Trianco Contractor Series, Contractor H.E. 50/90 EXTERNAL, Contractor HE. 100/125 EXTERNAL User, Installation, Comissioning & Servicing Instructions
H.E. 50/90 EXTERNAL
HE. 100/125 EXTERNAL
OIL-FIRED CENTRAL HEATING BOILER
1
2
CONTENTS
PAGE NUMBER
1. USER INSTRUCTIONS
Introduction
How to use the boiler
After-sales service information
2. INTRODUCTION TO INSTALLATION
3. TECHNICAL INFORMATION
Technical specifications
4. INSTALLATION
Regulations / Health & Safety
Siting
System design
Heating & hot water systems
Electrical supply
Wiring diagram
Condensate drain connections
5. OIL SUPPLY
Oil
Storage tank
Single pipe oil supply
Two pipe oil supply
Oil de-aerators
4
4/5
5
6
7
8
8/9
10
10
10
10
10
11
11
12
13
13
13
14/15
14/15
14
6. FLUE SSTEM
Installation/Clearances
Assembly
7. COMMISSIONING
8. SERVICING
9. BURNER FAULT FINDING
10. SPARES LIST
16
16
17
18
18/19
20/21
22
3
1. USER INSTRUCTIONS
BOILER LOCK-OUT
Please note, to assist Trianco in improving customer service,
it is important that the guarantee/registration card is
returned.
INTRODUCTION
The Trianco Contractor H.E. External boiler has been
designed and constructed to give years of trouble-free
service and these instructions are provided to assist you in
obtaining the best performance with the least trouble and
cost.
The boiler will provide both domestic hot water and central
heating with the simplest of controls. It is supplied with an
adjustable boiler control thermostat, and a manual-reset high
limit thermostat, requiring little attention, other than the
setting of any system controls (such as a room thermostat or
programmer).
TO FIRE THE BOILER
Before firing the boiler, ensure that the system is full of
water, that there is a sufficient level of oil in the storage tank,
and that all isolation valves are fully open.
Check that the time-switch/programmer (if fitted) is on and
that the room thermostat is calling for heat.
Set the boiler thermostat (fig.1) to the desired temperature.
BOILER CONTROL THERMOSTAT
The boiler control thermostat allows you to select the
temperature of the water leaving the boiler. It is calibrated
between High and Low, in five intermediate settings,
corresponding to a temperature range between 82°C (High)
and 55°C (Low). The thermostat is switched off when the knob
is turned fully anti-clockwise to position ‘O’.
Note: Where a cylinder thermostat or room thermostat is fitted,
ensure that the boiler thermostat is set above or equal to the
highest setting. satiatied
HIGH-LIMIT THERMOSTAT
The high-limit thermostat is factory-set and requires no
adjustment. Should the boiler thermostat malfunction and the
water temperature rise to 110°C, the limit thermostat will take
over and shut down the appliance.
The limit thermostat is located on the rear of the control box and
can be reset by pushing in the button. If the thermostat operates
frequently, consult your service engineer, as there may be a fault
in the system.
Note: the high-limit thermostat can only be reset when the water
temperature has dropped by at least 20°C.
BURNER LOCK-OUT
Switch on the electrical supply to the boiler. The burner
should fire after a few seconds.
Set the time-switch/programmer (if fitted) to the times and
programme required.
The boiler should now operate automatically, cutting in and
out according to the heat demand.
TO STOP THE BOILER
The boiler may be switched off by turning off the boiler
control thermostat (fig.1) fully anti-clockwise to the off
position, ‘O’.
If the boiler is to be off for a long period of time, it is
recommended that the mains supply to the appliance is
switched off, or the time-switch/programmer (if fitted) is set
to the OFF position.
FIG. 1
If the burner fails to light for any reason, the boiler will go into
lock-out mode, indicated by the illumination of the reset button on
the burner control box (fig. 2). To reset the burner, press this
button. If the burner returns to lock-out, wait for one minute
before pressing the button again.
If the burner still fails to light, follow the simple fault-finding guide
(page 5), before switching off the electrical supply to the boiler
and contacting your service engineer if the failure persists.
Important: do not attempt to reset the burner more than
twice – constant attempts to do so may cause permanent
damage to components within the burner.
LIGHT &
RESET BUTTON
FIG. 2
4
SYSTEM CONTROLS
ROOM THERMOSTAT
The room thermostat should not be positioned near a source
of heat, such as a radiator, or be exposed to direct sunlight,
as this will cause the heating to switch off before the room is
up to the correct required temperature. Always follow the
manufacturer’s instructions for the best siting position of the
room thermostat.
TIME-SWITCH/PROGRAMMER
When choosing the operating times for your boiler, it is
useful to remember that central heating systems usually take
between half an hour and an hour before becoming effective
and usually remain warm for up to half an hour after boiler
shut-down. The timer can therefore be switched off earlier as
an economy measure.
FROST PROTECTION
As the boiler will be sited externally to the property being
heated, the water may be in danger of freezing and, as such,
the appliance is protected by a factory-fitted frost thermostat,
which will cause the boiler to fire should the temperature
within the casings drop to below 7°C).
If the system is shut down for a long period during very cold
weather, it is also advisable to completely drain the system.
However, too frequent draining of the system should be
avoided, especially in hard water areas, as this could lead to
scaling of the boiler waterways.
See page 7 for flushing and water treatment.
SIMPLE FAULT-FINDING
If the boiler fails to start for no apparent reason, carry out the
following checks before calling your service engineer:
1. Check for failure in the electrical supply.
2. Check for a blown fuse. If the fuse has blown and the
replacement subsequently blows again, switch off the mains
electrical supply to the boiler and contact your service
engineer.
3. Check that there is adequate oil in the tank and that all
isolation valves are fully open.
4. Check for burner lock-out (see page 4).
5. Check for excess water temperature (see high-limit
thermostat details, page 4, for further details).
Note: If the boiler has been shut down due to a failure of the
power supply, it may be necessary to reset the timeswitch or programmer to the correct time, unless the
device has an in-built power reserve.
SERVICING
To ensure the efficient and reliable operation of the boiler it is
essential that the burner be commissioned immediately after
installation, and prior to first use. The boiler requires an annual
service thereafter.
SHUTTING DOWN FOR THE SUMMER
If the boiler is shut down for the summer months, it is
advisable to have it serviced and thoroughly cleaned as
soon as possible to minimise corrosion of the heating
surfaces.
OIL
The oil for your boiler is 28 sec. Kerosene class C2 to BS
2869.
Always ensure that the oil storage tank is topped up
regularly; do not wait until the tank is nearly empty before
refilling, as sludge and water could be sucked into the oil
pipe, affecting the operation of the burner and potentially
reducing the life of the pump.
After a delivery of oil, it is recommended that it be allowed to
settle in the tank for about half an hour before restarting the
boiler.
Sludge and water caused by condensation should be drawn
off at the drain-cock on the oil tank annually.
IMPORTANT NOTES
1. Only an OFTEC-trained and registered engineer can carry
out commissioning and service work.
2. Electrical safety checks should be carried out by a qualified
electrical engineer.
3. It is the responsibility of the installer to ensure proper
commissioning is carried out.
4. It is a requirement of the guarantee and any extended
warranty that an annual service is carried out.
5.
The system water must always be protected by a corrosion
inhibitor.
5
6
INSTALLATION INSTRUCTIONS
IMPORTANT NOTICE:
2. INTRODUCTION
The Contractor H.E. Extenal boiler has been designed to
conform to European Directive/Standards BED 92/42 EEC
LVD 73/23/EEC EMC 89/336/EEC.
The boiler design incorporates a secondary stainless steel
heat exchanger, which recovers heat from the flue gases
which would normally be lost when using conventional oilfired boilers.
The matched pressure-jet burner is exceptionally quiet in
operation and ensures clean and efficient combustion, with
low NOx emissions.
The boiler is suitable for all normal open-vented central
heating and indirect hot water systems. The boiler can also
be used with sealed systems up to a working pressure of 3
bar, with the appropriate sealed system safety equipment.
One return and two flow sockets are provided to facilitate
connection to the heating and hot water systems.
To ensure that the boiler is operating at maximum efficiency,
the central heating return temperature should be 50°C or
above. Maximum performance will be achieved by
maintaining a differential of 20°-30°C between the flow and
return water temperatures.
The Contractor H.E. External boiler is supplied with the burner
set for 28 sec. Kerosene Class C2 to BS 2869 fuel to meet the
Building Regulation requirements for low-level flue discharge.
FLUSHING AND WATER TREATMENT
The performance of the appliance could be impaired by system
debris or the effects of corrosion. New systems must be
thoroughly flushed to remove metal filings, solder, machining oils
and any other fluxes or greases before connecting the boiler.
When fitting the appliance to an existing system, it is advisable to
clean the system by using an appropriate flushing and descaling
agent. Refer to BS 7593 [1992] for guidance.
System additives - corrosion inhibitors and all flushing
agents/descalers should be suitable for steel boilers and comply
with BS 7593 requirements.
Always refer to manufacturers' instructions.
Failure to flush and add inhibitors to the system will
invalidate the appliance warranty.
The appliance is designed to be fitted to fully-pumped
systems only. Failure to do so will invalidate the
warranty.
The boiler must not be run without water in the
system.
Due to the high efficiency of this range of boilers, and to
comply with Building Regulations, Part L, it is essential that
the appliance be fitted on fully-pumped systems only.
All servicing can be carried out from the front of the boiler.
The front-mounted flue-cover permits easy access for
removal of the baffles and cleaning of heating surfaces.
The boiler is fully automatic in operation and incorporates all
necessary safety controls to ensure safe and reliable
running.
To comply with regulations in force, the boiler must be installed and commissioned by an
OFTEC-registered engineer. The installation must comply with all requirements of current
Building Regulations, Part L.
Failure to meet the terms of these requirements may invalidate the guarantee.
THE PERSON(S) WHO INSTALLS THIS APPLIANCE, SERVICES OF CARRIES OUT ANY
REMEDIAL WORK, i.e. ELECTRICAL FAULT-FINDING, MUST HAVE THE SUITABLE
ENGINEERING QUALIFICATIONS.
7
3. TECHNICAL INFORMATION
View of rear of boiler showing boiler
FIG. 4
FIG. 3 OUTLINE DIMENSIONS
connections. Connections can be
made on left or right side of boiler.
8
TECHNICAL SPECIFICATION
50/90 100/125
WEIGHT
WATER CONTENT
FLOW CONNECTIONS
RETURN CONNECTION
MAX OPERATING PRESSURE
TEST PRESSURE
STARTING CURRENT
RUNNING CURRENT
CONTROL THERMOSTAT
LIMIT THERMOSTAT
FROST THERMOSTAT
CASING FINISH
THERMAL INSULATION
ELECTRICITY SUPPLY
140kg 170kg
25 litres 32 litres
1” BSP 1¼” BSP
22mm Compression
3 bar (43.5 psi)
4.5 bar (65.3 psi)
3.5 amp
0.77 amp
Adjustable up to 82°C
Factory-set at 110°C
Factory-set at 7°C
Galvanised Steel, Painted Green
Boiler shell insulated with glass fibre
230/280V – 50Hz fused at 5 amp
BURNER INFORMATION
Model
Contractor
H.E. 50/90
Contractor
H.E. 100/125
Output
(non-condensing)
50,000 BTUs 51,272 53,022 0.45 x 80ºEH 120 psi 11.5
60,000 BTUs 61,526 63,626 0.5 x 80ºEH 140 psi 11.5
70,000 BTUs 71,781 74,231 0.65 x 80ºS 140 psi 11.0
80,000 BTUs 82,649 85,470 0.75 x 80ºEH 130 psi 11.5
90,000 BTUs 92,980 96,154 0.85 x 80ºS 105 psi 11.5
100,000 BTUs 102,360 109,866 1.0 x 80ºEH 96 psi 11.8
112,500 BTUs 115,326 120,102 1.1 x 80ºEH 104 psi 12.6
125,000 BTUs 129,656 132,726 1.1 x 80ºEH 120 psi 12.3
Output
(condensing
Input Nozzle
Pump
Pressure
CO2 (%)
9
4. INSTALLATION
REGULATIONS
Installation of the boiler must comply with the following
British Standards and Regulations:
BS 5410: Part 1 – Code of Practise for Oil-Firing.
BS 5449 – Forced Circulation Hot Water Central Heating
Systems.
Building Regulations - Part J (England and Wales)
- Part F sect. 111 (Scotland)
- Part L
The Control of Pollution (Oil) Regulations
Current I.E.E. Regulations
Local Water Undertakings Bylaws
OFTEC Installation Requirements for Oil-Fired Boilers and
Oil Storage Tanks, OFST 100 & OFST 200.
HEALTH AND SAFETY AT WORK ACT
The installer should be aware of his responsibilities under
the Act and provide, where necessary, appropriate
protection for all persons carrying out the installation.
In the interests of safety, it is required that the appliance is
installed, commissioned and serviced by and OFTEC
registered technician.
A guide to safe working practices for oil-firing technicians is
available from OFTEC.
Electrical work should be carried out in accordance with
BS 7671:2001 by a qualified electrical engineer.
SITING THE BOILER
Sound Levels
Whilst the low sound level of the boiler makes it suitable for
utility room installation, the following factors should be taken
into consideration before installation:
(a) Some people are particularly sensitive to low noise
levels – discuss with the householder.
(b) Low-level flue terminals produce some exhaust noise,
so care should be taken when siting adjacent to
neighbouring property, patios and play areas.
(c) Due to the condensing nature of the boiler, a plume of
water vapour will be discharged from the flue. This
should be taken into account when siting the flue
terminal. Refer to section on flue systems.
Clearance and Service Access
When siting the boiler, ensure adequate clearance is allowed for
making water and flue connections. As the boiler can be fully
serviced from the front, there is no need for headroom allowance.
However, a clearance of at least 750mm is required at the front
of the boiler for future service access.
Hearth
The boiler must be fitted on a non-combustible base, which is
level and capable of supporting the installed weight of the boiler,
including its full water content. The base should be above ground
level to prevent water damage.
SYSTEM DESIGN
To achieve the maximum system efficiencies, the heating system
should be designed to the following parameters:
Boiler Flow Temperature - 50°C to 80°C
Flow Differential Temperature - 10°C to 30°C
COMBUSTION AND VENTILATION AIR
The provision of an adequate supply of combustion air is
essential for the efficient and safe operation of the boiler. The
combustion air inlet is located at the top of the front door of the
appliance. Under no circumstances should this be covered or
blocked.
HEATING AND DOMESTIC HOT WATER SYSTEMS
The heating system should be installed in accordance with
current HVCA Codes of Practice and BS 5449 Part 1 – Forced
Circulation Hot Water Central Heating Systems.
The flow water connections can be made to the boiler by using
the tappings on the left or right hand side of the boiler. The return
is made via the connection on the secondary heat exchanger.
All exposed pipework connecting the boiler to the heating system
must be lagged.
A drain-off cock should be fitted in the lowest part of the system.
Where the boiler is also used for providing domestic hot water, a
double-feed indirect cylinder to BS 1566 Part 1 must be used.
Flush out the system to remove any residue before fitting the
circulating pump.
Make sure all unused boiler tappings are plugged before
filling the system.
10
ELECTRICAL SUPPLY
FIG. 7
230V single-phase 50Hz (fused 5 amp)
Note: this appliance must be earthed and the electrical
supply cable must be of a greater length than the
current-carrying conductor cables (i.e. live and
neutral supply cables).
All electrical wiring must be carried out by a qualified
electrician, in accordance with current I.E.E. Regulations and
any local regulations which may apply.
The 230V – 50Hz electrical supply must be fused by a
double-pole switch, with a contact separation of at least
3mm in both poles, and by a shuttered socket adjacent to
the boiler (both devices must meet the requirements of BS
1363).
The minimum requirement for the power supply cable is PVC
sheathed flexible cord, 0.75mm² (24x0.2mm, code
designation H05 VV-F or H05 VVH2-F), as specified in table
16 of BD 6500.
All external cables entering the control box must be secured
in position by the use of strain-relief bushes (supplied, see
fig. 7 for fitting instructions).
Terminal connections are also provided in the control box for the
ancillary controls.
It is strongly recommended that an RCD is fitted in the boiler
supply circuit.
See wiring diagram, Fig. 8 for further details.
High and Low Voltage Warning
In certain areas of the country, where there is a known risk of
high or low voltage fluctuations, the burner should be prevented
from starting by the use of a voltage-sensitive device if the
voltage drops or increases sufficiently to endanger the
installation.
FIXING OF STRAIN
RELIEF BUSHES
NOTE:
MAINS SUPPLY FOR EXTERNAL CONTROLS MUST
COME FROM THE BOILER AS SHOWN, VIA AN RCD
FIG. 8 – WIRING DIAGRAM
11
CONDENSATE DRAIN CONNECTIONS
DRAIN FROM BOILER
The condensate pipe can be run to either the left or the right
side of the boiler and for ease of installation should be fitted
before the boiler is positioned. Remove the boiler back
casing before installing the condensate pipework.
This process will also leave water inside the ‘U’ section of the
condensate pipework, creating a seal to stop the escape of flue
gases.
Failure to carry out this procedure will result in damage to
the boiler and invalidate the appliance warranty.
To install the condensate pipe, after deciding the direction in
which it should run, feed the long end through the side
casing from the inside. Attach the short end (with the
connecting nut) to the drain connector on the back of the
condensing unit, ensuring a watertight seal is made.
Where possible, connect the condensate pipework to an
external waste drain.
The drain pipe must be installed to allow the condensate to
drain naturally from the boiler, on a minimum fall of 1:20.
The drain from the boiler must be 22mm diameter pipework.
The pipework from the condensate trap to the external
drain is not supplied with the boiler.
Upon successful installation of the condensate pipework,
remove the inspection cover from the top of the condensing
unit and pour a small amount of water inside. Examine the
condensate pipework for any resultant leaks and rectify
accordingly.
Failure to fill the trap with water before firing the boiler may
result in damage to the drainage pipework and potentially
allow the escape of flue gases. Any damage caused as a
result of not filling the trap will not be covered by the
appliance guarantee.
IMPORTANT NOTES:
When running any external pipework from the trap to the drain, it
is essential that the pipework is kept to a minimum and is
insulated to prevent the condense from freezing.
MAINTENANCE:
The trap should be inspected at regular intervals to ensure
correct operation, and should be checked as part of the annual
service schedule.
FIG. 9 – CONDENSATE PIPEWORK
DRAIN FROM BOILER NOT SUPPLIED
NOT SUPPLIED
FIG. 10
12
5. OIL SUPPLY
To comply with OFTEC regulations, a CD/10 form must
installation.
OIL
The burner is factory-set to burn 28 sec. Kerosene Class C2
to BS 2869.
Trianco makes no guarantee as to the satisfactory operation
of the boiler using fuels other than that which is stated
above.
STORAGE TANK
The tank should be fitted with weather-protected fill and vent
connections, a drain-off cock, and an oil level indicator.
Size and Location of Tank
The tank should be large enough to allow for economic
deliveries and be located in an unobtrusive position, having
regard to the need for safety, filling, maintenance, and head
of oil required (see Fig. 11).
Steel Tanks
Steel tanks must comply with the requirements of BS 799
Part 5: 1987 and should be mounted on brick or block piers,
with a waterproof membrane fitted between the piers and
tank.
Plastic Tanks
Polyethylene tanks may be used, having several advantages
over traditional steel tanks:
To comply with Building Regulations, section J5:
1. Where the tank is close to a dwelling, fire protection must be
provided to the eaves, if less than 1.8 metres from the top of
the tank.
2. Cladding must extend at least 300mm beyond the tank.
3. The tank must be fitted on a non-combustible base.
Pollution Protection
To comply with Building Regulations, section J6, the tank must
be bunded (double-walled) if:
1. The tank is less than 10m from a stream
2. The tank is less than 50m from a well, spring, or other
source of drinking water.
3. The tank cannot be viewed from the point of delivery.
4. There is risk of oil reaching a manhole cover or drain in the
event of a leak.
5. The tank capacity exceeds 2,500 litres.
SUPPLY
A long-life flexible oil hose is supplied with the boiler. A filter and
shut-off valve are also required. These should be fitted as shown
on Figs. 11, 12, & 13.
(a) Pier supports are not required; the tank may be fitted
directly onto a flat surface.
(b) They do not corrode; therefore never require repainting.
(c) They are easier to handle because of lower weight.
(d) They are supplied with a 10-year manufacturer’s
guarantee.
Fire Protection
Whilst it is highly unlikely that a fire could start from a
domestic oil tank, protection is required from a fire which
may originate elsewhere. The tank should be at least 1.8
metres from a building and 750mm from a site boundary.
Where it is not feasible to adhere to these limits, the building
wall must not have any openings other than those for
ventilation, the wall must have at least a half-hour resistance
to fire, and must extend 1.8 metres from any part of the tank.
Alternatively, a non-combustible radiation barrier can be
employed, which meets all the requirements of BS 5410 Part
1. This standard applies to tanks up to a capacity of 3,500
litres.
See current OFTEC regulations for further details.
All oil line joints must be completely sealed and the total pipe run
should be flushed thoroughly before connection is made to the
burner. No soldered joints are permitted in the oil line.
Fire Valve
A remote-operated fire valve must be fitted in the oil supply line,
externally to the premises, with the sensing phial located at a
point above the burner.
be completed and left with the appliance upon
13
OIL SUPPLY (cont.)
REFER TO MANUFACTURER’S
Notes:
Single-Pipe Oil Supply (Fig. 12)
Where the lowermost part of the tank is above the level of
the burner, a single-pipe gravity system can be used. The oil
supply pipe should be connected to the suction port on the
burner pump via the flexible hose supplied.
Two-Pipe Oil Supply (Fig. 13)
Where the lowermost part of the tank is below the level of
the burner, a two-pipe suction lift is necessary.
When using the two-pipe system, it is important to convert
the suction pump on the burner to operate as such: remove
the end cover and filter, then remove the bottom screw and
the ‘U’ washer. Replace the screw, making sure it is fully
inserted. See the burner details leaflet for further information.
A spring-loaded non-return valve must be fitted in the suction
line to prevent the oil running back to the tank. No valves are
permitted in the return line.
An additional flexible oil line is also required.
1. The pump suction should not exceed 0.4bar, as dissolved
gas may be released from the oil, affecting combustion.
2. The return pipe must end at the same level as the suction
outlet to prevent loss of prime.
3. The outlet from the tank should be approximately 75mm (3”)
above the bottom to prevent sediment and water being
drawn into the supply line.
Single-Pipe Oil Supply with De-aerator (Fig. 11)
Where a two-pipe suction lift is required, but the return pipe
requirement is too long, or impractical to run, an oil de-aerator
can be used. The burner should be piped as for a two-pipe
system, up until the de-aerator, when a single pipe can be taken
the remaining distance to the storage tank. The de-aerator
should be fitted at the closest point to the boiler, externally to the
premises.
A non-return valve is not required with this system, but the ‘U’
washer must be removed in the same manner as a standard twopipe system.
INSTRUCTIONS FOR OIL DE-AERATOR
INSTALLATION DETAILS
FIG. 11
14
BOILER
FIG. 12 – SINGLE-PIPE OIL SUPPLY
BOILER
FIG. 13 – TWO-PIPE OIL SUPPLY
15
6. FLUE DISCHARGE
DIM ‘A’
Above ground or balcony level
FIG 14
To evacuate the products of combustion safely and
thoroughly, the boiler has a highly efficient integral flue
system and there is no need to fit the boiler to a separate
flue. See page 17 for flue fitting instructions.
INSTALLATION NOTES
a) Trianco H.E. boilers operate at high efficiencies
with low flue gas temperatures. The flue system
used on this boiler is suitable for low flue gas
temperatures and condensation.
b) Ensure that all the joints on the flue system are
adequately sealed, and that no condensation can
escape. It may be necessary to apply a thin bead of
silicone sealant or other lubricating substance
around the flue joints and ‘o’-ring seals before
assembling the flue.
c) Only 28 sec. Kerosene class C2 to BS 2869 is
permitted for boilers using low-level flue discharge.
d) Positioning of flues under balconies and carports is
to be avoided
e) Modern low-level flue boilers are designed to operate at
low noise levels. However, when positioning you boiler,
it is not recommended to have the terminal facing a
neighbour’s property or patio, etc.
f) The boiler should also be positions to avoid the products
of combustion entering the building. A distance of at
least 600mm must be allowed between the terminal and
any window, door or other opening into the building (see
fig. 14) for recommended terminal positions.
g) At certain times during operation, a plume of
condensation will be produced from the terminal. When
positioning the boiler, this should be taken into
consideration to ensure that it does not cause a
nuisance to neighbouring properties.
h) Keep the terminal clear of infra-red sensing devices,
such as those used to control security lighting.
i) The terminal must be protected by the guard supplied.
Directly below an opening, air brick, window, etc. 600mm
Horizontally to an opening, air brick, window, etc. 600mm
Below a gutter, eaves or balcony with protection 75mm
Below a gutter, eaves or balcony without protection 600mm
From vertical sanitary pipework 300mm*
From an internal or external corner 300mm*
From a surface or boundary facing the terminal 600mm
From another terminal facing the terminal 1200mm
Vertically from another terminal 1500mm
Horizontally from another terminal 750mm
300mm*
All distances in millimetres, as measured to the
termination point or rim of low-level discharge
TERMINAL POSITIONS
* Scotland 1990
16
FLUE ASSEMBLY
FIG 15
FLUE ASSEMBLY
The flue terminal pack (supplied) should contain the
following items. Check all components are present before
fitting:
1 x Flue Terminal Assembly
1 x Elbow & Sealing Plate Assembly
1 x ‘O’-Ring Seal
1 x Tube of Silicone Sealant
The flue may exit from the rear, right or left side of the boiler.
The termination point is angled, and can be rotated to enable
the combustion fumes to be directed away from areas where
they could cause a nuisance.
FITTING INSTRUCTIONS
1) Decide which direction the flue is to be pointed. Remove
the top panel and using the nuts provided, fit the
elbow/sealing plate assembly (item 1) onto the rubber
gasket on top of the boiler via the 4 x studs, ensuring
that the open end is pointed in the direction required.
2) Fit the ‘o’-ring seal (item 2) into the groove on the flue
terminal (item 3), ensuring that the flat, ribbed face is to
the inside.
3) Smear a thin bead of silicone sealant (supplied) around the
‘o’-ring seal and slide the terminal into the elbow from the
outside of the boiler casing, being careful to ensure that the
‘o’-ring remains in place. The rotation of the terminal should
be decided before applying the silicone sealant.
4) Place the terminal in the desired position and angle of
rotation. Ensure that a minimum distance of 50mm is kept
from the termination point to the face of the boiler casing.
5) Slide one of the sealing rubbers (item 4) over the terminal to
meet the boiler casing, ensuring the holes line up with those
in the casing.
6) Fit the collar plate (item 6) over the flue terminal and secure
to the boiler casing with the screws provided, clamping the
sealing rubber firmly in place.
7) Blank off the 2 x unused flue openings on the boiler casings
with the remaining sealing rubbers and blanking plates (item
5).
8) Replace the top casing and fit the terminal guard (item 7)
over the flue, securing in position with the screws provided.
17
To maintain the boiler’s high thermal efficiency and
with the appliance on-site.
water all year round, the best time for the annual
Condensate Unit & Trap
water should be retained within the ‘U’ trap.
ensure reliable operation, it should be serviced
annually by a qualified and registered OFTEC
engineer. Electrical work should be carried out by a
qualified engineer. A CD/11 servicing and
commissioning form should be completed and left
If the boiler is used to provide central heating and hot
service is just before the start of the heating season.
The condensate unit and trap should be inspected as
part of the annual service schedule. Remove the
access cover from the top of the condensate unit and
clean all deposits from within. Ensure there are no
blockages within the condensate pipework and the ‘U’
trap itself. When complete, recheck the integrity of the
pipework joints by pouring a small amount of water
into the condensate unit and looking for leaks. Some
Casing
Clean with a damp cloth. Check for signs of corrosion,
apply a suitable protective material if necessary.
18
Condensate Unit & Trap
FIG. 16 – BAFFLE ARRANGEMENTS
IMPORTANT:
FAILURE TO ENSURE THE CORRECT PLACEMENT OF BAFFLES WILL
RESULT IN THE INCORRECT OPERATION OF THE BOILER,
INVALIDATING THE APPLIANCE WARRANTY.
50/90
The condensate unit and trap should be inspected
as part of the annual service schedule. Remove the
access cover from the top of the condensate unit
and clean all deposits from within. Ensure there are
no blockages within the condensate pipework and
the ‘U’ trap itself.
100/125
When complete, recheck the integrity of the
pipework joints by pouring a small amount of water
into the condensate unit and looking for leaks.
Some water should be retained within the ‘U’ trap.
19
9. FAULT-FINDING
BURNER FAULT-FINDING
ELECTRICAL SAFETY - before making any electrical checks, switch off the mains supply to the boiler
FAULT
BURNER WILL NOT START
BURNER STARTS BUT
FLAME NOT ESTABLISHED
POSSIBLE CAUSE
Control box locked out
High limit stat tripped
System controls satisfied
Fuse blown
Motor or pump seized
No oil supply
Photocell not seeing flame
Air trapped in pump
Solenoid valve faulty
ACTION
Press orange reset button on front of
burner. NB: ONLY TRY TWICE
Press red reset button (under control
panel) and check function of boiler stat
Ensure all controls are calling for heat
Fit new fuse (5A). If problem persists,
check for short circuit in wiring
Check for rotation, replace as necessary
Check oil level in tank, check oil supply for
adequate flow
Clean photocell, ensure it is fully inserted
Bleed excess air via tapping on oil pump
Check coil for continuity, replace as
necessary
FLAME ESTABLISHED BUT
BURNER LOCKS OUT AFTER
A FEW SECONDS
Nozzle blocked
Electrodes incorrectly set
Electrode insulator cracked
Ignition transformer or leads faulty
Low oil pressure
Oil contaminated with water
Oil filter partially blocked
Photocell faulty
Low oil pressure
Replace nozzle with one of same
specification (see burner leaflet)
Reset gap and position to settings shown
in burner leaflet
Replace as necessary
Check for spark, check condition of HT
leads, replace as necessary
Check pump pressure and adjust to
settings shown in burner leaflet
Run off oil at burner until free of water and
drain condensation from tank
Wash filter clean with kerosene
Clean photocell, ensure it is fully inserted,
check for damage. Replace as necessary
Check pump pressure and adjust to
settings shown in burner leaflet
20
BURNER FAULT-FINDING (cont.)
ELECTRICAL SAFETY - before making any electrical checks, switch off the mains supply to the boiler
FAULT
MORNING START LOCKOUT
DELAYED IGNITION (BURNER
PULSATES ON STARTUP)
POSSIBLE CAUSE
Faulty non-return valve or air leak in
two-pipe system
Low voltage to appliance
Combustion settings incorrect
Oil level in tank falling below burner
Nozzle partially blocked
Low oil pressure
Flue blocked or damaged
Fan slipping on shaft
Pump coupling loose or worn
ACTION
Replace non-return valve, cure leak
Check with local electricity board
Check combustion under normal
running conditions, check against
settings shown in burner leaflet
Raise tank or fir two-pipe system
Replace nozzle with one of same
specification (see burner leaflet)
Check pump pressure and adjust to
settings shown in burner leaflet
Check flue and rectify/replace as
necessary
Check fan and retighten/replace as
necessary
Check fan and rectify/replace as
necessary
BURNER STARTS VIOLENTLY
BURNER REPEATEDLY
ATTEMPTS TO FIRE
(balanced flue only)
COMBUSTION FUMES SMELL
Delayed ignition
Exhaust gas in combustion air
Baffle access cover not secure
Baffle access cover seal damaged
Burner incorrectly fitted, or fixing
gasket damaged
Flue gasket damaged
Reset electrode gap and position to
settings shown in burner leaflet
Check electrodes for damage, replace
as necessary
Check condition of HT leads, replace
as necessary
Remove air hose from boiler end of
flue, leaving burner end in place. If
burner starts normally, check flue for
breakdown of seals and repair/replace
as necessary
If indeterminate, leaving hose
attached, pierce a small hole in air
hose and use flue gas analyser to
check for carbon dioxide. If more than
trace elements present, check flue for
breakdown of seals and repair/replace
as necessary
Tighten wing nuts, securing door in
position
Replace seal as necessary
Check burner fixing gasket, replace as
necessary. Tighten burner mounting
nuts
Check gasket, replace as necessary.
Tighten flue mounting nuts
21
SPARES
Item Description 50/90 Qty 100/125 Qty
1 Boiler Body 222421 1 223971 1
2 Right Side Panel Assembly 223496 1 223506 1
3 Left Side Panel Assembly 223495 1 223505 1
4 Top Panel 210952 1 221712 1
5 Front Door 223493 1 223503 1
6 Back Panel 223497 1 223507 1
7 Condensing Unit 223880 1 223880 1
8 Boiler Control Thermostat 206896 1 206896 1
9 High-Limit Thermostat 206892 1 206892 1
10 Frost Thermostat 209735 1 209735 1
11 Control Box Assembly 210799 1 210799 1
12 Flue Assembly 223470 1 223470 1
13 Flue Sealing Gasket 223071 1 223071 1
14 Flue Gasket 223787 1 223787 1
14a
15
16
Top Baffle
Middle Baffle
Bottom Baffle
17 Baffle Access Cover 208803 1 208803 1
18 Burner 223868 1 223928 1
19 Burner Cover 223444 1 223444 1
20 Burner Cover Plate 223447 1 223447 1
21
Flexible Oil Line
22 Acoustic Hose 209491 1 209491 1
23 Burner Mounting Flange 223118 1 223118 1
24 Burner Mounting Gasket 223108 1 223108 1
25 Condensate Pipework 223939 1 223939 1
26 Return Pipework Assembly 222973 1 223987 1
27 Drain Cock 99592 1 99592 1
28 Condensate Unit Access Cover 223898 1 223898 1
29 Condensate Unit Access Cover Gasket 223899 1 223899 1
30 Air Box Spigot 223863 1 223969 1
31 Automatic Air Vent 207296 1 207296 1
32 Flue Seal Clamping Collar 223844 1 223844 1
33 Flue Sealing Rubber 223853 3 223853 3
34 Blanking Plate 223842 2 223842 2
35 Casing Grommet 210787 6 210787 6
36 Terminal Guard 223479 1 223479 1
1
1
1
2
208838 3 223965 1
- - 222984 2
208834 1 223336 1
207019 1 207019 1
1
See Fig. 16 (page 19) for baffle configurations.
2
See burner details leaflet for further information.
22
23
April 200
7
Item No. 223839 Issue No. 1
Fax: (0114) 257 1419
TRIANCO HEATING PRODUCTS LTD
Thorncliffe, Chapeltown
Sheffield S35 2PH
Tel: (0114) 257 2300
Fax: (0114) 257 1419
www.trianco.co.uk
24
Loading...