Bosch DANESMOOR UTILITY 12-14 Technical data

DANESMOOR
UTILITY
12/14, 15/19, 20/25, 26/32, 32/50, 50/70
CONVENTIONAL FLUE AND ROOM-SEALED BF
FLOOR STANDING OIL-FIRED PRESSURE JET APPLIANCES
INSTALLATION AND
SERVICING INSTRUCTIONS
Worcester supports the
Benchmark code of practice
THESE INSTRUCTIONS ARE TO BE LEFT WITH THE APPLIANCE
This appliance must be installed and serviced by a competent person
Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Installation Regulations ...........................................Page 2
General Information .................................................Page 2
Technical Data...........................................................Page 3
Siting the Appliance .................................................Page 6
Removal of the Cabinet............................................Page 6
Air Supply..................................................................Page 6
Flue System...............................................................Page 9
Oil Supply ..................................................................Page 12
Heating and Hot Water System...............................Page 16
Electrical ....................................................................Page 16
Installation ................................................................Page 18
Commissioning the Appliance ................................Page 19
Instructions to the User ...........................................Page 23
Routine Cleaning and Inspection............................Page 23
Short Parts List..........................................................Page 26
Fault Finding .............................................................Page 27
1. Installation Regulations
2. General Information
1.1 General installation information and advice may be obtained
from the Oil Firing Technical Association for the Petroleum
Industry (OFTEC). Training courses are also offered by OFTEC,
leading to inclusion on their list of registered engineers.
1.2 The appliance should be installed by a competent person.
The person installing the appliance should be aware of the
Health and Safety at Work Act and take appropriate action to
ensure that the regulations are adhered to. In order to give
optimum efficiency and trouble free operation the appliance
should be commissioned by a qualified engineer. OFTEC
recommends the use of registered engineers for the
commissioning of oil-fired burners.
1.3 The manufacturers notes must not be taken, in any way, as
overriding statutory obligations.
1.4 The compliance with a British Standard does not, of itself,
confer immunity from legal obligations. In particular the
installation of this appliance must be in accordance with the
relevant requirements of the following British Standards and
regulations in respect of the safe installation of equipment.
BS 5410: part 1: Code of practice for Oil Fired Boilers.
BS 799: part 5: Specification for Oil Storage Tanks.
BS 7593: Code of Practice for treatment of water in domestic hot
water central heating systems.
BS 5449: part 1: Specification for forced circulation hot water
central heating for domestic premises.
BS 5955: part 8: Specification for the installation of
thermoplastic pipes and associated fittings for use in domestic
hot and cold water services and heating systems.
BS 7291: Thermoplastic pipes and associated fittings for hot and
cold water for domestic purposes and heating installations in
buildings.
BS 7074: part 1: Application, selection and installation of
expansion vessels and ancillary equipment for sealed water
systems.
BS 7671: IEE Wiring Regulations, current edition.
The Building Regulations Part J and L1 England and Wales; Part F
and Part J Section III Scotland; Part L and Part F Northern Ireland.
Local water company bye-laws.
The Control of Pollution (Oil) Regulations.
1.5 To ensure that the installation will perform to the highest
standards, the system and components should conform to those
mentioned in the instructions.
The Benchmark initiative is the new code of practice to
encourage the correct installation, commissioning and servicing
of domestic central heating boilers and system equipment.
The 'Log-book' is a vital document that must be completed
by the installer at the time of installation. It confirms that the
boiler has been installed and commissioned according to the
manufacturers instructions.
Without the completion of the Log-book, manufacturers may refuse
to respond to a call-out from a householder, who will be advised
that he or she must call back the installer, who has not fulfilled his
obligations to record the information required by the initiative.
It is important that:
The services and the system are properly flushed as specified.
The User is clearly instructed on the correct operation of the
appliance.
The benefits of regular servicing are explained - to maintain the
efficiency and extend the life of the appliance.
2.1 These instructions cover both conventional flue (CF)/low-level
discharge (LLD) and room sealed balanced flue (RS) appliances.
2.2 The Worcester Danesmoor range of appliances covered in these
instructions has been designed to serve domestic central heating
and hot water requirements ranging from 12kW to 70kW on
conventional flue models and 12kW to 32kW on room-sealed
models. The range may be used on sealed or open vent primary systems.
2.3 The RS balanced flue appliance forms a fully room sealed
system by surrounding the burner with a unique, fully sealed, push
fit box. This causes the combustion air to be drawn through a
factory sealed air duct formed at the rear and underside of the
boiler. The sealed burner cover gives excellent acoustic noise
reduction and alleviates the need for an air brick to be located in
the boiler room.
Because the balanced flue system does not rely on the cabinet
panels to form the room seal, combustion readings can be taken
from the flue outlet plate as on a conventional appliance, and the
cabinet panels can be easily removed during installation thereby
preventing any damage.
2.4 The boiler is factory set to the mid-range output and can be
altered, if necessary, by adjusting the burner as specified in Tables
2 to 8. The low level discharge and room sealed 12/14, 15/19,
20/25 and 26/32 models are only suitable for use with 28 second
Kerosene heating oil.
2.5 The appliances may be converted to burn 35 second Gas Oil by
changing the nozzle and burner settings as specified in Tables 3,4,5,7
and 8.
NOTE: It is a mandatory requirement of the building regulations that
only 28 second kerosene is used on low level discharge flues.
2
3. Technical Data
Table 1
Model
POWER SUPPLY
IP RATING
HEATING FLOW
HEATING RETURN
FUEL LINE
CF
RS
12/14
230V 50 Hz
15/19
230V 50 Hz
IP 20
1 in. BSP
1 in. BSP
IP 20
1 in. BSP
1 in. BSP
SPECIFICATIONS
20/25
230V 50 Hz
IP 20
1 in. BSP
1 in. BSP
26/32
230V 50 Hz
32/50
230V 50 Hz
50/70
230V 50 Hz
IP 20
11/4 in. BSP
11/4 in. BSP
IP 20
11/2 in. BSP
11/2 in. BSP
IP 20
11/2 in. BSP
11/2 in. BSP
1
1
1
/4 in. BSP
/4 in. BSP
/4 in. BSP
/4 in. BSP
10mm Compression 10mm Compression 10mmCompression 10mm Compression
100mm (4 in.)
100mm (4 in.)
100mm (4 in.)
125mm (5 in.)
/4 in. BSP
N/A
125mm (5 in.)
Balanced Flue Kit Balanced Flue Kit Balanced Flue Kit Balanced Flue Kit
Section 7.3
Section 7.3
Section 7.3
Section 7.3
N/A
1
1
CF
MINIMUM FLUE
REQUIREMENT
RS
1
/4 in. BSP
N/A
150mm (6 in.) Class 1
up to 12m flue length
175mm (7in.) Class 1
for flue length over 12m
N/A
Below 100°C
Below 100°C
Below 100°C
Below 100°C
Below 100°C
Below 100°C
30m (98 ft. )
30m (98 ft. )
30m (98 ft. )
30m (98 ft. )
30m (98 ft. )
30m (98 ft. )
20
litres
(4.4
gal.)
20
litres
(4.4
gal.)
23.5
litres
(5.2
gal.)
29.1
litres
(6.4
gal.)
44.3
litres
(9.8
gal.)
54
litres (11.9 gal.)
PRIMARY WATER CAPACITY
94 Kg (207 lbs)
97 Kg (214 lbs) 107 Kg (236 lbs) 138 Kg (304 lbs) 197Kg (434lbs) 242Kg (533lbs)
CF
WEIGHT
N/A
N/A
RS 100 Kg (220 lbs) 103 Kg (227 lbs) 113 Kg (249 lbs) 142 Kg (312 lbs)
Electro Oil
Electro Oil
Electro Oil
Electro Oil
Electro Oil
Electro Oil
BURNER
Inter B9 A
Inter B9 B
Inter B11C
Sterling 40
B20C
B20B
HEARTH TEMPERATURE
MAXIMUM STATIC HEAD
WATER SIDE RESISTANCE
10°C Difference
7 mbar
8 mbar
18 mbar
35 mbar
66mbar
195mbar
WATER SIDE RESISTANCE
20°C Difference
EXIT FLUE GAS
MASS FLOW
3 mbar
6 mbar
12 mbar
19 mbar
7mbar
10mbar
24 kg/hr
35 kg/hr
43 kg/hr
57 kg/hr
85 kg/hr
115 kg/hr
85.3%
85.5%
85.3%
85.3%
85.4%
85.2%
SEDBUK RATING*
( SEDBUK BAND C )
CONTROL THERMOSTAT
RANGE
55°C minimum cut in to 82°C maximum cut out
CONTROL THERMOSTAT
DIFFERENTIAL
5°C
HIGH LIMIT THERMOSTAT
BREAK POINT
100 + 0/ – 6°C
MANUAL RESET THERMOSTAT
BREAK POINT
110 + 0/ – 6°C
* The value is used in the UK Government Standard Assesment Procedure (SAP) for energy ratings for dwellings.
Fig. 1. Principal Dimensions. (All Dimensions are in millimetres)
3
Model
12/14
15/19
A
370
370
B
600
600
C
855
855
D
780
780
E
110
110
F
92
92
G
56
56
20/25
370
600
855
780
110
92
56
26/32
520
600
855
775
110
92
56
32/50
520
775
997
917
110
120
56
50/70
520
935
997
917
110
160
56
12/14 Table 2. Electro Oil Inter B9A Burner (See Fig. 18)
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene
28 Sec. Kerosene
Nozzle
Pump
Pressure
(p.s.i.)
0.40 60°ES
0.50 60°ES
130
100
Fuel Flow
Rate
Kg/h
l/h
1.11
1.41
1.30
1.64
Flue Gas
Temp.
(°C)**
180
195
%CO2
10.0
11.5
Approx.
Air
Setting
6.0
7.0
Appliance
Input
Output
kW
Btu/hr
kW
Btu/hr
13.5 46,000
12
41,000
15.5 53,000
14
48,000
15/19 Table 3. Electro Oil Inter B9B Burner (See Fig. 19)
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene
28 Sec. Kerosene
28 Sec. Kerosene
35 Sec. Gas Oil*
Nozzle
Pump
Pressure
(p.s.i.)
0.50 60°ES
0.55 80°EH
0.60 60°ES
0.50 80°S
110
115
105
155
Fuel Flow
Rate
Kg/h
l/h
1.40
1.77
1.59
2.01
1.78
2.25
1.80
2.12
Flue Gas
Temp.
(°C)**
215
225
235
235
%CO2
10.5
10.5
11.5
11.5
Approx.
Air
Setting
8.5
8.75
9.0
9.0
kW
17
19
21.5
21.5
Appliance
Input
Output
Btu/hr
kW
Btu/hr
58,000
15
51,000
65,000
17
58,000
73,000
19
65,000
73,000
19
65,000
20/25 Table 4. Electro Oil Inter B11C Burner (See Fig. 20)
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene
28 Sec. Kerosene
28 Sec. Kerosene
35 Sec. Gas Oil*
35 Sec. Gas Oil*
Nozzle
Pump
Pressure
(p.s.i.)
0.60 80°EH
0.75 80°EH
0.75 80°EH
0.60 80°S
0.60 80°S
130
105
130
120
150
Fuel Flow
Rate
Kg/h
l/h
1.87
2.37
2.10
2.66
2.34
2.96
2.13
2.51
2.37
2.79
Flue Gas
Temp.
(°C)**
190
205
220
205
220
%CO2
11.0-11.5
11.5-12.0
12.0-12.5
11.5-12.0
12.0-12.5
Approx.
Air
Setting
5.5
6.0
6.5
6.0
6.5
kW
22.5
25
28
25
28
Appliance
Input
Output
Btu/hr
kW
Btu/hr
77,000
20
68,000
86,000
22.5 77,000
96,000
25
85,000
86,000
22.5 77,000
96,000
25
85,000
26/32 Table 5. Electro Oil Sterling 40 Burner (See Fig. 21)
Conventional Flue Appliance (CF/LLD)
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene
28 Sec. Kerosene
28 Sec. Kerosene
35 Sec. Gas Oil*
35 Sec. Gas Oil*
35 Sec. Gas Oil*
Nozzle
Pump
Pressure
(p.s.i.)
0.85 80°EH
0.85 80°EH
1.00 80°EH
0.50 80°H
0.55 80°H
0.55 80°H
110
130
130
260
265
330
Fuel Flow
Rate
Kg/h
l/h
2.36
2.99
2.66
3.37
2.95
3.74
2.44
2.87
2.76
3.25
3.06
3.60
Flue Gas
Temp.
(°C)**
225
240
245
220
235
240
%CO2
11.0-11.5
11.0-11.5
11.5-12.0
11.5-12.0
11.5-12.0
12.0-12.5
Approx.
Air
Setting
11
12
16
9
14
16
kW
28.5
32
35.5
28.5
32
35.5
Appliance
Input
Output
Btu/hr
kW
Btu/hr
97,000
26
89,000
109,000
29
99,000
121,000
32
109,000
97,000
26
89,000
109,000
29
99,000
121,000
32
109,000
26/32 Table 6. Electro Oil Sterling 40 Burner (See Fig. 21)
RS Balanced Flue Appliance
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene
28 Sec. Kerosene
28 Sec. Kerosene
Nozzle
Pump
Pressure
(p.s.i.)
0.85 80°EH
0.85 80°EH
1.00 80°EH
110
130
130
Fuel Flow
Rate
Kg/h
l/h
2.36 2.99
2.66 3.37
2.95 3.74
Flue Gas
Temp.
(°C)**
225
240
245
4
%CO2
11.0-11.5
11.0-11.5
11.5-12.0
Approx.
Air
Setting
10
15
20
Appliance
Input
Output
kW
Btu/hr
kW
Btu/hr
28.5 97,000
26
89,000
32 109,000
29
99,000
35.5 121,000
32
109,000
32/50 Table 7. Electro Oil Inter B20C Burner (See Fig. 22)
Conventional Flue Appliance (CF)
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene*
28 Sec. Kerosene*
28 Sec. Kerosene*
35 Sec. Gas Oil*
35 Sec. Gas Oil*
Nozzle
Pump
Pressure
(p.s.i.)
0.85 60°ES
1.20 60°S
1.35 60°S
0.85 60°S
1.0 60°S
160
150
150
210
260
Fuel Flow
Rate
Kg/h
l/h
2.94
3.72
3.77
4.76
4.6
5.81
3.82
4.6
4.66
5.61
Flue Gas
Temp.
(°C)**
165
190
220
190
210
%CO2
12.0-12.5
12.0-12.5
12.0-12.5
12.0-12.5
12.5-13.0
Approx.
Air
Setting
1.0
2.75
4.75
2.75
6.5
Appliance
Input
Output
kW
Btu/hr
kW
Btu/hr
35.4 121,000
32
109,000
45.3 154,500
41
140,000
55.25 188,500
50
171,000
45.3 154,500
41
140,000
55.25 188,500
50
171,000
At 50kW 28sec. Kerosene the airguide should be removed (See Fig. 22 ).
50/70 Table 8. Electro Oil Inter B20B Burner (See Fig. 23)
Conventional Flue Appliance (CF)
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
Fuel
28 Sec. Kerosene*
28 Sec. Kerosene*
~28 Sec. Kerosene*
35 Sec. Gas Oil*
35 Sec. Gas Oil*
~35 Sec. Gas Oil*
Nozzle
1.35
1.75
2.00
1.00
1.35
1.35
60°S
60°S
60°S
60°S
60°S
60°S
Pump
Pressure
(p.s.i.)
175
140
135
245
175
245
Fuel Flow
Rate
Kg/h
l/h
4.62
5.85
5.55
7.03
6.47
8.19
4.69
5.52
5.63
6.62
6.57
7.73
Flue Gas
Temp.
(°C)**
195
210
225
195
210
225
%CO2
11.5-12.0
12.0-12.5
12.5-13.0
11.0-11.5
12.0-12.5
12.5-13.0
Approx.
Air
Setting
2.75
4
4.5
2.75
4
4.5
Appliance
Input
Output
kW
Btu/hr
kW
Btu/hr
55.5 190,000
50
171,000
67
229,000
60
205,000
78
268,000
70
239,000
55.5 190,000
50
171,000
67
229,000
60
205,000
78
268,000
70
239,000
~NOTE: At 70kW the air guide should be removed (See Fig. 23)
* NOTE: For use on conventional flue only.
** NOTE: The flue gas temperature is measured in the gas sampling hole on the flue outlet plate. The probe should be inserted to a depth of 50mm and angled towards the flue outlet.
The temperature measured is not an absolute flue gas temperature and is for general guidance purposes only!
NOTE: The pump pressure given is for general guidance only as variations in nozzle output can be up to ± 15%. It is, therefore, essential that the air is adjusted to give the correct CO2 value.
NOTE: The nozzle type used on 28 Sec. Kerosene outputs are nozzles calibrated specifically for use with 28 Sec. Kerosene which gives less variation in nozzle output than the standard
35 Sec. Gas Oil nozzles. However, if a 28 Sec. Kerosene nozzle is not available at servicing or commissioning it is appropriate to install a 35 Sec. Gas Oil nozzle providing the output, spray
angle and pattern of the nozzle is the same as the 28 Sec. Kerosene nozzle (e.g. 0.75 80°EH may be replaced with a 0.75 80°H).
5
ROOM SEALED BALANCED FLUE MODEL (RS)
6.4 The appliance does not require a separate vent for
combustion air.
6.5 Installation in cupboards or compartments require
permanent vents for cooling purposes, one at high level and one
at low level, either direct to outside air or to a room. Both vents
must pass to the same room or be on the same wall to the
outside air. The minimum air vent free area is given in Table 11.
6.6 There must be sufficient clearance around the appliance to
allow proper circulation of ventilation air. The clearances required
for Installation and Servicing will normally be adequate for
ventilation. See Section 4.4.
4. Siting The Appliance
4.1 The appliance is not suitable for external installation unless
a suitable enclosure is provided.
4.2 The appliance should be positioned on a non-combustible
solid base as near to the flue location point as possible. Care
should be taken to ensure that the appliance is level; use
packing at the corners where necessary.
4.3 When fitting a LLD or RS model the rear of the appliance
must be positioned against an external wall such that the flue
terminal can safely discharge the flue gases as described in
Section 7.
4.4 The following clearances must be left to allow access for
installation and servicing:
(a) Above 300mm
(b) In front - 600mm
(c) Right and left hand side – sufficient for panel removal and
access to pipe connections where required.
Table 9. Minimum Combustion Air Inlet Free Area for
Open Flue appliances.
5. Removal Of The Cabinet
See Figs. 2 and 3.
For installation and servicing of the appliance the cabinet should
be removed as follows:
5.1 Remove the cabinet top panel by lifting squarely upwards to
release the four ball stud connections.
5.2 Remove the front panel by pulling the bottom of the panel
forwards to release the lower ball studs and then repeat the
procedure at the top end to release the upper ones. Take care
not to pull the bottom end too far forwards as this may cause
damage to the spring clips.
5.3 The side panels are removed by firstly following procedures
5.1to 5.2 as described above, then remove screw (A) from the side
panel base and the three screws located in the upper flange of each
side panel. Ease the panel clear of the electrical control box and
slide forwards to release from the locating lugs on the base plate.
5.4 The control box can be removed by undoing the four screws
in the front facia cover and then removing the wing nut on the
underside of the control box. The thermostat phials should be
carefully removed from the phial pockets and the control box
placed in a safe place taking care not to kink the thermostat
capillary tubes.
5.5 On the RS balanced flue model, remove the burner box cover
by pulling forwards to release the ball studs. This will be found
easier by pulling on one side of the handle first to release two of
the ball studs and then repeating on the other side. Take care
not to pivot the remaining two ball studs too far around as this
will cause damage to the spring clips.
Appliance
model
AREA OF AIR INLET
in.2
cm2
12/14
15/19
77
105
12
16.5
20/25
26/32
32/50
50/70
138
176
275
385
21.5
27.5
43
60
Table 10. Minimum Air Vent Free Area for Open Flue
appliances installed in a compartment.
Appliance
model
12/14
15/19
20/25
26/32
32/50
50/70
Ventilation to room or
internal space
High Level
154cm2
209cm2
275cm2
352cm2
550cm2
770cm2
Low Level
231cm2
314cm2
413cm2
528cm2
825cm2
1155cm2
Ventilation to outside
High Level
77cm2
105cm2
138cm2
176cm2
275cm2
385cm2
Low Level
154cm2
209cm2
275cm2
352cm2
550cm2
770cm2
Table 11. Minimum Air Vent Free Area for Room Sealed
appliances installed in a compartment.
Appliance
model
12/14
15/19
20/25
26/32
6. Air Supply
OPEN FLUE MODEL (CF/LLD)
6.1 In order to ensure clean and efficient combustion an
adequate supply of air must be delivered to the combustion
chamber. To provide sufficient air a suitable inlet should be
provided into the room or space in which the boiler is situated,
the sizes of which are shown in Table 9. An air brick or other form
of continuous air supply may have to be built into the installation
in order to ensure an adequate supply of air.
6.2 If the appliance is to be installed in a confined space or
compartment, two air vents are required, one at high level and
one at low level. The minimum free area of each vent is given in
Table 10 and depends whether the air is taken from another
room or from outside the building. Where the air is taken from
another room that room must contain an air inlet as described in 6.1.
6.3 There must be sufficient clearance around the appliance to
allow proper circulation of ventilation air. The clearances required
for Installation and Servicing will normally be adequate for
ventilation. See Section 4.4
6
Ventilation to room or
internal space
High Level
154cm2
209cm2
275cm2
352cm2
Low Level
154cm2
209cm2
275cm2
352cm2
Ventilation to outside
High Level
77cm2
105cm2
138cm2
176cm2
Low Level
77cm2
105cm2
138cm2
176cm2
Fig. 2. Conventional Flue Appliance (CF/LLD).
Control Box Assembly
Manual reset overheat thermostat
phial
Split pin
Automatic reset high
limit thermostat phial
Control thermostat
phial
Top panel
Fire valve clip
High limit thermostat
Manual reset
overheat
thermostat
Burner plug-in
connector
Strain relief
bush
Optional pump
location
Burner
Burner locking
screw
Thermostat
knob
Burner seal
gasket
Side panel
locking screw (A)
Side panel
Front panel
7
Fig. 3. Room Sealed Balanced Flue Appliance (RS).
8
Down-draught conditions will adversely affect the operation of the boiler and must be avoided. Where possible the flue should be extended
beyond the apex of the roof and should always be taken beyond the
eaves of the building. Where down-draught is experienced a suitable
anti down-draught terminal should be fitted to the flue termination.
The natural flue draught must be checked in the flue pipe immediately above the appliance or in the hole provided in the flue
outlet plate. The flue draught should be no less than 0.75 mm
W.g. and no greater than 5.1 mm W.g. If a flue draught greater
than 5.1 mm W.g. is experienced a draught stabiliser should be
introduced into the flue and adjusted to achieve a flue draught
within the specified range.
7.2 Low Level Discharge (LLD)
(See Fig. 5).
The low level flue kit is not designed for use with this appliance
as there is no provision for installation of the flue gas purge
timer. However, where fume odour will not present a problem
(eg boilerhouse/outhouse) the flue kit may be used without the
purge unit. Alternatively, a standard Danesmoor kitchen
appliance or room-sealed utility model should be used.
The LLD kit converts the 12/14, 15/19, 20/25 and 26/32
conventional flue appliances to discharge the combustion
products from the rear of the appliance at low level.
The flue spigot should be removed from the flue outlet plate by
7. Flue System
A flue system must be provided in accordance with BS5410 and
the current Building Regulations. (See Section 1.4).
7.1 CONVENTIONAL FLUE (CF).
See Fig. 4.
Conventional Flue Diameters: 12/14 – 100 mm (4 in.)
15/19 – 100 mm (4 in.)
20/25 – 100 mm (4 in.)
26/32 – 125 mm (5 in.)
32/50 – 125 mm (5 in.)
50/70 – 150 mm (6 in.)
NOTE: On 50/70 models with flue lengths longer than 12
meters it is recommended that 175mm (7in.) flue pipe is used
from the boiler.
NOTE: External flues systems must be of the insulated flue type.
Fig. 4. Flue Installation.
Fig. 5. Flue Installation (Rear Discharge).
FLUE GUARD
See Fig. 7 for
flue terminating
positions.
766
80
min.
undoing the three retaining screws and the hole blanked off with
the plate provided in the kit.
Detailed instructions for converting the appliance to low level
discharge are supplied with the conversion kit.
NOTE: Under no circumstances may 35 Second Gas Oil be
burned with this type of flue terminal arrangement.
7.3 ROOM SEALED BALANCED FLUE MODEL (RS).
The appliance is supplied ready for installation as a low level
discharge balanced flue system by the simple addition of one of
the flue terminal kit options shown in Fig. 6.
The boiler is fitted with a conventional flue locating spigot. The
flue pipe fits into the spigot and should be correctly sealed with
fire cement.
NOTE: The size of the flue must never be reduced from the takeoff diameter. An increase in flue size is permissible provided that
the joint is sealed correctly.
When installed the flue should be vertical and contain as few
bends as possible. Where bends are necessary, a maximum of
two are permitted and 135 degree bends should be used.
All brick and masonry chimneys should be lined with a suitable
non-combustible material, properly jointed and able to withstand the effects of the working temperature of the appliance
and any condensate which may form.
Details of the installation procedure are included in the Flue
Terminal Installation instructions supplied with the terminal kit.
Alternatively, a range of room-sealed balanced flue kits are available
to convert the appliance to discharge the flue products to the left,
right, at a higher level, or vertically up to a roof height of 4.5 metres.
7.4 Siting the flue terminal
1. The flue terminal must be located in a suitable position, as
shown in Fig. 7, such that the products of combustion can be
freely dispersed without the possibility of the gases entering the
dwelling or that of a neighbouring dwelling.
2. Discharge of flue gases into car ports or narrow passageways
is not recommended.
9
Fig. 6. Room Sealed Balanced Flue Terminal Installation.
X = 180mm Maximum
X
(a) Rear Discharge 4" to 7" Single Skin Wall.
For use with non-standard/single skin walls up to
182.mm thick.
Where noise emission from the flue terminal is likely to
be of concern, it is recommended that the standard 12 in.
terminal is used and the appliance stood away from the
wall to take up the extra terminal body length.
X = 327mm Maximum
X
270mm
FLUE GUARD
340mm
(b) Rear Discharge 7" to 12" Wall.
766mm
For use in standard cavity walls and solid walls
up to 327mm thick. This terminal offers
maximum noise reduction of the flue gases.
This terminal is designed for use with the
extension kit.
(c) Rear Discharge Extension Kit
12" to 36" Wall.
For use where the wall thickness exceeds
327.mm or where the appliance is to be stood
away from the wall as shown. The system uses a
standard 12 in. RS Flue Terminal and up to two
extension kits, which simply bolt together.
One extension kit – X = 638mm Maximum
X
Two extension kits – X = 952mm Maximum
10
3. The terminal must not cause an obstruction nor the discharge
cause a nuisance as a result of either flue gases or terminal noise.
Fig. 8. Terminal guard Minimum dimensions.
4. If the terminal is fitted within 1m of a plastic or painted gutter or
within 500 mm of painted eaves then an aluminium or stainless
steel shield at least 1m long should be fitted to protect the surface.
265
5. If a terminal is fitted less than 2 metres above a surface to
which people have access, fit a terminal guard as shown in Fig. 8.
A suitable guard is available from Worcester, Bosch Group, Part
Number 7 716 190 009, or alternatively a proprietary terminal
guard may be used provided it has the minimum dimensions
shown in Fig. 8.
280
The guard should have suitable corrosion resistance due to the
acidic content of the flue gases.
6. The terminal guard must be evenly spaced about the flue
terminal and secured using screws so that the terminal guard
can be removed for maintenance to the flue terminal.
Terminal guard.
See 7.4.5.
7. In certain weather conditions a terminal may steam and siting
where this could cause a nuisance should be avoided.
280
8. Take care to ensure that combustion products do not enter
ventilated roof voids.
Fig. 7. Flue terminating positions for oil-fired appliances
NOTE: The dimensions given are for general guidance only. Other surrounding buildings or objects may affect the clearance of
combustion products. An alternative flue terminal position should be sought when there is any possibility of a nuisance being
caused by inadequate dispersal of flue products.
Terminals should be positioned so as to avoid products of combustion entering into buildings.
P
O
M
Boundry
M
N
C.D.
F
B
J
A
Window
H
K
E
Boundry
Flue
Terminal
G
F
F
L
Minimum Distance (mm)
Open
Low-Level
Vertical
Flue
Discharge
Balanced Flue
Terminal Position
A
B
C
D
Directly below an opening, air brick, window, etc. ..........................................
Horizontally to an opening, air brick, window, etc. ........................................
Below a gutter or sanitary pipe if combustible material protected. ..............
Below a balcony, eaves, gutter or drainage without protection
to combustible material. ......................................................................................
E From vertical sanitary pipework.. .......................................................................
F From an internal or external corner or boundry along side terminal. ..........
G Above ground or balcony level. ..........................................................................
H From a surface or boundry facing the terminal. ..............................................
J
From a terminal facing the terminal. .................................................................
K Vertically from a terminal on the same wall. ...................................................
L Horizontally from a terminal on the same wall. ..............................................
M Above an intersection with the roof. .................................................................
N From a vertical structure on the side of the terminal......................................
O Above a vertical structure less than 750mm from the side of the terminal.
P From a ridge terminal to a vertical structure on the roof................................
11
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
Not allowed
600
750
600
1500
600
600
75
600
300
300
300
600
1200
1500
750
Not applicable
Not applicable
Not applicable
Not applicable
Not allowed
''
''
''
''
''
''
''
''
''
732
750
732
Not applicable
gns shown in Fig. 8.
8. Oil Supply
Fig. 9. Oil Pump.
1 INLET
A. Danfoss BFP 41.
(See Figs. 9, 10 and 11).
8.1 Plastic or steel tanks should be installed to BS5410.
A steel tank should also conform to BS799: part 5 and be arranged
with a slope of 1 in 24 away from the outlet valve with a sludge
cock at its lower end.
8.2 Do not use galvanised steel tanks or pipework for the oil
supply system.
8.3 Do not use soldered joints in the oil supply pipework as this
could cause a hazard in the case of a fire.
8.4 The burners on all appliances are supplied so as to be
connected to a single pipe gravity feed system. Details of how to
convert the burners to a double pipe sub-gravity feed system are
shown in Fig. 9
8.5 Oil Supply System
(a) Single Pipe System
If a single pipe system is employed, then the tank must be
positioned such that the oil level does not exceed 4 metres
above the level of the burner oil pump and in addition the oil
level must be at least 0.3 metres above the level of the oil pump.
Should it prove impossible to site the tank below the 4 metres
maximum oil level head breaking device must be installed
between the tank and the burner.
(b) Double Pipe System
If a double pipe system is used then the maximum suction
height allowable is 3.5 metres.
(c) Single Pipe Suction Lift with De-aerator
If a single pipe suction lift with a de-aerator is used, the oil tank must
be positioned below the burner. An inlet and return loop should be
created between the de-aerator and oil pump. The oil pump should be
connected as for a double pipe system. Details of how to convert to a
double pipe system are shown in Fig. 9.
Oil inlet and return flexible hoses should be connected to the oil
pump inlet and return ports.
Table 14 is a general guide to determine the maximum allowable
pipe run when using a de-aerator.
Table 14 does not override the de-aerators manufacturers
instructions and should only be used in conjunction with the
manufacturers instructions.
If a non-return valve is not incorporated within the de-aerator
unit, a non-return valve should be fitted in the oil line between
the oil tank and the de-aerator.
NOTE: If a de-aerator is used it should be fitted externally to the building.
8.6 Oil Supply Pipework
a) The oil supply pipe diameter can be determined using Tables 12,
13 and 14 depending on whether a single or double pipe system or
single pipe suction lift system is being installed. Selection of the
correct pipe diameter will depend on the position of the oil storage
tank relative to the burner and the length of pipe run.
b) The oil supply pipe should be laid as level as possible to avoid
air pockets and unnecessary friction losses.
c) The following components should be fitted in the fuel line
between the storage tank and burner:
1. A Manual isolating valve installed as close to the tank as possible.
2. A fire valve in accordance with BS5410, as shown in Fig 10. The
fire valve should be fitted externally with a fire detection element
located within the appliance case. Use of a capillary type valve will
allow a neat and simple installation. A suitable valve is the KBB
manufactured by Teddington Controls Limited. A spring clip has
been provided behind the electrical panel on CF/LLD models, shown
in Fig 2 and on the burner box on RS models, shown in Fig 3 to
allow a fire valve element to be mounted. Alternatively a fusible link
or electrical system may be used. Under no circumstances should a
combination isolating/fire valve be used as the sole fire protection
device.
3. An oil filter should be fitted close to the oil storage tank. If
there is doubt about the internal oil line condition, a further filter
should be fitted near the boiler.
2 RETURN
Cartridge filter
3
3 BLEED AND PRESSURE
GAUGE PORT
4 VACUUM GAUGE PORT
6
5
5 PRESSURE ADJUSTMENT
6 NOZZLE OUTLET
4a
2
1
To convert to a double pipe system, remove plug 4a and insert
the grub screw provided into the
threaded hole. Connect flow and
return pipes to (1) and (2).
4
B. Danfoss BFP 11 Oil Pump.
3
6
5
A
4
1
2
To convert to a double pipe system: Remove the pump front
cover, remove the changeover
screw (A) nearest to ports 1 and
2, and the horseshoe washer
underneath. Replace the
changeover screw back into the
threaded hole. Connect the flow
and return pipes to 1 and 2.
Note: When removing the pump
front cover ensure that a suitable
receptacle is placed below the
pump to catch the oil residue.
C. Suntec AS47C Oil Pump.
3
4
5
B
To convert to a double pipe system, remove the return port plug
(2) and insert the grub screw (A)
provided into the threaded hole
(B). Connect flow and return pipes
to (1) and (2).
3
2
1
A
TABLE 12 Single Pipe Gravity Feed System
HEAD (metres)
MAXIMUM ALLOWABLE PIPE RUN
(metres)
0.5
1.0
1.5
2.0
2.5
3.0
3.4
4.0
8 mm inside dia. pipe 10 mm inside dia. pipe
(10 mm O.D. copper)
(12 mm O.D. copper)
12
30
25
69
37
91
49
100
62
100
74
100
87
100
99
100
TABLE 13 Double Pipe Sub-Gravity Feed System
12
HEAD (metres)
MAXIMUM ALLOWABLE PIPE RUN
(metres)
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
8 mm inside dia. pipe 10 mm inside dia. pipe
(10 mm O.D. copper)
(12 mm O.D. copper)
50
100
44
100
38
95
32
80
26
66
20
51
14
37
8
22
TABLE 14 Single Pipe Suction Lift with De-aerator
MAXIMUM ALLOWABLE PIPE RUN FROM TANK TO DE-AERATOR (metres)
5.0 (kg/h)
100
95
80
70
60
45
35
25
6 mm inside dia. pipe
(8 mm O.D. copper)
55
45
40
35
30
25
15
10
10.0 (kg/h)
10.0 (kg/h)
26
23
20
17
14
11
8
5
8 mm inside dia. pipe
(10 mm O.D. copper)
100
100
90
75
65
50
35
20
Fig. 10. Oil Supply.
Wall
Full base
(for plastic tanks)
Filter
Isolating
valve
Isolating
valve
Non return
valve
(b) Double pipe system.
Oil tank
Fire detection
element
Fire valve to
BS 5410
Filter
Non return
valve
Isolating
valve
Wall
Fire detection
element
Isolating
valve
Isolating
valve
Burner
Burner
150 mm
Full base
(for plastic tanks)
Isolating
valve
Fire valve to
BS 5410
Wall
(c) Single pipe lift system with de-aerator.
Fire detection
element
De-aerator
Oil tank
Filter
Fire valve to
BS 5410
Full base
(for plastic tanks)
H = 0.3 m (1 ft) minimum
Oil tank
Paper element
oil filter
Isolating
valve
Burner
Isolating
valve
13
H = 4 m (13 ft) maximum
Maximum oil level
(a) Single pipe system
H = 3.5 m (11.5 ft) maximum
0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
2.5 (kg/h)
H = 3.5 m (11.5 ft) maximum
Fuel
Flowrate
HEAD
(metres)
Fig. 11. Oil Pipe Installation.
Fig. 12. Typical Open Vent Fully Pumped System (Honeywell ‘Y’ plan).
14
Fig. 13. Typical fully pumped sealed system (Honeywell ‘Y’ plan).
Automatic
air vent
Domestic hot
water
cylinder
Diverting
valve
Safety valve
N.B. A drain cock should be
installed at the lowest point of
the heating circuit
Pressure
gauge
Pump
Radiator
Expansion
Vessel
Boiler
To system filling device (see Fig.14)
Automatic bypass valve to be fitted
where thermostatic radiator valves
are fitted on all radiators
Fig. 14. System filling and make-up
Heating
return
Auto air
vent
Make up
vessel
Non return
valve
Stop
cock
Fill point.
Heating return
Temporary
hose
METHOD 1
METHOD 2
15
30mm (12in) min.
above highest
point of the system
.
9. Heating And Hot Water System
10. Electrical
The heating and hot water system must be provided in accordance with the current Building Regulations.
9.1 The appliance is suitable for connection to all conventional
indirect hot water systems utilising an indirect double feed cylinder.
9.2 The flow and return sockets are located at the rear of the
appliance, two at high level (flow) and two at low level (return).
Connection of the flow and return sockets can either be made on
diagonally opposite sockets or on the same side of the boiler.
9.3 Provision has been made for locating the circulating pump
within the appliance cabinet. If required, the socket located in
the top front of the boiler should be used and the flow pipe run
either side of the boiler (See Figs. 2 and 3).
9.4 On new installations it is recommended a room thermostat
or programmable room thermostat is used in the main zone and
thermostatic radiator valves are used in further heating zones.
On existing systems where a room thermostat is already fitted it
is recommended to fit thermostatic radiator valves at least in the
sleeping zones.
A automatic system bypass should be fitted on heating systems
when all of the radiators are fitted with thermostatic radiator valves.
9.5 The pressure jet burner fitted to the appliance has full
automatic control and hence there is no requirement for heat
leak radiators.
9.6 Any unused boiler tappings should be plugged prior to
filling. It should be noted that the flow tapping on the front of the
boiler requires plugging when not used.
9.7 The primary system should be flushed and treated in
accordance with the recommendations of BS 7593 before the
system is handed over to the user.
9.8 The pump should be set in accordance with the heating load
requirements to give a flow and return differential temperature
of 11°C under full load conditions.
Open Vent Primary System (See Fig. 12).
The following points are for guidance only. The system installation
should be carried out in accordance with BS 5449: Part 1.
1. System Pipework
The first metre of pipework from all appliance connections must be
in copper; afterwards copper or plastic pipe can be used. The
plastic pipe must be manufactued to BS 7291 and installed to BS
5955 part 8. It is important to protect the system components; the
plastic pipe specified must be resistant to the ingress of oxygen.
2. Feed and Expansion System
The feed and expansion pipes must rise continuously from the
appliance and must be of the minimum diameter shown in
Fig. 12.
The cistern must be arranged to provide a minimum static head of
1 metre above the top of the highest point in the heating circuit.
3. Filling and Venting
Air in the appliance is expelled through the vent pipe or
dissipated into the system. Manual air vents should be fitted at
any high points in the system.
Sealed Primary System (See Figs. 13 and 14).
The appliance is supplied with a manual reset high limit thermostat
and may therefore be fitted to a sealed heating system.
1. System Pipework
Copper pipework must be used when installing the appliance on
a sealed system.
2. General
The system should be installed in compliance with the
requirements of BS5449: Part 1. The boiler must be fitted with a
spring loaded safety valve set to operate at 3 bar (45 psi) and the
pipe connections made throughout the system must be capable
of sustaining a pressure of up to 3 bar.
The following is a list of major items which must be fitted to the
system:
1. Safety valve – 3 bar
2. Pressure gauge – 0 to 4 bar.
3. Expansion vessel
4. Automatic air vent
(See Fig. 15).
10.1 The wiring between the appliance and the electrical supply
shall comply with current IEE wiring regulations (and any local
regulations which apply) for fixed wiring to a stationary appliance.
NOTE: It must be possible to completely isolate the appliance.
10.2 To gain access to the electrical terminal strip.
1. Isolate the mains electrical supply.
2. Remove the cabinet front panel by pulling forwards to
release the ball studs.
3. Pull the thermostat control knob forwards to remove from
its spindle.
4. Undo the facia retaining screws and remove the plate.
10.3 Mains Wiring
Mains supply - 230V AC ~ 50 Hz 5A External Fuse to
BS1362.
LIVE - Brown, NEUTRAL - Blue, EARTH - Green/Yellow
Mains Cable: 0.75mm2 (24 x 0.20mm) to BS 6500 Table 16.
The supply to the boiler must be the only electrical supply to the
system. This ensures the safety of a single fused supply.
The mains supply cable should be connected into the terminals
marked L (Live), N (Neutral) and E (Earth) on the appliance
terminal strip and securely held in the cable clamp located in the
right-hand side of the electrical tray base. To secure the cable,
remove the clamp retaining screw and pull its inner body out to
allow the cable to be fed through. With the cable in position refit
the screw and fully tighten to grip the cable. Feed the cable
between the side panel and the boiler insulation jacket and route
to the connection point avoiding any hot surfaces.
The appliance must be earthed.
10.4 Programmer
A time clock or programmer may be added to the control system. A
two channel programmer will allow independent control of the central
heating and hot water.
NOTE: Under no circumstances should the timer be connected to
a separate electrical supply. Safety is assured from a single fused
supply to the boiler.
10.5 Safety Check
In the event of an electrical fault after the installation of the
appliance, the electrical system shall be checked for short
circuits, fuse failure or incorrect polarity of connections.
10.6 Pre-wired Remote Y Plan or S Plan System
(See Fig.16).
If the system is fully pre-wired at a junction box remotely from
the boiler it can be connected to the boiler. The diagram showsconnection details of two popular proprietary systems
(Honeywell and Invensys), for these and other systems from
other manufacturers always use the boiler instructions in conjunction with the system instructions.
10.7 Frost Protection
For full frost protection a frost thermostat should be fitted so
that both the boiler and the circulating pump circuits are
energised under frost conditions.
16
Fig. 15. Wiring Diagram (Standard).
Fig. 16. Pre-wired Remote ‘Y’ Plan or ‘S’ Plan.
Remote Pre-wired
Junction Box
10 WAY JUNCTION BOX
External Timer
Pump
System Water Valves
Room Stat
Tank Stat
Mains Wiring
230V 50Hz (5 amp fuse)
If the system is fully pre-wired at a junction box remotely from the boiler
it can be easily connected into the Worcester Utility Oil Boiler.
NOTE: If a frost thermostat is required it
can be wired to the remote junction box.
NOTE: The 10 way junction box must be
a terminal block type and current rated
to at least 5 amps.
OUTSIDE BOILER
INSIDE BOILER
Control Box
Connector Block
Live
Neutral
17
Earth
5. The primary system should be flushed and treated in
accordance with the recommendations of BS 7593.
11. Installation
11.5 Oil supply installation (See Figs. 9 to 11).
NOTE: Never route the oil supply pipe/hose directly below the
combustion chamber base.
NOTE: Connection of rigid copper pipe to the oil pump is not recommended. Connection to the oil pump should be made with
flexible oil hoses.
11.1 After unpackaging the appliance it is recommended that all
cabinet panels are removed, as described in Section 5, and
stored in a safe place to avoid damage during installation and
allow easy inspection for any leaks after the system has been
filled.
11.2 Remove the burner as described below and store in a safe
place until the appliance is ready for commissioning.
Conventional flue appliance (CF/LLD).
1. Fit the oil supply pipe as described in Section 8. The pipe can
be routed down either side of the boiler in the gap between the
base tray and the boiler shell.
NOTE: Never use soldered joints on oil supply pipes as this could
cause a hazard in the case of a fire.
2. Fit an isolating valve at the end of the oil line close to the burner
and ensure that the valve is closed. Continue from step 11.5 (b) 5.
Room-sealed balanced flue appliance.
(a) Single pipe suction lift with de-aerator.
For connection of single pipe suction lift with de-aerator follow
the proceedure as for a double pipe system as described below.
(a) Conventional Flue Appliance (CF/LLD).
1. Remove the burner plug-in connector by removing the
electrical facia and pulling the three pin connector free. Slide the
locating bush from the electrical box.
2. Remove the burner from the boiler by slackening the two M6
retaining screws located in the burner housing ring and pulling
the burner clear. This will require the use of a 5mm allen key.
Fig. 17. Removal of burner plug-in
connector burner box
(b) Double pipe system oil return pipe.
1. Remove the isolating valve bulkhead fitting by unscrewing
the locknut on the underside.
2. Remove the blind grommet from the fixed burner surround
box and discard.
3. Replace the blind grommet with the open grommet supplied
in the plastic bag.
4. Slacken the pipe retaining clip screw located directly below
the grommet hole. When using 12mm copper pipe replace the
clip with the larger one supplied.
5. Bend a piece of 10mm or 12mm copper tube ( as selected ) to
the correct profile to allow the pipe to be fed down the side of
the appliance. Make a slight chamfer on the end of the pipe to be
fed through the grommet to facilitate easy insertion.
6. Lubricate the grommet hole with vaseline (or butter etc.) and
slide the pipe through the hole, supporting the grommet on its
underside to prevent it dislodging.
7. Feed the pipe through the retaining clip, allowing approximately
80 mm of pipe to project beyond the clip, and tighten the retaining
screw. Take care not to overtighten the screw!
8. Hold the pipe at the retaining clip and gently pull the pipe
forward sufficiently to allow a compression to 1/4 inch BSP female
fitting to be fitted for connection to the oil return flexible hose.
9. Connect the fitting to the pipe and fit a 1/4 inch BSP taper thread
flexible hose, ensuring a good seal using PTFE tape or suitable oil
sealing compound. The flexible hose should have a 1/4 inch BSP
rotating union taper fitting at the other end with a 90 degree bend
and 1/4 inch BSP nipple for connection to the oil pump.
10. Replace the isolating valve bulkhead fitting.
11. Fit the oil supply pipe as described in the following section.
(c) Single pipe system oil supply pipe.
1. Bend a piece of 10mm or 12mm copper tube (as selected) to the
correct profile to allow the pipe to be fed down the side of the appliance. The pipe may be routed along either the right or left hand
side of the boiler as required. When using 12mm pipe fit a 12mm
to 10mm compression coupling and connect to the valve with a
short piece of 10 mm pipe, otherwise connect direct to the valve.
Note: never use soldered joints on oil supply pipes as this could
cause a hazard in the case of a fire.
2. Route the pipe back to the oil supply tank ensuring that it is
hard against the boiler, to allow installation of the side panel.
3. With the isolating valve in the correct orientation tighten the
back-nut.
4. Turn the isolating cock fully clockwise to close the valve.
5. Open the main oil supply valve at the tank and check for any
leaks.
6. Place a suitable container below the bulkhead fitting and
open the valve.
(b) Room Sealed Balance Flue Appliance (RS).
1. Remove the burner box cover by pulling forwards to release the
ball studs. This will be found easier by pulling on the one side of
the handle first to release two of the ball studs and then repeating
on the other side. Take care not to pivot the remaining two ball
studs too far around as this will cause damage to the spring clips.
2. Remove the burner plug-in connector by removing the
electrical facia and pulling the three-pin connector free. Slide the
locating bush from the electrical box.
3. Push the electrical lead grommet back through the burner
surround box and feed the lead through the hole until the burner
plug-in connector reaches the burner box. Insert one of the
burner plug-in connector pins through the hole into the burner
box as shown in Fig. 17. Gently push on top of the burner plug-in
connector at the same time guiding the electrical cable through
the hole.
4. Remove the burner from the boiler by slackening the two M6
retaining screws located in the burner housing ring and pulling
the burner clear. This will require the use of a 5mm allen key.
11.3 Flue system installation.
Install the appliance flue system as described in Section 7.
11.4 Heating system installation.
Before the appliance is fitted to the heating system
flush the system and mains water supply.
1. Plumb the boiler into the central heating system.
2. Check that all unused sockets have been plugged.
3. Fill the system and vent all radiators and high points to
remove air from the system.
4. Check the boiler and all pipework connections for leaks.
18
7. Draw off at least 2.5 litres of oil until a steady flow of clear
uncontaminated oil can be seen and turn off the isolating valve.
Note: This method may not be possible on some installations
where a sub-gravity system is used. Where this problem arises
bleed the system using the oil pump as described in Section 12
and remove and clean the oil pump filter to remove any debris
collected as a result of installation.
11.6 Replace the electrical control panel and side panels in
reverse order to the removal procedure of Section 5 and connect
the electrical supply as described in Section 10.
Section 10.
2. Check the combustion chamber base insulation is positioned
correctly in the bottom of the boiler.
3. Check that all baffles are correctly located and the heat shield
is correctly mounted (20/25, 26/32, 32/50 and 50/70 models
only) as shown in Fig. 24.
4. Check that the baffle retainer is correctly mounted (20/25, 26/32,
32/50 and 50/70 models only) as shown in Fig. 24c, 24d and 24e.
5. On the 50/70 remove and discard the transit baffle retainer,
as shown in Fig. 24e.
6. Ensure that the cap is firmly seated in position and check the
cap retainer is correctly mounted (32/50 and 50/70 models
only) as shown in Fig. 24d, 24e and 25.
7. On the 32/50 ensure the tabs of the top baffle are positioned
at the front of the boiler.
8. Check that the control thermostat and auto reset high limit
thermostat phials are correctly located in the boiler thermostat
pocket positioned in the top front of the boiler.
9. Check that the manual reset limit thermostat is located in the
steel pocket above the electrical box mounting bracket on the
front face of the boiler.
10. Check that all of the air-ways to the burner are clear of any
obstruction.
12.7 Fit a pressure gauge and manifold to the burner pump at
the point indicated in Fig. 9 or the pressure gauge port shown in
Fig. 20 on the 20/25.
12.8 Turn on the electricity to the appliance.
12.9 Bleed the burner.
Single Pipe System
Release the fuel bleed port on the manifold and place a suitable
receptacle beneath. Turn on the boiler thermostat and allow the
burner to run through to lockout. Wait two minutes and reset
the burner control box. Repeat the procedure at least three
times or until a steady stream of oil, without air, is exhausted
from the bleed port. Re-lock the bleed port.
Double Pipe System
A double pipe system will automatically vent the air back to the
oil tank. Turn on the boiler thermostat and allow the burner to
run through to lockout. Wait two minutes and reset the burner
control box. Repeat the procedure until the burner fires and runs
in a steady state. This may take several attempts depending on
the oil pipe length and height.
Single pipe suction lift system with de-aerator
A single pipe suction lift system with de-aerator will automatically vent air through the de-aerator by turning on the boiler thermostat and allowing the boiler run to lockout. Wait two minutes
and reset the burner control box. Repeat the procedure until the
burner fires and runs in a steady state.
On long oil pipe runs from the oil tank to the boiler it is recommended that the de-aerator be primed to prevent damage to the
oil pump.
To prime the the de-aerator follow the following procedure:
12. Commissioning The Appliance
Ensure that no foreign matter is left in the system as this could
cause damage to the appliance.
12.1 Check that the electrical supply to the appliance is
switched off.
12.2 When commissioning the appliance after initial installation
follow the procedure from 12.3, otherwise remove the burner
first as described in section 14.3.
Benchmark Water Treatment: For optimum performance after
installation, this boiler and its associated central heating
system should be flushed in accordance with the guidelines
given in BS7593:1992 - Treatment of water in domestic hot
water systems. Full instructions are supplied with proprietary
cleansers sold for this purpose. If an inhibitor is to be used
after flushing, it should be used in accordance with the
inhibitor manufacturers instructions.
Suitable flushing agents and inhibitors are available from Betz
Dearborn Tel: 0151 4209595 and Fernox Tel: 01799 550811.
Instructions for use are supplied with these products.
IMPORTANT: Any system cleanser must be flushed from the system
before an inhibitor is added.
12.3 Prepare the heating system
1. After initial installation and checking for leaks, as previously
described, drain down the system sufficiently to add a flushing
agent. After flushing drain the system before re-filling.
2. Refill the system
12.4 Check the Burner
1. Check that the nozzle and electrode settings are correct for
the relevant burner. (See Figs. 18, 19, 20, 21,22 and 23).
2. Check that the nozzle lies central with the combustion head hole.
3. Check for any visible defects.
12.5 Replace the burner
1. Connect the flexible oil supply hose to the isolating valve and
tighten sufficiently to form a good seal. Where a double pipe
system or single pipe system with de-aerator is being used fit the
bypass plug, as described in Fig. 9, and connect the oil return
flexible hose to the return pipe fitting.
2. With the sponge O-ring gasket around the burner blast tube
insert the burner into the housing tube. Push the burner firmly
forward to compress the gasket and tighten the two locking
screws using a 5mm Allen key.
Note: It is important that a good seal is made between the
burner and the boiler to prevent re-circulation of the flue gases
from the combustion chamber to the burner inlet or the room in
the case of CF/LLD appliance.
3. On the RS balanced flue model feed the electrical lead back
through the hole in the burner surround housing (in the reverse
order to that described in 11.2) and fit the grommet into the hole
ensuring a seal is made.
4. Re-connect the electrical lead plug into the control box.
12.6 Check the installation
1. Check that the appliance is correctly wired as described in
a) Disconnect the flexible oil inlet hose end nearest the
de-aerator and place in a container of oil.
b) Place an empty container to collect oil from the oil
inlet pipe connection of the de-aerator.
c) Prime the de-aerator and reconnect the de-aerator
to the flexible oil inlet hose.
12.10 Adjust the air shutter and pump pressure to the settings
recommended in Tables 2 to 8. After a pre-ignition period of
approximately 15 seconds the burner should ignite. Flame sensing
is carried out by means of a photocell mounted in the burner
body. Should the boiler fail to establish a normal firing pattern (or
should flame failure occur during running), the absence of a flame
is sensed and the control box is monitored to a safe lockout condition and the boiler is shut down. The lockout indicator light/reset
button in the burner control box will illuminate indicating that the
19
burner has gone to lockout. In this instance wait two minutes and
press the lockout reset button to initiate another start sequence.
Repeat the procedure until a flame is established.
Note: Persistent lockout when running indicates a fault and a
Service Engineer should be consulted.
12.11 Run the boiler for approximately 3 minutes and switch off
checking that there is no after-spurting from the nozzle. This can
be detected by oil saturation on the blast tube. If after-spurting
occurs remove the burner from the boiler, unscrew the nozzle,
and while holding the burner in a vertical position, fill the nozzle
holder with oil and refit the nozzle. Replace the burner and
continue to run the boiler for three minute periods until afterspurting stops.
Note: In order that after-spurting is reduced to a minimum
during the commissioning period it is recommended that a
pressure gauge only is fitted on the external pressure gauge port
on the Electro Oil B11 (See Fig. 20). Use of a “T” piece pressure
gauge manifold will increase the oil line volume and hence
increase the degree of after-spurting.
12.12 Run the boiler for a further 15 minute period and then
finally fine tune the air shutter setting to give the CO 2 level
specified in Tables 2 to 8 less 0.5%CO . During this period some
smoke will be emitted due to the burning of the organic binder in
the base insulation board. Smoke readings will therefore be
inaccurate at this point.
Note: A flue gas sampling point is located on the boiler top plate.
12.13 Check that the smoke reading is in the range 0-1. If this
cannot be achieved then check that the burner head is set
correctly and the nozzle is in good condition.
12.14 Check that the flue temperature does not exceed the
value specified in Tables 2 to 8. If this is the case then check that
the baffles are correctly located. If the baffles are correctly
located then reduce the pump pressure since nozzle variations
of up to + or – 15% may occur.
12.15 Remove the oil pressure gauge and manifold and check
all oil system joints for any signs of leakage.
12.16 On the RS balanced flue model fit the burner cover box
supplied in the flue terminal kit by lining up the four ball studs
and the polarising pin in the top flange of the box and firmly
pushing forward. Check that the cover is properly seated by
pressing forwards on the front top and then bottom face of the
box to ensure a room seal is achieved.
12.17 Allow the burner to run for a further five minutes and
then recheck the CO 2 level and adjust the air setting if
required. Check that the smoke number is in the range 0-1.
Repeat the fine tuning procedure if found necessary.
12.18 Refit the cabinet top and front panels in the reverse
order to that described in Section 5.
12.19 When the heating circuit has reached full operating
temperature check the whole system for any leaks.
12.20 Add a suitable proprietary corrosion inhibitor such as
Fernox or Sentinel. This will inhibit corrosion, protect the
circulating pump and valves and reduce the possibility of
"kettling" noises resulting from deposits of scale and sludge in
the boiler. Refer to the product manufacturers instructions for
further information.
Fig. 18. Electro Oil Inter B9A Burner.
(12/14 model)
Combustion Head
2mm
A
Spark gap
2 -2.5 mm
10mm
Draught tube
Nozzle block
Nozzle
Output
Dimension
kW
Head Type
A
12
PL 6/7/21.5/10-E
3 mm
14
PL 6/7/21.5/10-E
5 mm
To adjust the nozzle position, undo the
locking screw located at the rear of the
nozzle line and rotate the adjusting
disc one turn anti-clockwise to move
forward by 1 mm.
20
Fig. 19. Electro Oil Inter B9B Burner.
(15/19 model)
Locking screw
Combustion head
Combustion Head
A
Spark gap
2-2.5 mm
2 mm
Photocell
10 mm
Adjusting
disc
Transformer
Draught tube
Nozzle
Nozzle block
Output
Dimension Pressure Adjustment
Screw
kW
Head Type
A
15
PL 6/7/21.5/10
3 mm
17
PL 6/7/21.5/10
5 mm
Oil pump
19
PL 6/7/21.5/10
5 mm
To adjust the nozzle position, undo the
locking screw located at the rear of the
nozzle line and rotate the adjusting
disc one turn anti-clockwise to move
forward by 1 mm.
Control box
Lockout reset button
Air control indicator
Air adjustment screw
(4mm hexagonal head)
Fig. 20. Electro Oil Inter B11 Burner.
(20/25 model).
Combustion Head
A
Spark gap
3-3.5 mm
1 mm
8 mm
Draught tube
Output
kW
20/25
Nozzle
Nozzle block
Combustion Head
PL 10/4/24/10 x 78 mm
Dimension
A
5 mm
21
Fig. 21. Electro Oil Sterling Burner.
(26/32 model).
Combustion Head
Spark gap
2.5-3.0mm
A 0mm
7.5mm
Draught tube
Output
kW
26-32
Nozzle
Nozzle block
Dimension
A
3.5mm
Combustion Head
PL 6/7/21.5/10 x 78 mm
Fig. 22. Electro Oil Inter B20C Burner
(32/50 model).
Combustion Head
PL 10/8/10/6/19/10 - E x 78mm
0mm
Spark gap
2.5 to 3mm
A
Air guide
(Remove at 50kW
28sec only)
7.5mm
Blast tube
Nozzle block
Nozzle
Output
kW
32
41
50
41
50
Fuel
28sec. Kerosene
28sec. Kerosene
28sec. Kerosene
35sec. Gas Oil
35sec. Gas Oil
Dimension (mm)
A
3
6
6
6
6
22
Fig. 23. Electro Oil Inter B20B Burner.
(50/70 model).
Combustion Head
(Type K x 94mm)
(PL 21.5/10)
Output
kW
50
60
70
50
60
70
Fuel
28sec. Kerosene
28sec. Kerosene
28sec. Kerosene
35sec. Gas Oil
35sec. Gas Oil
35sec. Gas Oil
Dimension (mm)
A
B
24
10
26
10
28
10
20
8
22
8
24
8
6. Check and clean the cap retainer (32/50 and 50/70 models).
7. Check and clean the baffles.
8. Check and clean the heat exchanger surface.
9. Check the heat shield (20/25, 26/32, 32/50 and 50/70
models).
10. Check the combustion chamber base insulation board.
11. Check that the flue system is unobstructed and clean as
necessary.
12. If the appliance has been installed in a compartment check
that the ventilation areas are clear.
13. Clean all oil filters.
Some of the servicing points are covered more fully in the
following instructions:14.2 Pre-Service Check
1. Remove the cabinet front and top panels as described in
section 5 .
2. On the RS balanced flue model remove the burner box cover
as described in Section 5.5.
3. Operate the appliance and system, noting any faults which
may need to be corrected during the service.
14.3 Cleaning the Burner
IMPORTANT: Disconnect the electrical supply at the mains
before commencing any servicing. Turn off the oil at the service cock.
1. Remove the burner.
Conventional Flue Appliance (CF/LLD).
(a) Isolate the oil supply at both the oil tank and the isolating
valve located close to the burner.
(b) Slacken the two M6 burner locking screws, using a 5mm
Allen key, and remove the burner.
Room Sealed Balanced Flue Appliance (RS).
(a) Isolate the oil supply at both the oil tank and the isolating
valve situated above the burner on the right-hand side.
(See Fig. 3).
13. Instructions To The User
13.1
Hand the users instructions and Benchmark booklet to the user or purchaser for retention and instruct them in the
efficient and safe operation of the appliance and the heating/hot
water system.
13.2 Advise the user or purchaser of the precautions necessary
to prevent damage to the heating/hot water system and to the
building in the event of the heating system remaining
inoperative during frost conditions.
13.3 Finally advise the user or purchaser that for continued
efficient and safe operation of the appliance it is important that
adequate servicing is carried out by a qualified engineer at least
once per year.
Worcester, Bosch Group will be pleased to discuss and offer a
comprehensive maintenance contract.
13.4 Set the system controls to the users requirements.
14. Routine Cleaning And Inspection
14.1 The following should be carried out at least once per year
for 28 second Kerosene and twice per year for 35 second Gas Oil,
to ensure efficient, trouble free operation.
1. Carry out a pre-service check noting any operational faults.
2. Check and clean the burner.
3. On the CF model check and clean the air intake grille located
in the boiler room.
4. On the RS balanced flue model check and clean the air intake
ducts at the rear and underneath the boiler and the air intake
grille at the end of the terminal.
5. Check and clean the baffle retainer (20/25, 26/32, 32/50 and
50/70 models).
23
(b) Remove the burner box cover by pulling forwards to
release the ball studs. This will be found easier by pulling
on one side of the handle first to release two of the ball
studs and then repeating on the other side. Take care not
to pivot the remaining two ball studs too far around as
this will cause damage to the spring clips.
(c) Disconnect the burner plug-in connector by removing the
electrical facia and pulling the three-pin connector free.
Fig. 24
Slide the locating bush from the electrical box.
(d) Feed the electrical lead back through the grommet seal to
give sufficient play to allow withdrawal and inspection of
the burner.
(e) Slacken the two M6 burner locking screws, using a 5mm
Allen key, and remove the burner.
Location of Boiler Flueway Baffles.
(a) 12/14
(c) 20/25 and 26/32
(b) 15/19
Baffle
retainer
Baffle
Baffle
Heat
shield
(e) 50/70
(d) 32/50
Cap
retainer
Top Baffle
(The tabs on the
baffle must be
positioned at the
front of the boiler)
Cap
retainer
Cap
Transit
retainer
Cap
(remove & discard)
Baffle
Baffle
retainer
Baffle
Baffle
retainer
Heatshield
Burner
Mounting
Flange
Heatshield
Burner
Mounting
Flange
ENSURE THAT ALL BAFFLES ARE SEATED IN POSITION
24
(c) Check that the impeller rotates freely.
(d) Clean the air damper which is attached to the fan cover
and check that the adjustment mechanism operates
freely.
(e) Re-assemble the components.
Fig. 25. Location of cap retainer (32/50 and
50/70 models) and location of top baffle. (32/50
model only).
Access Door
3. Remove the combustion head and thoroughly clean all deposits.
Fig. 26. Mechanical Shut-off Valve.
Top Baffle
(32/50 model
only)
Cap Retainer
Cap
4. Inspection of Mechanical Shut-off Valve.
a) Remove the nozzle.
b) Fasten an M5 screw, with a minimum length of 30mm, into the
threaded hole (A) and pull the screw to withdraw the check valve.
c) Check that the nozzle holder is clear of any debris and clean if
necessary.
d) Check that the 3 holes in the check valve are clear of any
debris. Discard the check valve if the holes cannot be cleared or
if the unit is defective and replace with a new one.
e) Replace in the reverse order.
5. It is strongly recommended that the oil atomising nozzle is
replaced at each service. If this is not possible then remove and
clean the integral filter, but under no circumstances should the
nozzle be stripped into its component parts and never attempt
to clean the nozzle tip.
6. Check and reset the electrodes, where necessary, as shown in
Figs. 18, 19, 20, 21, 22 and 23.
7. Replace the combustion head and check that the nozzle lies
central to the combustion head and the head settings are as
shown in Figs. 18, 19, 20, 21, 22 and 23.
8. Withdraw the photocell from its housing and clean.
9. Remove and clean the oil pump internal filter using kerosene
or white spirit. The internal filter is accessed by removing the oil
pump cover on the Danfoss BFP 11 and Suntec AS47C and by
unscrewing and withdrawing the cartridge on the Danfoss BFP
41 as indicated in Fig. 9.
10. It is recommended that the standard flexible oil line is
replaced at each yearly service to prevent the possibility of a
leak due to ageing.
11. Re-assemble the burner components.
12. Check the sponge O-ring seal located around the combustion
head and replace if necessary. It is imperative that this seal is in
good condition since failure will cause the flue gases to be recirculated into the burner inlet, or the room in the case of a
CF/LLD appliance.
14.4 Remove the paper element from the external oil filter and
replace. If the filter contains a washable element then
thoroughly clean in Kerosene or white spirit and re-assemble
into the filter.
14.5 Clean the air ducts. (RS balanced flue model only).
1. Remove the rear duct top cover.
2. Shine a light down the rear duct and inspect both the rear and
under duct for any sign of debris and clean where necessary
using a flexible hose connected to a vacuum cleaner. A short
length of garden hose would be suitable for this purpose.
3. Replace the rear duct top cover.
4. Check that the oil bleed holes are clear. These are located in
the base of the burner cover box and the bottom front face of
the burner housing.
2. Clean the fan impeller using the following procedure:
Electro-oil Inter B9 Burner
(a) Remove the two screws holding the combustion head in
position and withdraw the combustion head and air guide
collar (where fitted).
(b) Remove the three remaining screws holding the front
cover plate in position and withdraw the cover to expose
the fan impeller.
(c) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(d) Check that the impeller rotates freely.
(e) Clean the air inlet passage and check that the adjustment
mechanism operates freely.
(f) Re-assemble the components.
Electro Oil Inter B11
(a) Remove the acoustic fan inlet cover.
(b) Remove the three screws holding the fan cowl in position and
remove the cowl noting how the fan control flap is positioned.
(c) Check that the air control flap pivots freely and ensure the
air path to the burner head is clear.
(d) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(e) Check that the impeller rotates freely.
(f) Re-assemble the components.
Electro Oil Sterling
(a) Remove the air adjustment cover.
(b) Separate the main body of the burner from the burner
front by removing the M6 allen screw (located beneath the
air adjustment screw), using a 4mm allen key.
Check the condition of the Gasket between these two parts
and replace if necessary.
(c) Note the position of the air damper adjustment and check
the air damper moves freely.
(d) Check the air path to the burner head is clear.
(e) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(f) Check the impeller rotates freely.
(g) Re-assemble the components.
Electro Oil Inter B20
(a) Remove the four screws holding the fan cover and remove.
(b) Clean both sides of the fan impeller and remove any debris
from the burner housing.
25
located within the appliance case. A fire valve clip is provided
for this purpose as shown in Figs 2 & 3. Test the operation of the
fire valve to ensure that the mechanism operates and that the oil
supply is completely isolated.
NOTE: The fire sensing element must be located on the top face of
the burner surround box on RS balanced flue models, as shown
in Fig.3, to allow quick detection of a dangerous situation.
14.8 Recommission the Burner.
1. Connect the flexible oil supply hose to the isolating valve and
tighten sufficiently to form a good seal. Where a double pipe
system is being used connect the oil return flexible hose to
return pipe fitting.
2. With the sponge O-ring gasket around the burner blast tube
insert the burner into the housing tube. Push the burner firmly
forward to compress the gasket and tighten the two locking
screws, using a 5mm Allen key.
Note: It is important that a good seal is made between the
burner and the boiler to prevent re-emission of the flue gases
from the combustion chamber to the burner inlet, or the room in
the case of a CF/LLD appliance.
3. On the RS balanced flue model feed the electrical lead back
through the hole in the burner surround housing (in the reverse
order to that described in 11.2) and fit the grommet into the hole
ensuring a seal is made.
4. Reconnect the electrical lead plug into the control box.
5. Turn on the oil supply at the service cock.
6. Recommission the burner as described in Section 12.
14.6 Clean the Boiler
1. Remove the boiler top access door by releasing the M10 nuts
and check the fibreglass rope seal. Replace the seal if necessary.
2. Remove the burner mounting flange by releasing the three
M10 nuts and check the fibre glass gasket, it is imperative that
this seal is in good condition. Replace the seal if necessary
(32/50 and 50/70 models only).
3. Remove and check the baffle retainer, where fitted (20/25,
26/32, 32/50 and 50/70 models). See Fig. 24.
4. Remove the baffles, clean and check their condition. Replace
any baffles considered to be badly corroded.
5. Remove and check the cap retainer, where fitted (32/50 and
50/70 models only). See Fig. 24d, 24e & 25.
6. Remove the cap (32/50 and 50/70 models only) and check
the ‘rocksulate’ gasket. Replace the seal if necessary.
7. Thoroughly clean all of the heat exchanger surfaces using a stiff
wire brush and vacuum clean all loose debris from the combustion
chamber. Take care not to damage the base insulation!
8. Remove and check the heat shield where fitted (20/25,
26/32, 32/50 and 50/70 models). (See Fig. 24).
9. Check the combustion chamber base insulation board and
replace if there is any sign of damage.
10. Check and clean the flue.
11. Replace the items in reverse order noting the baffle positions
shown in Fig. 24.
14.7 Fire Valve.
Check that a fire valve is fitted to the incoming oil line with the
body located outside the premises and the detection element
15. Short Parts List
Part
Burner for 12/14
B9A Combustion Head
Burner for 15/19
B9B combustion Head
Burner for 20/25
B11C Combustion Head
Burner for 26/32
Sterling 40 Combustion Head
Burner for 32/50
B20C Combustion Head
Burner for 50/70
B20B Break Plate
B20B Blast Tube
Burner control 1.
Control Box
B9, B11 and B20
Photocell
Sterling 40
Photocell
Control Box Base
Ignition Electrode
Motor B9
Motor B11 and B20
Motor Sterling 40
Oil Pump B9
Oil Pump (B11, B20 and Sterling 40)
Transformer
Mechanical Shut-Off Valve
Flexible Oil Line Kit
Burner 'O' Shaped Gasket
Control Thermostat
Automatic Reset High Limit Thermostat
Manual Reset High Limit Thermostat
Manufacturers Reference
Bentone B9A
PL 6/7/21.5/10-E x 78mm
Bentone B9B
PL 6/7/21.5/10 x 78mm
Bentone B11C
PL 10/4/24/10 x 78mm
Bentone Sterling 40
PL 6/7/21.5/10 x 78mm
Bentone B20C
PL10/8/10/6/19/10-E x 78mm
Bentone B20B
PL 21.5/10 (type K)
Type K x 94mm
Satronic TF 832.3
Satronic MZ770
Satronic MZ770
Satronic S01 S701
AEG or Simel 70 W
AEG (FHP) 90W
AEG (FHP) 90W
Danfoss BFP41L3
Danfoss BFP11L3
Danfoss EBI 052F0030 (excludes cable)
Worcester
Worcester
Siebe K36-P2312
Siebe LO7-P1022
Siebe LM7-P5075
26
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Worcester Part No.
8 716 104 431 0
8 716 157 041 0
8 716 142 705 0
8 716 156 697 0
8 716 104 432 0
8 716 142 784 0
8 716 142 700 0
8 716 156 697 0
8 716 104 546 0
8 716 104 769 0
8 716 104 547 0
8 716 156 518 0
8 716 142 739 0
8 716 156 648 0
8 716 142 735 0
8 716 156 692 0
8 716 142 782 0
8 716 142 752 0
8 716 156 597 0
8 716 142 732 0
8 716 156 645 0
8 716 142 743 0
8 716 142 736 0
8 716 156 696 0
8 716 156 658 0
8 716 156 663 0
8 716 140 902 0
8 716 142 309 0
8 716 142 311 0
8 716 142 310 0
27
Worn motor bearings.
Replace motor.
Worn pump.
Replace.
Pump noise.
Air in pump.
Noisy operation.
Electrode
settings
incorrect.
See installation
instructions.
High tension
leads faulty.
Electrical connections
not properly
made in
control box.
Fan out of balance.
Replace fan.
External controls not
operating correctly.
Faulty boiler thermostat.
Replace if necessary.
FAULTY BOILER OPERATION
Electrodes
broken.
Open circuit
ignition.
IGNITION FAILURE
Photocell
filmed over.
Clean.
Boiler thermostat
differential incorrect.
Should be 5°C ± 2°C.
Short circuit boiler thermostat.
Take out of circuit to check.
Boiling.
BURNER FAILS TO START
Boiler rating incorrect.
If overrated heat load
satisfied very quickly.
Numerous lockouts.
Cure the lockout
condition.
Leaks at tubing connectors.
Ensure end of
tubing is secure.
Odour in boiler room.
Oil leaks pipe fittings.
Take apart and
remake if necessary.
Faulty burner
operation.
Oil soaked hearth.
OIL SMELLS
Target wall incorrectly
positioned or faulty
(where fitted).
Combustion Faulty nozzle.
Replace nozzle.
settings
incorrect.
Set up as in
installation
instructions.
Oil pressure incorrect.
Incorrect components
Adjust to recommended
used on combustion
pressure settings.
head. Check with installation
instructions.
Fumes on start-up.
Blocked flue.
Check flue with gauge.
Pulsation
on start.
Intermittent flame
detection fault.
See flame detection
fault.
PULSATION ON START
Flue draught
incorrect.
Check flue
draught.
HIGH SMOKE NUMBER
Faulty control
box. Replace
if necessary.
Incorrect combustion
settings. Readjust as in
installation instructions.
Short cycling.
Air intake blocked.
Check air intake is clear.
Programmer
open circuit.
Boiler does not respond to a call for heat.
Downdraught.
Intermittent
lockout.
Extend flue above
Fit a downdraught
eaves, or if possible cowl if flue cannot
above roof apex or
be extended.
adjacent obstructions.
Check control box
connections.
Bad electrical
connection.
Control box fault.
Replace if necessary.
Burner motor fails
to operate.
Check motor across
mains supply.
Faulty control box.
Replace if
necessary.
Thermostat bulb not fully
home in pocket.
Ensure bulb is
pushed fully home.
Boiler thermostat
faulty. Check by
linking out high
limit and control
thermostats.
Photocell
faulty.
Replace.
Flame detection fault.
Faulty nozzle.
Replace nozzle.
Faulty control box.
Replace control box.
Mechanical shut off
valve clean or
replace.
Air adjustment fault.
CO2 should be
as specified in
tables 2 to 8.
Faulty pump or
faulty pump drive.
Replace if necessary.
Filters or oil line
blocked. Check
filters from tank
to boiler and clean
if necessary.
Nozzle blocked.
Replace nozzle.
Faulty ignition
transformer.
Replace
if necessary.
Air in pump.
Bleed pump.
No oil in tank.
Check tank and
replenish if
necessary.
No oil at
oil pump.
No oil delivery
from nozzle.
Check oil supply
at oil pump.
Oil at
oil pump.
Ignition failure
To Re-set wait 2 minutes and press re-set button
INDICATED BY RED LAMP ON CONTROL BOX
LOCKOUT
16. Fault Finding
www.worcester-bosch.co.uk
Bosch Group
Worcester, Bosch Group, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: 01905 754624. Fax: 01905 753130.
Technical Helpline 08705 266241.
Worcester, Bosch Group is a trading name of BBT Thermotechnology UK Limited.
This booklet 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 improvement.
All goods sold are subject to our official Conditions of Sale, a copy of which may be obtained on application.
8 716 114 746a (11/07)