig. 10 - Combustion and ventilation air supply for conventional flue boilers

See Figs. 11 and 12

Grant boilers have high operating efficiencies. Care must be taken to ensure the flue system is suitable for the low flue gas temperatures.

1 An insulated flue terminating in a down draught

free area, i.e. at least 600 mm above the point of exit through the roof or preferably above the ridge level, will normally provide the necessary draught of at least 8.7 N/m2 (0.035 in wg) as measured close to the boiler connection. If a draught of 37 N/m

(0.15 in wg) or more is measured, then a draught stabiliser should be fitted in the flue.

2 The flue terminal must be at least 600 mm from

any opening into the building, and 600 mm above any vertical structure or wall less than a horizontal distance of 750 mm from the terminal. See Fig. 13.

Conventional flue system

3.6

3 If an existing chimney is used, it must be lined with

a stainless steel liner for use with fuel oil. The top and bottom of the annular space must be sealed and the void filled with a suitable insulating material to reduce cooling of the flue gases.

4 If a rigid flue is used either internally or externally, it

must be of the twin wall type with a stainless steel inner skin suitably insulated and weather proofed.

5 The flue diameter must be as specified in

Section 1.1 for the size of boiler in question.

6 The flue must be run upwards following as near a

vertical route as possible. Horizontal runs must be avoided and no bends should have an angle of more than 45° from the vertical. There should be at least 600 mm of vertical flue above the boiler before the first bend.

Page 18

Multi Pass Oil Boilers

External High level (Vertical flue system) See Fig. 12

A twin wall stainless steel insulated flue system is available from Grant UK.

The Starter kit fits as a low level balanced flue kit. See Fig. 18. A Tee assembly replaces the low level terminal and flue guard supplied with the boiler. The flue system is room sealed.

The Grant External flue system connects to the Tee and may terminate at high level or vertically as required. See Fig. 12.

The following components are available from Grant UK.

7 A sealed cleaning door must be provided near the

base of the flue.

8 The exposed flue pipe between the boiler and the

chimney must not be of an asbestos material and aluminium must not be used in any part of the flue.

9 If the draught conditions are satisfactory, the flue

should terminate with a standard cowl. Where the flue cannot terminate above the ridge of the roof, use an 'OH' or similar type cowl where downdraughting occurs.

10 Refer to the locally applicable Building

Regulations, BS 5410:1 and OFTEC Installation Requirements (Books 2 and 3) for further guidance on conventional flue systems.

11 To allow for flue gas analysis and combustion testing,

a test point is provided in the cleaning door.

Kitchen models:

1 Lift off the rear part of the case top. 2 Remove the insulation from the rear top panel (do

not discard it) and remove the blanking panel. Discard the panel, retaining the nuts and washers.

3 Unscrew the protective covers from the studs on

the flue dress panel, supplied in the literature pack. Place the panel in position in the rear case top panel and secure in place using the washers and nuts previously removed.

Note: The first section of flue must be in single wall rigid steel vitreous enamel flue pipe.

4 Cut the insulation into three equal pieces and

replace two - either side of the flue opening in the case top panel.

5 Position the flue pipe into the boiler flue socket

and make good the connection using a suitable flexible high temperature sealant (e.g. Silastic or similar) and rope seal.

6 Position the rear section of the previously prepared

case top over the first section of the flue.

7 Replace the rear section of the case top.

All Boiler House models:

1 Position the flue pipe into the boiler flue socket. 2 Make good the connection using a suitable flexible

high temperature sealant (e.g. Silastic or similar) and a rope seal.

3 - GENERAL BOILER INFORMATION

Connect a conventional flue

3.7

90/140, 140/160 and 160/200 models

Item

Starter kit - standard Starter kit - short 150 mm extension 250 mm extension 450 mm extension 950 mm extension 195-270 mm adjustable extension 45° elbow High level terminal Vertical terminal Wall bracket - standard Wall bracket - extended

Part No.

GK200 GK200S GX150/200 GX250/200 GX450/200 GX950/200 GXA250/200 GE45/200 GTH200 GTV200 GWB200 GEB200

50/70 and 70/90 models

Item

Part No.

GK90 GK90S GX150/90 GX250/90 GX450/90 GX950/90 GXA250/90 GE45/90 GTH90 GTV90 GWB90 GEB90

Page 19

Multi Pass Oil Boilers

Fig. 11 - Typical conventional flue with brick chimney

3 - GENERAL BOILER INFORMATION

Page 20

Multi Pass Oil Boilers

3 - GENERAL BOILER INFORMATION

Fig. 12 - External flue (Green system)

Page 21

Multi Pass Oil Boilers

3 - GENERAL BOILER INFORMATION

Balanced flue options

3.8

To suit wall thickness (mm)

70/90 Boiler House 90/140 Boiler House 140/160, 160/200 Boiler House 50/70, 70/90 Kitchen & System 90/140 Kitchen & System 140/160, 160/200 Kitchen

Rear exit Side exit

Short Kit Min. Max.Max. Min.

110 120 110 140 240 220

220 230 220 250 240 220

190 200 190 220 420 400

400 410 400 430 420 400

20 20

N/A

30 140 100

120 130 100 150 140 100

100

80 N/A 110 300 260

300 290 260 330 300 260

Concentric low level balanced

flue kits

Standard Kit

1 Apart from a conventional flue/chimney, several

balanced flue options are available for use with the Multi Pass boiler.

a Concentric (round) low level horizontal balanced

flue (Yellow system) - available in Short and Standard kits. Extensions are available which extend the flue by 225 mm, 450 mm or 675 mm. A 90° and 45° elbow are also available.

The maximum flue length with or without elbows is 2.0 m.

b High level horizontal balanced flue (White

system) - allows the flue to rise between approximately 1.7 to 2.2 m above floor level before exiting through the rear or side wall. It is adjustable to suit the following wall thicknesses:-

Rear 215 to 450 mm (approximately) Side 120 to 350 mm (approximately)

Extension kits are available which extend the flue by 950 mm, 450 mm, 225 mm or 275 to 450 mm telescopic.

c A vertical balanced flue kit (White system) -

adjustable to 3 m (maximum 6 m with extensions). Extension kits are available which extend the flue by 950 mm, 450 mm, 225 mm or 275 to 450 mm telescopic. A choice of two waterproof flashings (flat or pitched) and a wall bracket are also available.

2 The minimum dimensions for positioning the flue

terminal are shown in Fig. 13.

3 If the flue terminal is fitted less than 2 m above a

surface to which people have access, the terminal must be protected by a guard. A suitable guard is supplied with the low level flue kits. The guard must be fitted centrally over the flue terminal and securely fixed to the wall.

4 The terminal should be positioned so as to avoid

products of combustion accumulating in stagnant pockets around the building or entering into buildings.

When a low level concentric (round) balanced flue is used, the terminal guard must be fitted in all circumstances to prevent objects entering the flue pipe.

The wall thicknesses quoted above for side flue assumes that the boiler will be spaced off the wall by a nominal 20 mm (to provide clearance for the plugs for the water connections). Water connections may be taken from one side only, if required (see paragraph 2 in Section 3.11).

Page 22

Multi Pass Oil Boilers

3 - GENERAL BOILER INFORMATION

Fig. 13 - Clearances for Balanced flues

Notes: * 75 mm with protection.

** 300 mm British Standards

(600 mm recommended for high level balanced flue)

Distances measured to rim of terminal.

Clearances recommended by Grant Engineering (UK) Limited in accordance with British Standards and Building Regulations.

A Below a gutter or sanitary pipework B Horizontal from an opening, air brick or window C Above ground or balcony level D Below eaves or balcony E From an internal or external corner F From a terminal facing the terminal G From a surface facing the terminal H Vertical from terminals on the same wall I Horizontal from terminals on the same wall J Below an opening, air brick, window etc. K From vertical sanitary pipework L Vertical flue from a wall M From an oil storage tank

Min. distance (mm)Terminal position

* 600

600

**300

*600

**300

1200

600

1500

750 600 300 600

1800

Notes:1 An opening means an openable

element, such as an openable window, or a permanent opening such as a permanently open air vent.

2 Notwithstanding the dimensions

given, a terminal should be at least 300 mm from combustible material, e.g. a window frame.

3 A way of providing protection of

combustible material would be to fit a heat shield at least 750 mm wide.

Page 23

Multi Pass Oil Boilers

For additional protection of either the entire heating system, or the boiler and localised pipework, it is recommended that a frost thermostat be installed. Refer to Section 7 for connection details.

To protect the heating system the frost thermostat should be sited within the house in such a place that it can detect any rise and fall in the ambient air temperature, i.e. in a room with a radiator.

Where the frost thermostat is installed outside the house (to protect a boiler installed in an external boiler room or garage) or in an attic, it is recommended that it be used in conjunction with a pipe thermostat to avoid unnecessary and wasteful overheating of the property. The pipe thermostat should be located on the boiler return pipe, and set to operate at 25°C. Refer to Section 8 for connection details.

1 The boiler must stand on a surface that is firm and

level. It does not require a special hearth as the temperature of the boiler base is less than 50°C.

2 Sufficient clearance must be allowed at the front of

the boiler to remove the burner and baffles for servicing.

3 Kitchen models - Once the boiler has been

installed, a permanent worktop may be fitted over it as access to the top of the boiler is no longer required after installation.

4 If the boiler is to be installed with a side against a

wall, allow a nominal clearance of 20 mm for the plugs for the water connections. Water connections may be taken from one side only if required (see Section 3.11, paragraph 2).

5 Boiler House models - Sufficient clearance must

be allowed around the boiler for the following:Access above the boiler to replace the boiler thermostat/overheat thermostat and access to remove the burner.

1 A high level flow and low level return connection

are provided on each side of the boiler. See Fig. 1. 1" BSP connections are used on the 50/70 and 70/90

models. 11/4" BSP connections are used on the 90/140,

140/160 and 160/200 models.

3 - GENERAL BOILER INFORMATION

Frost protection

3.9

Boiler location

3.10

2 Flow and return connections should be diagonally

opposed, i.e. to opposite sides of the boiler. If the boiler is to be positioned against a wall, the water connections may be taken from one side only, in which case the thermostat phials should be located on the same side as the connections.

Note: All models have two tappings (½" BSP) on the top for the thermostat pocket supplied with the boiler (Kitchen models) or burner (Boiler House models). The other tapping should be plugged, using the plug supplied.

3 All water connections have been temporarily sealed

with plastic caps to prevent any residual water (from factory testing) leaking from the boiler during transit. All the caps must be removed before connecting any fittings.

4 A ½" BSP tapping is provided at the bottom right

hand corner on the front of the boiler to allow the fitting of the drain tap supplied.

Plug all unused connections.

5 Fit drain taps in the central heating and domestic

hot water systems to allow the complete system to be fully drained.

To avoid the danger of dirt and foreign matter entering the boiler the complete heating system should be thoroughly flushed out - before the boiler is connected and then again after the system has been heated and is still hot. This is especially important where the boiler is used on an old system.

For optimum performance after installation, this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS 7593:1992 'Treatment of water in domestic hot water central heating systems'.

This must involve the use of a proprietary cleaner, such as BetzDearborn's Sentinel X300 or X400, or Fernox Restorer. Full instructions are supplied with the products, but for immediate information, please contact BetzDearborn on 0151 4209563 or Fernox on 0179 9550811.

For Long term protection against corrosion and scale, after flushing, it is recommended that an inhibitor such as Betzdearborn's Sentinel X100 or Fernox MB1 is dosed in accordance with the guidelines given in BS 7593:1992.

Failure to implement the guidelines may invalidate the warranty.

Water connections (kitchen & boiler house)

3.11

Page 24

Multi Pass Oil Boilers

3.12.3 Sealed system - (See Fig. 16)

Grant sealed system kits and sealed system boilers, incorporating factory fitted systems and circulating pumps are available.

1 The boiler is only suitable for use with a sealed system

complying with the requirements of BS 5449. The maximum temperature of the central heating water is 85°C.

See Figs. 14, 15 and 16

3.12.1 Gravity domestic hot water - (See Fig. 14)

3 - GENERAL BOILER INFORMATION

Heating system diagrams

3.12

3.12.2 Fully pumped - (See Fig. 15)

Fig. 14 - Gravity domestic hot water system

Fig. 15 - Fully pumped system

2 The system must be provided with the following

items:a Diaphragm expansion vessel complying with

BS 4814. b Pressure gauge. c Safety valve. d Approved method for filling the system.

Refer to BS 7074:1 for further guidance.

Page 25

Multi Pass Oil Boilers

3 - GENERAL BOILER INFORMATION

Fig. 16 - Sealed system

3 The expansion vessel can be fitted in either the

return or flow pipework in any of the recommended positions as shown in Fig. 16. To reduce the operating temperature of the expansion vessel diaphragm, position it below the pipe to which it is connected. The expansion vessel may be positioned away from the system, providing the connecting pipe is not less than 13 mm diameter.

4 The pressure gauge should have an operating range

of 0 to 4 bar.

5 The safety valve, set to operate at 3 bar, should be

fitted in the flow pipework near to the boiler. The pipework between the safety valve and boiler must be unrestricted, i.e. no valves. The safety valve should be connected to a discharge pipe which will allow the discharge to be seen, but cannot cause injury to persons or property.

6 Provision should be made to replace water lost

from the system. This can be by manual or automatic means.

7 An automatic air vent should be fitted to the

highest point of the system.

8 All fittings used in the system must be able to

withstand pressures up to 3 bar.

9 Radiator valves must comply with the requirements

of BS 2767(10):1972.

10 One or more drain taps (to BS 2879) must be used

to allow the system to be completely drained.

11 For proprietary expansion vessel/valve/gauge

packs, refer to the manufacturers instructions for the correct location on the heating system.

Underfloor heating systems

3.13

Fig. 17 - Underfloor system

See Fig. 17

On underfloor systems it is essential that the return is

pre-heated by mixing flow water into the return before

it enters the boiler. The return temperature must be

maintained above 55°C to prevent internal corrosion

of the boiler water jacket.

General - Grant boilers are compatible with both

copper and plastic pipe. Where plastic pipe is used it

must be of an oxygen barrier type. The first metre of

pipe connected to the boiler must be made in copper.

Sealed systems - Where a sealed heating system is

fitted to the boiler only copper tube may be used.

Underfloor systems - Plastic pipe may be used on

underfloor systems where the plastic pipe is fitted after

the thermostatic mixing valve. Copper tube must be

used for the primary pipework between the boiler and

the underfloor mixing/blending valves.

Pipework materials

3.14

Page 26

Multi Pass Oil Boilers

Kitchen models

1 Carefully remove the packaging from the boiler

and remove it from the transit pallet.

2 Open the boiler door (open from the right hand

side) and remove the literature pack.

Boiler House models

1 Carefully remove the packaging from the boiler.

The literature pack is supplied on top of the boiler.

2 Unpack the burner.

The pack contains the burner and combined boiler control /overheat thermostat.

Refer to Section 3.7 to fit a conventional flue.

Unpack the boiler

4.1

4 - BOILER INSTALLATION

Prepare the wall - balanced flue

4.2

See Figs. 18 and 19

If the boiler is to be used with a balanced flue, make the hole in the wall for the flue, as shown in Fig. 18 or Fig. 19.

Note: Dimensions A and B given in Fig. 18 and 19 include clearance for fitting.

Fig. 18 - Concentric low level balanced flue (Yellow system) and external high level/vertical flue (Green system)

Kitchen & System models - 50/70, 70/90 Kitchen & System models - 90/140 Kitchen models - 140/160, 160/200 Boiler House models - 70/90 Boiler House models - 90/140 Boiler House models - 140/160, 160/200

A 756 950

1065

754 948

1063

B 125 130 155 150 130 155

C 127 155 155 127 155 155

Dimension (mm)Model

Page 27

Multi Pass Oil Boilers

Fig. 19 - High level balanced flue (White system)

4 - BOILER INSTALLATION

A (dia)

175 200 200 175 200 200

B (min)

1215 1465 1585 1245 1480 1585

B (max)

2115 2205 2325 2145 2220 2325

Dimension (mm)Model

C (side)

115 115 142 145 135 135

High level/vertical balanced flue (White system)

4.3

Fitting instructions for the high level balanced flue and vertical balanced flue are supplied with the flue kits.

Adjustable sections: The adjustable extensions are telescopic. The wall terminal section is adjustable and is suitable for a wall thickness of 215 mm to 450 mm. Simply adjust to the required length using a twisting motion. The outer pipes must overlap by a minimum of 25 mm.

Extensions: The vertical height and horizontal length of the flue may also be increased using extensions. The extensions are available in fixed lengths of 225 mm, 450 mm and 950 mm. An adjustable extension (275 450 mm) is also available.

Bends: 45° bends are available and may be used to create an offset or deviation in the flue system. The distance between the bends should be kept as short as possible with a maximum length of 950 mm.

The equivalent flue length of each elbow is approximately one metre. Only two bends should be used.

Note: The overall assembled flue length for high level flues should not exceed 4.0 metres from the top of the boiler to the end of the terminal. The overall assembled flue length for vertical flues should not exceed 6.0 metres from the top of the boiler to the end of the terminal.

Accessories available:

Extension 225 mm Extension 450 mm

Extension 950 mm Adjustable extension 275 - 450 mm 45° bend Wall bracket

Note: Flue sections cannot be cut.

Page 28

Multi Pass Oil Boilers

1 Fit the thermostat pocket (supplied with the burner)

into one of the tappings on the top of the boiler - If both heating flow and return connections are on one side, position the pocket on that side. Use a small amount of jointing compound on the threads.

Note: Boiler House models - Use the thermostat pocket supplied with the boiler/overheat thermostat assembly.

Plug the other connection using the ½" BSP plug supplied with the boiler.

2 Fit any elbows, bushes etc. to the water

connections before placing the boiler in position if access will be restricted.

Note: If the boiler is to be positioned against a side wall, the water connections may be taken from one side only, (see paragraph 1 for thermostat pocket position).

3 Ensure that all the plastic caps have been removed

from the boiler connections.

4 Fit the drain cock (supplied), in the bottom right hand

connection on the front of the boiler (½" BSP).

5 Plug all connections not to be used and carefully

manoeuvre the boiler into position.

6 Balanced flue models - Do not make any water

connections at this stage.

7 Conventional flue models only - Complete the

water connections and fill the water system. Check for leaks, rectifying where necessary.

4 - BOILER INSTALLATION

Fig. 20 - High level balanced flue

Make the water connections

4.4

Page 29

Multi Pass Oil Boilers

4 - BOILER INSTALLATION

2 Check that the 'O' ring is in position (around the collar

of the burner combustion head). Position the burner on the boiler by sliding the combustion head into the mounting flange on the boiler. With the burner level and correctly located over the fixing stud, secure it in position using the nut previously removed.

Kitchen models are supplied with the burner fitted. To fit the burner to a Boiler House model proceed as follows:-

Riello RDB burner - see Fig. 21

1 Remove and retain the burner fixing nut from the stud

on the burner fixing flange on the front of the boiler, see Fig. 21. Leave the small nut in position (ensure it is located up against the mounting flange).

Note: Do not remove the fixing flange from the boiler.

Fit the burner

4.6

Fig. 21 - RDB burner components

1 Pump 2 Control box 3 Reset button with lock-out lamp 4 Flange with gasket (do not remove from boiler)

5 Air damper adjustment screw 6 Air supply tube connection (balanced flue) 7 Pump pressure adjustment screw 8 Pressure gauge connection

Boiler House models (conventional flue only) - Note: Remove the factory fitted air inlet spigot adaptor from the air intake on the top right hand side of the burner and fit the grey plastic air inlet grille in its place (item 6, above).

See Note below

Page 30

Multi Pass Oil Boilers

EOGB Sterling 90 burner - see Fig. 22

1 Position the burner gasket over the base of the

combustion head and insert the burner mounting bolt so that it passes through the burner lug. Mount the burner assembly so that the combustion head is inside the combustion chamber. Ensure that the burner gasket remains in position on the face of the burner mounting flange.

2 Tighten the single mounting bolt so that the burner

is securely attached to the boiler mounting flange.

4 - BOILER INSTALLATION

Fig. 22 - EOGB Sterling 90 Burner components

1 Lock-out lamp and reset button 2 Control box 3 Ignition transformer 4 Ignition cables 5 Nozzle assembly 6 Nozzle 7 Diffuser plate 8 Combustion head 9 Ignition electrodes 10 Connecting pipe 11 Air damper

12 Solenoid valve 13 Pump 14 Drive coupling 15 Air damper indicator (under cover plate) 16 Fan wheel 17 Air damper adjustment (under cover plate) 18 Photocell (under cover plate) 19 Motor 20 Main burner assembly to front assembly fixing bolt 21 Nozzle adjustment (under cover plate)

12 3 4567

141516171819

Page 31

Multi Pass Oil Boilers

If the optional plug-in electronic programmer is not fitted, it is recommended that the boiler should be connected to a switched mains power supply from an external timer or control system. Refer to Section 8 for a typical control system wiring diagrams.

1 Lift off the boiler case top panel, if it has not

already been removed.

2 Carefully uncoil the two thermostat capillaries and

fit the two thermostat phials into the pocket previously fitted on either the left or right connection on top of the boiler. Ensure that the phials are fully inserted and take care not to damage or kink the capillaries.

3 Remove the wiring cover and open the cable

clamp. Route the supply cable through the hole in the rear panel (using the grommet supplied) up to the control panel, pass it through the cable clamp and connect to the boiler terminal block (refer to Fig. 35 or 36) as follows:Brown to mains live (terminal 1) Blue to mains neutral (terminal 2) Green/Yellow to mains earth (terminal 4)

If the plug-in programmer is not fitted, ensure that the RED wire link, between terminals 1 and 9 on the 12way boiler terminal block is fitted, (not 140/160 or 160/200).

Note: Ensure that the route and length of the cable is such that the boiler front cover plate can be easily removed without disconnecting the supply cable from the terminal block.

4 If the optional plug-in electronic programmer is to

be fitted, follow the fitting instructions given in

Section 4.8 at this point. 5 Secure the cable in the cable clamp. 6 Place the wiring cover in position over the terminal

block, taking care not to trap any wires and secure

in position with the two M4 screws provided. 7 Ensure that all external wiring is adequately

supported. Do not switch on the electricity supply at this stage.

4 - BOILER INSTALLATION

Note: Not applicable to 140/160 or 160/200 models.

Important: Ensure the electrical supply to the boiler

has been isolated before fitting the programmer.

Remove the screws holding the back of the control panel in place and move it back enough to allow access to the rear of the timer aperture.

1 From underneath the control panel, remove the

screw securing the bracket behind the timer aperture. Withdraw and discard the bracket.

2 Remove the blanking piece from the timer aperture,

in the control panel fascia, by firmly pressing on the Grant logo (in the centre of the black square) until it is detached from the rear of the fascia. Remove the blanking piece from the panel and discard.

3 Check that the wiring harness supplied with the

programmer is correctly connected to it as follows:Brown wire to Mains Line (L) terminal of programmer Blue wire to Mains Neutral (N) terminal of programmer Red wire to Heating On terminal of programmer Brown wire to Water On terminal of programmer Yellow wire to Water Off terminal of programmer

4 Connect the programmer to the boiler wiring by

connecting the 6-way plug and socket, ensure the plug is pushed firmly into the socket.

5 Carefully fit the programmer into the aperture and

gently push fully home.

6 Connect the control system wiring to the 12-way

boiler terminal block. Refer to Section 8 for details of typical system control wiring diagrams.

Important: Disconnect and remove the RED wire link between terminals 1 and 9 on the 12-way boiler terminal block.

7 Replace the back of control panel and complete the

electrical connection procedure from paragraph 2 of Section 4.7. Refer to the User's Operating manual provided with the boiler for the operation and setting of the programmer.

Connect the power supply - Kitchen models

4.7

Fit the programmer - Kitchen models

4.8

Page 32

Multi Pass Oil Boilers

4 - BOILER INSTALLATION

It is recommended that the boiler should be connected to a switched mains power supply from an external timer or control system.

1 Position the thermostat phials of the combined

boiler/overheat thermostat in the thermostat pocket on the top of the boiler. Push the assembly fully home onto the pocket, with the cable entries to the front and secure in position by tightening the two fixing screws.

2 Undo the three screws securing the combined

boiler/overheat thermostat cover and lift off the cover.

3 Withdraw the cable support bushes from the cover.

Pass the burner supply cable through one of the bushes and connect it to the boiler (control) thermostat (refer to Fig. 43) as follows:Brown to terminal 1 on the control thermostat Green/Yellow to the earth terminal, marked , on the control thermostat

4 Pass a switched mains power supply through the

other cable support bush and connect it to the overheat thermostat (refer to Fig. 43) as follows:Switched live (brown) to terminal C on the overheat thermostat Earth (green/yellow) and earth fly lead from casing to the earth terminal, marked , on the overheat thermostat The Blue (neutral) wire from the burner supply must be linked to the incoming neutral of switched mains supply using a single connector (not supplied). Refer to Section 8. For other systems not covered, contact Grant Engineering (UK) Ltd.

DO NOT connect the neutral wires to either of the two thermostats.

5 Connect a link between terminal 2 on the overheat

thermostat and terminal C on the control thermostat.

6 There are no connections to terminal 1 on the

overheat thermostat and terminal 2 on the control thermostat.

7 Position the support bushes so as not to strain the

connections when the cover is replaced. Place the cover in position locating the bushes at the same time.

Note: It may be necessary to rotate the thermostat knob to engage it on the operating spindle as the cover is replaced.

8 Secure the cover in position by tightening the three

screws. Tighten the cable support bush nuts to secure the cables.

9 Ensure that all external wiring is adequately

supported.

Do not switch on the electricity supply at this stage.

See Fig. 6 or 7

If a two pipe system is to be used refer to Section 3.3.6. 1 Remove the oil inlet plug from the fuel pump and

connect the elbow of the flexible fuel line supplied with the boiler.

2 Connect the flexible fuel line to the rigid supply

using the adaptor supplied. For Kitchen models the supply enters through one of the holes at the bottom of the case sides or the back panel.

Connect the fuel supply

4.10

Connect power supply - Boiler House models

4.9

Page 33

Multi Pass Oil Boilers

5 - COMMISSIONING

Fig. 23 - Kitchen models

°C

Boiler

thermostat

Overheat thermostat

reset button

(under plastic cap)

Combined Boiler/Overheat thermostat

of the Boiler House models

Fig 24 - Boiler House models

Refer to Figs. 23 or 24 for boiler controls

It is important that the following commissioning procedure is carried out to ensure safe and efficient operation of the boiler. If the boiler output is to be adjusted from that which is factory set, refer to Section 2.2 or 2.3 for the required settings, Section 7.4 for burner head/ nozzle change instructions and Figs. 30 to 34 for baffle adjustment as appropriate.

Note: Check that the baffles are in position and that the cleaning cover is correctly fitted and a good seal made.

1 Check that the water system has been vented (and

pressurised if sealed system) and there are no

leaks. 2 Check that all fuel line valves are open. 3 Remove the plastic burner cover (two screws) if it

was not previously removed. To gain access on

Kitchen models, it may be necessary to remove the

plinth - loosen the screw securing the right hand

side of the plinth, then withdraw the plinth forward

from the right and away from the case. 4 Connect a combined vent manifold and pressure

gauge to the pressure gauge connection port on the

oil pump. See Fig. 6 or 8. Open the vent screw on

your vent manifold to vent the supply while the

pump is running.

5 Set the boiler On/Off switch to Off (Kitchen

models only). Check that all system controls are calling for heat and turn the boiler thermostat to maximum. Switch on the electricity supply.

Note: Boiler House models will start as soon as the electricity supply to the boiler is switched on.

6 Set the boiler On/Off switch to On (Kitchen models

only). The burner fan should start and the burner should light within about 20 seconds. If the burner does not light and the 'Lock-out' reset button lights, wait for about 45 seconds then press the reset button to restart the ignition process. This procedure may have to be repeated several times during first lighting.

Page 34

Multi Pass Oil Boilers

5 - COMMISSIONING

Fig. 25 - EOGB Sterling 90 burner

Nozzle

adjustment

Air shutter

adjustment

Control cover plate

7 With the burner alight, check the fuel pressure.

Refer to the Technical Information, Sections 2.2 and 2.3. Adjust the pressure if necessary - see Fig. 6 or 8. Note that the 'Boiler On' neon lights when the boiler is switched on, but does not necessarily indicate the burner is firing, (140/160 and 160/200 models do not have a 'Boiler On' neon).

8 Operate the boiler until it reaches normal operating

temperature. Check oil supply/return pipe for leaks, rectifying where necessary.

9 With the burner alight, re-check the fuel pressure

and re-adjust if necessary. Turn the boiler off, remove the pressure gauge and replace the plug in the pump.

10 a Having ensured that there are no oil leaks, replace

the burner cover. Ensure the flexible air tube is connected to the burner (balanced flue models).

b Replace the plinth to the Kitchen model (if removed). Locate the left hand side over the locating stud and locate the slot in the right hand side over the screw previously loosened. Tighten the fixing screw.

11 Relight the boiler and allow it to run for 20 minutes

then check the following:CO2 level, Flue gas temperature and Smoke

Number. Refer to the Technical Information in Sections 2.2 and 2.3. A flue gas sampling test point is provided in the cleaning door on the front of the boiler.

Note: The flue gas temperature measured using the cleaning door test point is approximately 25°C higher than at the the flue.

12 Check the smoke number, if satisfactory check the

CO2. Riello RDB burner: Use the hexagonal key

supplied to adjust the burner air damper (see Fig.

21) as required. Turning the screw anti-clockwise closes the damper and increases CO2 level, turning the screw clockwise opens the damper and reduces CO2 level.

EOGB Sterling 90 burner: Adjust the burner air regulator, to gain access remove the controls cover plate, see Fig. 25. Turning the adjustment screw (4 mm allen key) anticlockwise (towards -) closes the damper and increases CO2 level, turning the adjustment screw clockwise (towards +) opens the damper and reduces CO2 level. Replace the cover plate.

Re-check the smoke number if the air damper has been moved. Under no circumstances must the smoke number be above 1. A suitable position for the air damper is one which gives 1% less CO2 than that which has a smoke number of 1.

Note: It is important that the air damper is correctly set.

13 Check the flue gas temperature. 14 Check the boiler overheat thermostat by removing

the boiler thermostat phial (the shorter one for Kitchen models) from the pocket in the top of the boiler shell. The boiler should switch off on the overheat thermostat. Replace the phial. Unscrew and remove the plastic cap covering the reset

button, press the reset button and replace the cap. 15 Replace the case top. 16 When the boiler has been adjusted and is running

satisfactorily, balance the central heating system by

adjusting the radiator lock shield valves. Start with

the radiator nearest the boiler and adjust the valves

to achieve the required temperature drop across

each radiator. 17 Switch off the boiler.

Page 35

Multi Pass Oil Boilers

5 - COMMISSIONING

6 - INFORMATION FOR THE USER

18 With the hot water system hot, check again for

leaks, rectifying where necessary. Drain the system while it is hot to complete the flushing process. Refill and vent (and pressurise if a sealed system) the system.

19 A suitable central heating system inhibitor must be

added to protect the system against the effect of corrosion.

20 Close the front door panel.

Note: After commissioning the boiler you should complete the the Commissioning Report on page 2 of these instructions.

If the boiler is to be left in service with the User, set the controls, timer (If optional programmer is fitted, see instructions supplied in kit) and room thermostat (if fitted) to the User's requirements then refer to Section 6.

If the boiler is not to be handed over immediately, close the boiler fuel supply valve and switch off the electricity supply.

If there is any possibility of the boiler being left during frost conditions, then the boiler and system should be drained.

IMPORTANT NOTE:

To allow the boiler to be commissioned and serviced correctly a combustion test point is provided on the front cleaning door.

The CO2, flue gas temperature and smoke test may all be carried out using this test point. The test point is not suitable for measuring boiler efficiency or conventional flue draught.

When using the test point on the cleaning cover note that the flue gas temperature reading will be considerably higher than that measured in the flue thus resulting in an inaccurate efficiency reading. To obtain an accurate flue gas temperature and efficiency, the reading can only be measured outside through the low level flue terminal. For high level and vertical balanced flues the reading may be taked from the flue kit test point provided . Refer to Section 2.2 and 2.3.

For Conventional flue draught measurement and efficiency a hole must be drilled in the conventional flue pipe. Seal the hole after testing.

The User must be advised (and demonstrated if necessary) of the following important points:-

1 How to light and turn off the boiler and how to

operate the system controls.

2 The precautions necessary to prevent damage to

the central heating system and to the building, in the event of the boiler not being in operation during frost conditions.

3 The importance of servicing the boiler to ensure

safe and efficient operation. This should normally only be required once a year.

4 The type of fuel used.

5 That any servicing or replacement of parts must

only be carried out by a suitably qualified engineer.

6 Ensure that the boiler controls and room thermostat

(if fitted) are set to the User's requirements.

7 If the boiler is used on a sealed heating system, tell

the user the system pressure and show them the position of the safety valve discharge pipe.

8 Show the User how to reset the overheat thermostat

and how to restart the boiler if it goes to 'Lock-out'.

Leave this Instruction manual with the User.

Page 36

Multi Pass Oil Boilers

Important notes prior to servicing

7.1

7 - BOILER SERVICING

Dismantling prior to servicing

7.2

Cleaning the boiler

7.3

To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once per year should be adequate.

Servicing and replacement of parts must only be carried out by a suitably qualified engineer.

Important: Details of every service should be entered in the Service Log, on page 2 of these instructions. This information may be required to validate the Grant extended warranty.

IMPORTANT

Before starting any work on the boiler, or fuel supply please read the health and safety information given in Section 11 on page 50.

1 Check the flue terminal and ensure it is not blocked

or damaged.

2 Run the boiler and check the operation of its

controls.

3 Ensure that all water/fuel system connections and

fittings are sound. Remake any joints and check the tightness of any fittings that may be leaking.

If the boiler is used on a sealed central heating system, check the system pressure. Refill, vent and re-pressurise the system as necessary.

4 Check that any ventilation openings are adequate

and are clear. See Section 3.5.

5 Remove any sludge/water from the fuel tank by

opening the sludge valve at the lower end of the tank.

6 With the fuel supply valve closed, clean/replace the

filter element and clean the filter bowl.

7 Flexible fuel supply pipes should be inspected

annually when the boiler is serviced and replaced every two years. If in doubt replace the pipes.

Warning: Before servicing, set the boiler On/Off switch to Off (Kitchen models only), isolate the electricity supply and close the fuel supply valve. Allow the boiler to cool.

The data label on the inside of the case side panel for Kitchen models or on the front panel for Boiler House models, will indicate the fuel used and nozzle fitted.

1 Kitchen models - Open the case door and remove

the plinth - loosen the screw securing the right hand

side of the plinth inside the case. Withdraw the

plinth forward from the right and away from the

case. 2 If necessary disconnect the flexible air tube from

the burner. 3 Remove the burner fixing nut (top of mounting

flange) and withdraw the burner.

If required, disconnect the flexible oil pipe(s), use

a suitable container to prevent any oil spillage.

Note: If two flexible pipes are connected to the

burner, identify (mark if necessary) which is the

inlet and return if they are to be disconnected.

See Fig. 26

1 Remove the four nuts and washers securing the

front cleaning door and withdraw the door. Take

care - it is heavy. 2 Remove the baffles as shown in Fig. 26 (baffles

shown for 70/90 model). Refer to Figs. 30 to 34 for

other baffle configurations. 3 Remove all deposits from the baffle plates and all

the boiler internal surfaces using a stiff brush and

scraper if necessary. 4 Check the condition of the flue, clean as necessary. 5 Check the condition of the front cleaning door seal,

replace if necessary. 6 Replace the baffles, ensuring they are correctly

fitted. See Fig. 26. 7 Replace the front cleaning door, ensuring the seal

is in good condition and secure it in position with

the four nuts and washers previously removed.

Tighten to form a seal.

Page 37

Multi Pass Oil Boilers

7 - BOILER SERVICING

Fig. 26

Cleaning the burner

7.4

Fig. 27 (70/90 & 90/140 RDB shown)

IMPORTANT: The electrode settings given above MUST be observed

4 ± 0.3 mm

2 to 2.5 mm (50/70) 3 to 3.5 mm (70/90, 90/140)

Clamp screw

See Section 10

1 Combustion head - Loosen the two screws

securing the combustion head and withdraw the head. Clean and replace the combustion head.

EOGB burner - To adjust the nozzle to combustion head position (see Fig. 28), remove the controls cover plate (see Fig. 25) and turn the adjustment screw (4 mm allen key) anticlockwise (towards -) increases the gap, turning the adjustment screw clockwise (towards +) reduces the gap. Replace the cover plate.

2 Inspect the ignition electrodes

Riello burner - Remove the combustion head. EOGB burner - Detach the main burner assembly

by loosening the 4 mm socket headed bolt (see Fig.

29) and remove it from the front assembly. Both burners - Loosen the electrode clamp screw

and withdraw the electrode assembly. Wipe clean and check for any cracks in the ceramic insulation. Replace if necessary.

Check the electrode settings Riello burner - Electrode tips approximately 4 mm

apart and 2 to 2.5 mm (50/70) or 3 to 3.5 mm (70/90, 90/140) in front of the nozzle, see Fig 27.

EOGB burner - see Fig. 28.

3 Nozzle - Check that the nozzle size and type are

correct, refer to tables in Sections 2.2 or 2.3 and boiler data label. Clean the nozzle with kerosene if necessary. Do not use a pin or piece of wire to clean the nozzle. Replace the nozzle if a build up of carbon is present.

With the combustion head removed (Riello burner) or the burner assembly split (EOGB burner, see paragraph 2 above), loosen the electrode assembly clamp screw and slide the electrodes away from the nozzle. Remove the nozzle using a good fitting spanner (16 mm). The use of an ill-fitting spanner will damage the nozzle and could lead to an incorrect flame pattern. Always check the electrode settings (and nozzle to combustion head position for EOGB burner) after replacing the nozzle, see Fig. 27 or 28.

Page 38

Multi Pass Oil Boilers

7 - BOILER SERVICING

Fig. 28 - EOGB Sterling 90 burner head/electrode settings

36 mm

0.0 to 2.0mm

1.7 to 3.7mm

9.5 to 11.5mm

IMPORTANT:

The electrode settings given MUST be observed

Fig. 29 EOGB Sterling burner

Main burner assembly

Front assembly

Measured from the face of the nozzle

to the front edge of the blast tube

4 Riello burner photocell - The photocell is a push-

fit in the burner body. Carefully pull out the photocell to clean.

EOGB burner photocell - Remove the controls cover plate (see Fig. 25) and carefully withdraw the photocell, see Fig. 22.

5 Riello burner fan - With the air intake grille or

spigot removed, remove the screws securing the fan housing cover (R/H side of burner) and remove the cover. Inspect the fan and housing and clean as necessary. Replace the cover.

EOGB burner fan - The fan wheel and housing are accessible when the main burner and front assemblies are separated. Clean as necessary.

6 Pump filter - With the burner cover removed

(Riello burner), remove the four screws securing

the pump end cover. Remove the filter and wash in

kerosene. Replace the filter and end cover, ensure

the 'O' ring is in position. Re-assemble in reverse order.

To ensure safe and efficient operation of the boiler it is important that re-commissioning is carried out, especially combustion checks (CO2 level, flue gas temperature and smoke number) after the boiler has been serviced.

Refer to the Commissioning instructions starting on page 33.

Page 39

Multi Pass Oil Boilers

7 - BOILER SERVICING

Fig. 30 - 50/70 Baffle arrangement

Note: Secure plates in position A for 70 000 Btu/h output

Secure plates in position B for 60 000 Btu/h output Secure plates in position C for 50 000 Btu/h output

Fig. 31 - 70/90 Baffle arrangement

Note: Secure plates in position A for 70 000 Btu/h output

Secure plates in position B for 80 000 Btu/h output Secure plates in position C for 90 000 Btu/h output

Page 40

Multi Pass Oil Boilers

7 - BOILER SERVICING

Fig. 32 - 90/140 Baffle arrangement

Note: Secure plate in position as shown for 140 000 Btu/h output

Remove plate completely for 110 000 Btu/h output

Fig. 33 - 140/160 Baffle arrangement

Left Right

Page 41

Multi Pass Oil Boilers

7 - BOILER SERVICING

Fig. 34 - 160/200 Baffle arrangement

Left

Right

Page 42

Multi Pass Oil Boilers

8 - WIRING DIAGRAMS

Fig. 35

Fig. 36

Kitchen boiler control panel wiring diagram (50/70, 70/90, and 90/140)

8.1

Kitchen boiler control panel wiring diagram (140/160 and 160/200)

8.2

Page 43

Multi Pass Oil Boilers

8 - WIRING DIAGRAMS

HONEYWELL Y PLAN WIRING DIAGRAM HONEYWELL S PLAN WIRING DIAGRAM

HW & CH controlled by two valves

Fig. 38 Fig. 39

LN E

240 V 50 HZ

Frost

Thermostat

Pipe

Thermostat

(if fitted)

Honeywell wiring centre

45 6 7 8 9 10

763NL

ST699B 1002

Time Controller

(Add LinkL-5-8)

Boiler Terminal Block

L641

Cylinder

Stat

T6160

Room Stat

Pump

E N L

V4043H

Zone Valve

Motor

HTG

V4043H

Zone Valve

Motor

DHW

Grey

Blue Blue

Brown

Green/Yellow

Orange

Grey

3456789101112

Fig. 37

Kitchen model with Honeywell S Plan (HW & CH controlled by two valves)

Typical control system wiring diagram (Kitchen models)

8.3

Control system wiring diagrams (Kitchen models with optional programmer fitted)

8.4

Page 44

Multi Pass Oil Boilers

8 - WIRING DIAGRAMS

HONEYWELL C PLAN WIRING DIAGRAM

HW controlled by valve

GRAVITY HOT WATER & PUMPED C/HEATING

Fig. 40 Fig. 41

Fig. 42

HONEYWELL Y PLAN WIRING DIAGRAM

HW controlled by mid position valve

L641

Cylinder

Stat

Overheat

stat

Control

stat

LN E

240 V 50 HZ

T6160

Room Stat

V4073A

Mid Position

Zone Valve

Pump

E N

Blue

Green/Yellow

White

Grey

Orange

Frost

Thermostat

Burner

LNE

Honeywell wiring centre

12345678910

763NL

ST699B 1002

Time Controller

(Add Link L - 5 - 8)

Control system wiring diagram (Boiler house models)

8.5

Page 45

Multi Pass Oil Boilers

8 - WIRING DIAGRAMS

Overheat thermostat

Control thermostat

Mains supply

Supply to burner

Note:

No connection to terminal 1

Note:

No connection to terminal 2

Connector to link neutral wires (not supplied)

Fig. 43

Dual thermostat wiring diagram (Boiler house models)

8.6

9 - FAULT FINDING

Riello RDB burner fault finding

9.1

Page 46

Multi Pass Oil Boilers

9 - FAULT FINDING

Fault Possible causes Remedies

Motor runs

Burner pre-purges

Flame occurs

Burner locks out

Motor runs

Burner pre-purges

No flame occurs

Burner locks out

Flame instability

Incorrect head settings

Low oil pressure

Excess air

Photocell not seeing light

Photocell failed

Control faulty

False light

No spark

No oil

Check nozzle to burner head dimension

and electrode position

Check oil pressure

Adjust air damper

Check photocell is clean and unobstructed

Confirm with new photocell

Check operation of magnetic valve

Confirm with new control. (NB. it is advisabel

to change photcell when changing control)

Check that photocell is not seeing ambient light

Check that HT leads are sound and are

not arcing other than at electrode gap

Check oil supply to burner - check that

the pump is not airlocked

BURNER FAILS TO START

BURNER FAILS TO START AFTER NORMAL OPERATION

Burner fails to start

Lock-out light not lit

Motor runs

Burner runs to lock-out

Fuse has blown

Appliance thermostat has not reset

Appliance overheat device has operated

Control relay or photocell defective

No oil being delivered

Excessive flue draught is preventing

flame establishment

No spark

Check or replace fuse.

Check reason for failure

Adjust thermostat

Reset overheat device. Find reason for

its operation and rectify

Check by replacement

Check that tank, oil lines, fire valve, pump

and nozzle are all in good order

Rectify condition

Check ignition transformer. Check

electrode gap and ceramic insulators

DELAYED IGNITION, BURNER STARTS VIOLENTLY

Burner pulsates on start-up

only with hot flue

Burner pulsates on start-up

Burner starts violently

Excessive draught

Nozzle partially blocked

Oil pressure too low

Flue blocked or damaged

Fan slipping on shaft

Pump coupling loose or worn

Delayed ignition

Recommission burner

Replace nozzle

Check and recommission

Check and rectify

Check and retighten

Check and replace

Check the electrode settings

Check electrodes for damage

Check for loose or damaged HT leads

EOGB Sterling 90 burner fault finding

9.2

Page 47

Multi Pass Oil Boilers

9 - FAULT FINDING

Warning: Always isolate the electricity supply to the boiler before working on the boiler.

Ensure that an adequate supply of fuel is available and that the fuel supply valve is open. Check the condition of the fuel filter, clean if necessary. Ensure fuel supply is reaching burner and vent pump.

Ensure electricity supply to the boiler is switched on and that all controls are calling for heat. Ensure that the overheat thermostat has not tripped, reset if necessary. Check that a mains supply is present at the burner terminal block. If not, check the boiler and overheat thermostat.

Press the reset button on the burner control box if it is lit. Refer to burner fault finding flow diagram.

If the flame is unstable, check the combustion settings. Refer to burner fault finding flow diagram.

Insufficient air supply - check the air damper setting and the condition of the fan. Check room ventilation is adequate, see Section 3.7. Check the nozzle size and type. Fuel pressure may be too high - check and adjust.

Insufficient air supply - check the air damper setting and the condition of the fan. Check room ventilation is adequate, see Section 3.7. Check the nozzle size and type.

Undersize nozzle and/or low fuel pressure. Check condition of boiler heat exchanger and clean if necessary. Check the boiler thermostat. Check the combustion settings. Check the condition of the fuel filter.

Faulty boiler thermostat.

Check the condition of the chimney, ensure it is not blocked and is high enough to produce the required draught. Check that there is an adequate air supply near the burner and that a kitchen fan is not drawing products out of the burner.

Check all fuel line connections, remake as necessary.

Check boiler cleaning cover and seal are correctly fitted. Check burner is correctly fitted onto flange. Check flue is correctly sealed into flue outlet of boiler.

Faults Remedies

Boiler will not start

1 No fuel supply.

2 No electricity supply.

3 Burner not starting - fuel and

electricity supplies present.

4 Burner lights but goes to 'lock-out'.

Boiler works but:-

5 Visible smoke from flue or high

smoke number.

6 Burner pulsates.

7 Flame slow to stabilise during start up.

8 Water temperature low.

9 Boiler operating on overheat

thermostat.

10 Fumes and puffing during starting

(conventional flue).

11 Oil odours.

12 Combustion fumes smell.

Boiler fault finding

9.3

Page 48

Multi Pass Oil Boilers

10 - BURNER SPARE PARTS

Riello RDB burner - exploded view

10.1

1 Not applicable - 2 Flange 3005786 RBS28 3 Combustion head LD2 3008724 RBS126 3 Combustion head LD3 3008768 RBS127 3 Combustion head LD3A 3008769 RBS128 4 Electrode assembly 3007513 RBS108 5 Electrode bracket 3006552 RBS29 6 Nozzle holder 3008642 RBS111 7 Collar 3008643 RBS112 8 High voltage lead 3008794 RBS129 9 Air damper assembly 3008647 RBS116 10 Fan 3005708 RBS39 11 Photocell 3008646 RBS115 12 Capacitor 4.5 µF 3002837 RBS149 13 Seal kit 3008878 RBS140 14 Needle valve 3007582 RBS109 15 Regulator 3008651 RBS120

Key

No.

Description Riello

Part No.

Grant

Part No.

Key No.

Description Riello

Part No.

Grant

Part No.

16 Pump seal 3000439 RBS14 17 Pump 3008654 RBS101 18 'O' ring 3007162 RBS08 19 Filter - 'O' ring 3008653 RBS122 20 Connector 3003602 RBS35 21 Flexible pipe 3007672 RBS36 22 Tube 3008644 RBS113 23 Pressure gauge connector 3008876 RBS138 24 Drive coupling 3000443 RBS16 25 Solenoid 3008648 RBS117 26 Motor 3002836 RBS102 27 Cover 3008649 RBS118 28 Control box assembly 3008652 RBS103 29 Solenoid lead 3008851 RBS139 30 Cover 3008879 RBS141 31 Air tube spigot 3062774 RBS143 32 Air intake cover RBS142

Page 49

Multi Pass Oil Boilers

10 - BURNER SPARE PARTS

Description

Key

No.

EOGB

Part No.

Grant

Part No.

1 Control box S01-TF830-2B SBS01 2 Photocell S01-MZ7705-80 SBS02 3 Pump D01-071N0142 SBS03 4 Solenoid coil E01-071N-0010 SBS04 5 Motor M02-1-125-02 SBS05 11 Transformer D01-052F0030 SBS11 12 Drive coupling B03-00-111-27823 SBS12 13 KA brake plate B03-00-118-85801 SBS13 14 Burner head (140/160) B03-00-117-28401 SBS14 15 Burner head (160/200) B03-00-117-38514 SBS15 16 Control box base S01-5071 SBS16 26 Nozzle/electrode assy. B03-00-118-86701 SBS26 33 Air intake gasket B03-00-119-05701 SBS33

14, 15

EOGB Sterling 90 burner - exploded view

10.2

Page 50

Multi Pass Oil Boilers

11 - HEALTH AND SAFETY INFORMATION

Under the Consumer Protection Act 1987 and Section 6 of the Health & Safety at Work Act 1974, we are required to provide information on substances hazardous to health (COSHH Regulations 1988). Adhesives, sealants and paints used in the manufacture of the product are cured and present no known hazards when used in the manner for which they are intended. The following other materials are present in the product:

Insulation materials

Material Types: Ceramic fibre board, mineral wool. Description: Rigid board, slabs, sleeves, gaskets, ropes. Known Hazards: May cause temporary irritation or rash to skin. High dust levels may irritate eyes and upper

respiratory system.

Precautions: Avoid unnecessary or rough handling, or harsh abrasion of boards. Normal handling and use of

material should not produce high dust levels. Avoid inhalation, and contact with skin and eyes. After handling always follow normal good hygiene practices.

Protection: Use disposable gloves, face mask and eye protection. First Aid: Eyes - If irritation occurs, wash eyes with copious amounts of water. If symptoms persist, seek

immediate medical advice. Skin - If irritation occurs, wash under running water before washing with soap and water. Inhalation - Remove to fresh air, drink water to clear throat and blow nose to remove dust/fibres. Ingestion - Drink plenty of water.

Sealants

Material Types: Silicone elastomer. Description: Sealant and adhesive. Known Hazards: Irritation to eyes. Precautions: Avoid inhalation of vapour, contact with eyes and prolonged or repeated contact with skin.

After handling always follow normal good hygiene practices.

Protection: Use eye protection. Rubber or plastic gloves should be worn where repeated contact occurs and a

face mask worn when working in confined spaces.

First Aid: Eyes - Flush eyes with water for 15 minutes. Seek immediate medical attention.

Skin - Wipe off and wash with soap and water. Inhalation - Remove to fresh air.

Kerosene and Gas oil fuels (Mineral oils)

Known Hazards: The effect of mineral oils on the skin vary according to the duration of exposure and the type of oil.

The lighter fractions remove the protective grease naturally present on the skin, leaving it dry, liable to crack and more prone to damage by cuts, abrasions and irritant chemicals. Skin rashes (Oil acne) most often on arms, but also on any part of the body in contact with oil or oily clothing. Contact with fuel oils can cause dermatitus.

Precautions: Avoid as far as possible any skin contact with mineral oil or with clothing contaminated with

mineral oil. The use of a lanolin-based barrier cream is recommended, in conjunction with regular washing with soap and rinsing with water to ensure all oil is removed from the skin. Take care to prevent clothing, especially underwear, from becoming contaminated with oil. Do not put oily rags or tools in pockets, especially trouser pockets. Have first-aid treatment at once for an injury, however slight. Do not inhale any vapours from mineral oils.

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Multi Pass Oil Boilers

Page 52

D171

Grant Engineering (UK) Limited

Hopton House, Hopton Industrial Estate, Devizes, Wiltshire SN10 2EU

Telephone: (0870) 7775553 Fax: (0870) 7775559

email: info@grantuk.com website: www.grantuk.com

This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.

All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.

Manual compiled and designed by Publications 2000 Tel: (01670) 356211

12 - EC DECLARATION OF CONFORMITY

We declare that the Multi Pass range of Oil Boilers equipped with Riello RDB and EOGB Sterling 90 burners approved to EN 267: 1991 satisfy the requirements of the following European Directives:-

1. 89/336/EEC - Electromagnetic Compatibility Directive Referred to the generic standards EN 55014: 1993, EN 50082: 1: 1992

2. 73/23/EEC - Electrical Equipment Safety Regulations Directive Referred to the generic standard NO: 3260: The Electrical Equipment (Safety) Regulations: 1994

3. 92/42/EEC - Hot Water Boiler Efficiency Directive Referred to the generic standard The Boiler (Efficiency) (Amendment) Regulations 1994 (SI 1994/3083)

Complies with the EC Low voltage, Electromagnetic compatibility and Boiler efficiency Directives

89/336/EEC 73/23/EEC 92/42/EEC

OFCERT Licence Numbers:-

Multi Pass 70/90CF Kitchen ................. 002039501

Multi Pass 70/90BF Kitchen ................. 002089721

Multi Pass 90/140CF Kitchen ............... 002029608

Multi Pass 90/140BF Kitchen ............... 002089725

Multi Pass 140/160CF Kitchen ............. 002089727

Multi Pass 160/200CF Kitchen ............. 002079628

Multi Pass 70/90CF Boiler House ........ 002029609

Multi Pass 70/90BF Boiler House ........ 002089722

Multi Pass 90/140CF Boiler House ...... 002029611

Multi Pass 90/140BF Boiler House ...... 002089726

Multi Pass 140/160CF Boiler House .... 002089717

Multi Pass 160/200CF Boiler House .... 002079615

Grant 50/70, 70/90, 90/140, 140/160, 160/200 User, Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual