Potterton Statesman 45-50-70-90-110 installation and servicing manual

Installation & Service Instructions
Statesman
45/50, 50/70, 70/90, 90/110,
System, Flowsure, Flowsure +
About the Boiler
This is a Floor Standing, Horizontally Fired, Automatic Pressure Jet Oil Boiler.
The boiler can be flued conventionaly or with a kit as a balanced flue.
This boiler is for use with Kerosine or Gas Oil and for use in GB & IE.
About Safety
Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
Leave these instructions with the user for use on future calls.
Contents
Section 1 - Technical Data...............................................4
Health & Safety Information..........................................4
Sealed System Components.......................................6
Control Panel Wiring Diagrams..................................10
Technical Data............................................................13
Boiler Dimensions & Clearances................................14
Flue Layouts...............................................................15
Section 2 - Pre-Installation Requirements..................16
Chimneys/Flues.........................................................17
Combustion & Ventilation Air Requirements...............18
Balanced & Low Level Terminal Clearances...............19
Oil Tanks & Layouts....................................................21
Floor Temperatures....................................................23
Sealed System Requirements...................................23
Section 3 - Installation & Commissioning..................27
Conventional Flue......................................................28
Electricity Supply........................................................28
Fuel Pipes..................................................................29
Wiring Diagrams.........................................................30
Water Connections.....................................................34
Thermostats...........................................................34
Commissioning.......................................................36
Section 4 - Servicing & Maintenance...........................39
Servicing................................................................39
Maintenance...........................................................39
Replacement of Parts.................................................40
Thermostats - Statesman & System..........................41
Limit Thermostat........................................................41
Boiler Control Thermostat..........................................41
Thermostats - Flowsure/Flowsure+...........................42
Boiler Control Thermostat..........................................42
Limit Thermostat........................................................42
Pump Overrun Thermostat.........................................42
Tank Limit Thermostat................................................42
DHW Overheat Thermostat........................................42
Heatstore Thermostat................................................42
Automatic Air Vent......................................................42
Pressure Relief Valve.................................................43
Circulating Pump........................................................43
Expansion Vessel.......................................................43
Pressure & Temperature Gauge.................................43
Diverter Valve.............................................................43
Flow Switch................................................................43
DHW Hot Water Plate Heat Exchanger...................44
Section 5 - Fault Finding..............................................47
Burner does not start, motor does not run..................47
Burner starts, no flame established, no
oil to burner.................................................................47
Burner starts, no flame but oil to burner......................48
Burner starts, flame established but goes to
lockout after 15 seconds.............................................48
Locks out in mornings only.........................................48
Flame established but not maintained........................49
Burner runs but smoke, and or smell,
and or pulsation..........................................................49
Other problems..........................................................50
Section 6 - Spare Parts.................................................52
Section 7 - Flue Kit Options..........................................54
2
Contents
Part No. 5102478
WARNING ! - this is about YOUR safety
Safe use of Kerosines and Gas Oils
Hazards
These fuels give off a flammable vapour when heated even moderately.
This vapour ignites easily, burns fiercely and can be explosive.
Vapour can flow along at ground level and collect as an explosive mixture in drains, cellars etc. at considerable
distances from open containers or spillages.
Fuels remove natural oils and fats, and may thus cause cracking and irritation of the skin.
Gas oil may also cause irreversible damage to your health on prolonged or repeated skin contact.
Precautions
ALWAYS HANDLE
fuels in the open air or in a well ventilated place, well away from all sources of ignition
such as fires, sparks, hot surfaces and DO NOT SMOKE.
ALWAYS DRAIN
fuels using a proper fuel retriever, mechanical siphon or funnel.
NEVER SUCK
fuels up a tube by mouth. If accidentally swallowed - call a doctor - DO NOT INDUCE
VOMITING.
NEVER APPLY
heat to a fuel tank, pipework or container.
AVOID INHALING
fuel vapour; it can make you light-headed and seriously impair your judgement.
ALWAYS STORE
fuels in a properly constructed and labelled tank.
If there is a Fuel Spillage
IMMEDIATELY
STOP/SWITCH OFF all electrical and other ignition risks
REMOVE
all contaminated clothing to safeguard yourself against fire risk and skin damage.
Wash the affected skin thoroughly with soap and water and remove the clothing to a safe, well
ventilated place and allow to air before washing or dry cleaning.
CONTAIN
and smother the spill using sand, soil or other suitable incombustible material.
DO NOT ALLOW spilled fuel to escape into drains or water courses. If fuel does enter a drain, warn the Water
Authority and Fire Brigade.
CONSULT
your Local Authority about disposal of contaminated soil.
FIRST AID
if fuel is accidentally swallowed, SEEK IMMEDIATE MEDICAL ATTENTION - DO NOT INDUCE
VOMITING.
if fuel is splashed into eyes, wash out with running water for at least 10 minutes and SEEK
IMMEDIATE MEDICAL ATTENTION.
Part No. 5102478
Safety
3
1 - Technical Data
•
•
•
•
•
•
The Statesman boilers are horizontally fired,
automatic pressure jet boilers. These boilers are
intended for use on indirect central heating systems.
Their use on direct systems is not recommended.
The boilers as supplied can be installed directly to
suitable conventional chimneys. For balanced flue
installations, an appropriate flue kit is additionally
required.
The Statesman boilers have been independently
tested to standards EN 55014 and EN 50082-1 and
show compliance with the E.M.C. Directive 89/336/
EEC.
The boiler has an easily removable front access door
which gives quick access for cleaning.
The maximum static head of water permissible is
27.44 metres (90 ft).
Water flow and return connections are provided on
each side and rear of the boiler (dependant on model).
Flue Gas Sampling Point
To aid commissioning, a flue gas sampling point is
built into the heat exchanger front access door. If
this door is removed make sure that when re-fitted,
the sampling point is at the top.
Oil Pipe Installation
The boiler base features "Knock Out" holes for
installation purposes. Remove using a drift or dot
punch as required. Grommets are provided for cable
protection within the connection pack. Additional
holes have been provided in the front of each side of
the base. These are to provide more options when
bringing in the fuel hoses and if required, electrical
wiring.
Burner
Note: When installing the boiler, make sure all
unwanted tappings are blanked off.
Health & Safety Information for the Installer &
Service Engineer
Under the Consumer Protection Act 1987 and Section
6 of the Health and Safety at Work Act 1974, we are
required to provide information on substances
hazardous to health.
Small quantities of adhesives and sealants used in
the product are cured and present no known hazards
when used in the manner for which they are intended.
The following substances are also present:
Insulation and Seals
Material - Man Made Mineral Fibre.
Description - Boards, Ropes, Gaskets.
Known Hazards - Some people can suffer reddening
and itching of the skin. Fibre entry into the eye will
cause foreign body irritation which can cause severe
irritation to people wearing contact lenses. Irritation
to respiratory tract.
Precautions - Dust goggles will protect eyes. People
with a history of skin complaints may be particularly
susceptible to irritation. High dust levels are only likely
to arise following harsh abrasion. In general, normal
handling and use will not present high risk, follow
good hygiene practices, wash hands before, touching
eyes, consuming food, drinking or using the toilet.
First Aid - Medical attention must be sought following
eye contact or prolonged reddening of the skin.
4
Technical Data
The burner is an automatic pressure jet type, pre-wired,
with a photocell flame failure control.
The standard burner fitted is the Riello RDB with
different combustion heads to suit boiler ratings.
Boiler Thermostats
A pre-wired control thermostat is provided with each
boiler. This thermostat is calibrated to give a maximum
boiler temperature of 82°C (180 °F) and a minimum
temperature of 55 °C (130 °F). Under no circumstances
should the boiler be operated below the minimum
indicated setting, or below a flow temperature of 55
°C (130 °F). For best operation it is suggested that
the boiler should be operated at a setting just below
maximum on the thermostat setting. The boiler also
has a limit (overheat) thermostat calibrated to operate
at 110 °C (230 °F). This is located on the underside
of the control panel, see the Users Instructions.
Statesman, Statesman System
System & Boiler Control
Due to the high efficiency of the Statesman boilers,
the following should be taken into consideration during
installation:Control of the Boiler: When the demand for heating
and/or hot water is satisfied, the controls should be
arranged such that the burner is switched off. If due
to the system design nuisance tripping of the overheat
thermostat occurs, it may be advisable to fit a pump
overrun device (Incorporating a by-pass system
where necessary).
Part No. 5102478
Statesman
Top Flue
Knockout
Top Casing
Side Flue
Knockout
Thermostat
Pocket
Flue Outlet
Flange
Programmer
(Optional)
Side Flue
Knockout
Indicator Lights
Control
Thermostat
Flow Outlet
Thermostat
Pocket
Front Access
Door
Boiler Shell
Flue Gas
Sampling
Burner
Air Inlet
Side
Cover
Burner Lead
Return Inlet
Viewing Window
Front Cover
Burner Oil
Feed Pipe
ST00205A
Knock-out
Holes For
Cables And
Fuel Pipes
Lockout Reset
Button
Burner
Fig. 1
Part No. 5102478
Technical Data
5
Statesman System, Flowsure & Flowsure+
Principal boiler components
Automatic and Manual Air Vents
Manual air vents are provided on the Flowsure and
Flowsure+ only.
Pressure Relief Valve
This is factory set at 3 bar (45 lb/in²).
Pump
An integral circulating pump is incorporated within
the boiler casing. This also serves the functions of
both the central heating circuit and domestic hot
water (Flowsure/Flowsure+).
Expansion Vessel
A 10 litre expansion vessel, charged to 0.5 bar and
is suitable for a static head of 5 metres (16.5 ft), is
included within the boiler casing.
pressure domestic hot water. The domestic hot
water temperature can be increased by reducing
the water flow rate at the tap (Flowsure) or adjusting
the hot water mixing valve to a higher setting
(Flowsure+).
Pump overrun
On the Flowsure and Flowsure+, a pump overrun
facility has been incorporated into the electrical
control panel which allows excess heat to be
dissipated to either the central heating circuit or
boiler shell, dependant on mode selected. This
prevents the possibility of the boiler overheating.
Heatstore tank
On the Flowsure+, the heatstore tank is a heatbank
containing 40 litres (8.8 gallons) of primary hot
water. The tank temperature is controlled by the
DHW thermostat to approximately 75 °C.
Note: A bypass system should be fitted between
the flow and return pipes, where primary water
flow may be prevented during a pump overrun
situation (Flowsure, Flowsure+).
Diverter Valve
DHW Mixing Valve (Flowsure+ Only)
On the Flowsure and Flowsure+, a motorised
diverter valve is located on the pump outlet. The
valve is normally closed to the central heating circuit
and is powered open when there is a demand for
central heating via the room thermostat.
Flow Switch
On the Flowsure and Flowsure+, the domestic
mains water inlet is connected to a flow switch, this
detects when a domestic hot water tap has been
opened. This activates the burner and pump.
Domestic Service Cock
The domestic service cock fitted to the mains water
inlet of the Flowsure and Flowsure +, incorporates
a pre-set flow regulation device, this restricts the
maximum flow of domestic hot water to the taps,
13 l/m and 17.5 l/m respectively.
The DHW mixing valve is factory set to the mid
position, this will give a blended water temperature
of approximately 60°C. After removing the front
casing (Pull forward off the mounting clips), the
control knob (top right, behind control panel) will
be accessible and can be turned as required.
Clockwise to decrease and anti-clockwise to
increase temperature - See Fig. 4. for the position
of the valve.
MIN
Turn the
Control Knob
anti-clockwise
3 notches for
mid position
Mid
Position
Turn the
Control Knob
anti-clockwise
3 notches for
fully open position
Fully
Open
+ Temp.
- Temp.
60˚ Approx.
Domestic Hot Water Heat Exchanger
ST00193A
On the Flowsure and Flowsure+, a water to water
heat exchanger is located within the boiler casing.
Primary water is pumped from the boiler (heatstore
tank on Flowsure+) to the heat exchanger whenever
there is a flow of domestic water through a hot water
tap. The domestic water thereby extracts the heat
from the plate heat exchanger giving mains
6
Technical Data
Part No. 5102478
Statesman
Automatic
Air Vent
Pump
Conventional
Flue
Pressure
Relief Valve
Thermostat
Pocket
Main Facia
Panel
Control
Thermostat
Flow
(22mm)
C
O
M
PACT
Indictator
Thermostat
Pocket
Programmer
(Optional)
Expansion
Vessel
Lights
Pressure and
Temperature Gauge
Burner Air
Inlet Pipe
Expansion Vessel Cradle
Combustion Chamber
Access Panel
Lockout
Reset
Button
Combustion Chamber
Viewing Window
Burner Oil
Feed Pipe
Return (1" B.S.P.)
Left & Right-hand
ST00206A
Expansion Vessel
Connection Pipe
Expansion
Vessel
Connection &
Boiler Drain Valve
Burner
Knock-out Blanks For
Cables And Fuel Pipes
Fig. 2
Part No. 5102478
Technical Data
7
Statesman
Certain Items Removed For Clarity
Conventional
Flue
Flow Switch
(Type 2)
Manual
Air Vent
Automatic
Air Vent
Pressure
Relief Valve
Pump
Overrun
Pocket
Flow
Switch
(Type 1)
Boiler
Thermostat
Sleeve
Domestic
Service
Cock
NOT
Supplied
Cold Water
Feed (15mm)
3 bar
D.H.W. Flow
(15mm)
C.Heating
Flow (22mm)
D.H.W.
Overheat
Thermostat
Pump
Plate Heat
Exchanger
3 Way
Diverter
Valve
Double
Check
Valve
Boiler limit Stat
& Temp Guage
Bulb Pocket
System Fill Flexible Hose
(DO NOT use as
a permanent fitting)
Expansion
Vessel Support
Bracket
Expansion
Vessel
Valve
System Fill
Isolation Valve
Cold Main
Isolation Valve
Viewing
Window
Expansion
Vessel
Connection
Pipe
System
Fill Pipe
Expansion Vessel
Connection &
Boiler Drain Valve
ST00207A
Expansion
Vessel
C.Heating
Return (1" B.S.P.)
System Fill
(15mm)
C.Heating
Return (1" B.S.P.)
Fig. 3
8
Technical Data
Part No. 5102478
Flow
Switch
(Type 1)
Flow Switch
(Type 2)
Statesman
NOT Supplied
Certain Items Removed For Clarity
Tank Limit
Thermostat
Pocket
Pump
Overrun
Pocket
D.H.W.
Flow
(15mm)
Cold
Water
Feed
(15mm)
Mixing
Valve
Conventional
Automatic Flue
Air Vent
Domestic
Service
Cock
Plate Heat
Exchanger
Pressure
Relief Valve
Manual
Air Vent
Boiler
Thermostat
Sleeve
NOT
Supplied
C.Heating
Flow (22mm)
Pump
3 Way
Diverter
Valve
Boiler limit
Stat & Temp
Guage Bulb
Pocket
Plate Heat
Exchanger
Double
Check
Valve
Heatstore
Thermostat
Temp./Press Valve
Connection Point
C.Heating
Return (1" B.S.P.)
Expansion
Vessel
Support
Bracket
System Fill Flexible Hose
(DO NOT use as
a permanent fitting)
System Fill
Isolation Valve
Expansion
Vessel
Valve
Expansion
Vessel
Connection
Pipe
Heatstore
Drain Valve
Cold Main
Isolation Valve
System
Fill Pipe
Expansion
Vessel
Connection &
Valve
ST00208A
Expansion
Vessel
System Fill
(15mm)
Primary Water
Heatstore
Fig. 4
Part No. 5102478
Technical Data
9
N
Pump
L
b
E
g/y
br
Boiler Control Panel
Wiring Diagram
Statesman.............
S/L
E N
S/L
E N
Link to be replaced with
room thermostat
Tray Assembly
S/L
S/L
L
E
N
L
E
N
g/y
Boiler
Stat.
b
gy
L
N
L
N
L
N
Burner
Lockout
1
bl
b
r
bl
2
b
br
br
Colour Coding
For The Wiring
1
bl
br
b - Blue
br - Brown
gy - Grey
r - Red
bl - Black
g/y - Green/Yellow
Limit
Stat.
Terminal
Block
br
br
b
g/y
b
Overheat
L
N
L
N
L
N
Boiler
Terminal
Socket
(6 way)
2
br
Mains
On
b
r
Terminal
Block
N N E L
Burner
Socket
br
L2
E
L1
N
br
Boiler
Terminal
Plug
(6 way)
gy
br
g/y
b
b
br
g/y
Live
Chassis Earth
Earth
Main
Supply
Connection
Main Socket
N
N E L
E L
Neutral
Main
Supply
Connection
gy
br
g/y
Boiler
Stat.
b
gy
br
Mains
On
L
N
L
N
L
N
Burner
Lockout
1
r
bl
Terminal
Block
br
br
br
1
Colour Coding
For The Wiring
bl
br
Limit
Stat.
b - Blue
br - Brown
gy - Grey
r - Red
bl - Black
g/y - Green/Yellow
b
g/y
r
Burner
Socket
Chassis Earth
L2
E
L1
N
g/y
b
br
b
Live
N E L
Earth
Main
Supply
Connection
Main Socket
N E L
E L
Boiler Control Panel
Wiring Diagram
Statesman
N
Main
Supply
Connection
br
2
b
b
N N E L
L
E
N
bl
b
Terminal
Block
br
br
g/y
b
b
Overheat
L
N
L
N
L
N
S/L
L
E
N
Boiler
Terminal
Socket
(6 way)
2
S/L
Neutral
ST00123C
N E L
Boiler
Terminal
Plug
(6 way)
b
Fig. 5
10 Technical Data
Part No. 5102478
b
br
br
N E L
Terminal
Block
Overheat
Burner
Lockout
Chassis
Earth
Main
Supply
Connection
Main
Socket
g/y
0.47 UF Capacitor
br
br
N E L
b
N N E L
b
b
g/y
Live
Mains
On
Main Supply
Connection
r
L
N
L
N
L
N
L
N
L
N
L
N
br
L1
L2
b
N
E
Burner
Socket
Terminal
Block
E L
Part No. 5102478
g/y
N
Fig. 6
Technical Data 11
b
g/y
ST00092D
b
bl
br
r
br
gy
Neutral
Earth
bl
br
br
br
bl
gy
bl
Limit
Stat.
22
21
2
3
Boiler
Stat.
L
N
Pump
r
E
Tray Assembly
2
4
Pump
Overrun
Stat.
3
br
br
g/y
b
bl
bl
br
g/y
L1 E
L1 E
b
br
b
N
N
b
r
b
o
o
v
o
b
br
w
22(5)
bl
31(11)
A2(10)
32(8)
br
Flow
Switch
b
34(9)
y
L S/L L
L S/L L
br
Diverter Valve
1
2
gy
A1(2)
v
p
b
o
gy
D.H.W. Thermostat
gy
14(3)
12(4)
24(7)
11(1)
21(6)
Relay
p
w
br
y
S/L
N
L
S/L
CH
ON
N
L
HW
ON
b
1a 1 1b
C.Heating
w
br
y
3 Position Switch
p
y
LINK to be replaced
with room thermostat
o
br
gy
1a 1
Boiler
2 Position Switch
3
br
2
b
1
Electro-mech.
Clock
5
y
- Blue
- Red
bl - Black
p - Pink
o - Orange
y - Yellow
v - Violet
w - White
g/y - Green/Yellow
r
gy - Grey
br - Brown
b
For The Wiring
Colour Coding
w
Control Panel
Wiring Diagram
Statesman
b
br
br
N E L
Overheat
Burner
Lockout
Chassis
Earth
Main
Supply
Connection
Main
Socket
g/y
Terminal
Block
0.47 UF Capacitor
br
br
N E L
b
N N E L
b
b
g/y
Live
Mains
On
Main Supply
Connection
r
L
N
L
N
L
N
L
N
L
N
L
N
b
bl
br
r
br
ST00124D
b
N
L1
br
E
L2
Burner
Socket
Terminal
Block
E L
12 Technical Data
g/y
N
Fig. 7
Part No. 5102478
b
g/y
gy
br
br
bl
Neutral
Earth
br
bl
gy
bl
Limit
Stat.
22
21
2
3
Boiler
Stat.
L
N
Pump
r
E
Tray Assembly
2
4
bl
bl
br
g/y
L1 E
L1 E
gy
Pump
Overrun
Stat.
3
br
br
g/y
b
b
br
b
N
N
b
r
o
v
b
o
v
y
o
b
br
w
2
22(5)
1
y
bl
31(11)
A2(10)
32(8)
br
Flow
Switch
b
34(9)
L S/L L
L S/L L
br
Diverter Valve
3
gy
A1(2)
4
2
v
w
br
p
b
o
y
S/L
N
L
S/L
Tank Limit Thermostat
gy
14(3)
12(4)
24(7)
11(1)
21(6)
Relay
p
Tank
Thermostat
CH
ON
N
L
HW
ON
b
C.Heating
1a 1 1b
w
br
y
3 Position Switch
p
y
LINK to be replaced
with room thermostat
o
br
gy
1a 1
Boiler
2 Position Switch
w
3
br
2
b
1
- Blue
- Red
bl - Black
p - Pink
o - Orange
y - Yellow
v - Violet
w - White
g/y - Green/Yellow
r
gy - Grey
br - Brown
b
For The Wiring
Colour Coding
Electro-mech.
Clock
5
y
Control Panel
Wiring Diagram
Statesman
Technical Data
Model
45/50
Maximum Output
Minimum Output
Factory Set Output
Kerosine
Gas Oil
Btu/h
51,000
44,000
51,000
51,000
Kerosine
Gas Oil
RDB1
LD2SH
LD2SH
RDB1
LD2SH
LD2SH
RDB1
LD3
LD3
RDB2
LD3
LD3
RDB1
LD3
LD3
%
m³
kg/h
93.2
0.041
23.42
87.5
0.041
32.81
92.6
0.058
41.72
89.8
0.055
52.14
88.0
0.058
40.98
°C
200
220
230
235
245
mbar
°C
0.15
60
0.4
62
0.55
50
0.7
50
0.7
65
mbar
mbar
11.0
4.0
11.0
4.0
21.2
6.7
18.3
1.9
15.0
6.0
Riello Burner Type
Combustion Head Type
Nett Full Load Efficiency
Boiler Gas Volume
Exit Flue Gas Mass Flow (Max)
Flue Gas Temperature Rise
Above Ambient
Resistance To Combustion
Products
Maximum Hearth Temperature
Water Side Resistance (Cold)
10 °C Differential
20 °C Differential
50/70
kW
15
13
15
15
Btu/h
68,000
51,000
61,000
61,000
70/90
System
Flowsure
Flowsure+
kW
20
15
18
18
Btu/h
89,000
68,000
82,000
82,000
90/110
kW
26
20
24
24
Btu/h
110,000
89,000
102,000
102,000
kW
32
26
30
30
Btu/h
85,000
68,000
82,000
82,000
Maximum Static Head
Minimum Static Head
Maximum Operating Temperature
Minimum Operating Temperature
Maximum Boiler Operating Pressure
Conventional Flue Draught at Boiler
Flue Outlet
Limit Thermostat Setting
Maximum Casing Panel Temperature
Maximum Surface Temperatures of
Adjusting, Control & Safety Devices
Electrical Supply
90 ft. Water (40 p.s.i.)
5.0 ft. Water (3.0 p.s.i.)
82 °C (180 °F)
55 °C (131 °F)
3 Bar (43.5 p.s.i.) (Class 2)
Model
Flowsure
DHW Limit Thermostat Setting
DHW Store Thermostat Setting
DHW Store Limit Thermostat Setting
Pump Overrun Thermostat Setting
73 °C (163 °F)
88 °C (190 °F)
73 °C (163 °F)
88 °C (190 °F)
88 °C (190 °F)
Flow Restrictor
13 l/m (Brown)
17.5 l/m (Green)
Maximum DHW Flow Rate
Minimum DHW Flow Rate
Maximum DHW Inlet Pressure
Minimum DHW Inlet Pressure
DHW Temperature Rise At a Constant
13 ± 1.5 l/m (2.9 ± 0.3 g/m)
2.5 ± 0.5 l/m (0.5 ± 0.1 g/m)
10 Bar (145 p.s.i.)
1 Bar (14.5 p.s.i.)
17.5 ± 1.5 l/m (3.9 ± 0.3 g/m)
2.5 ± 0.5 l/m (0.5 ± 0.1 g/m)
10 Bar (145 p.s.i.)
1 Bar (14.5 p.s.i.)
12.5 l/m (2.7 g/m)
7.5 l/m (1.6 g/m)
17.0 l/m (3.7 g/m)
12.0 l/m (2.6 g/m)
0.035 "w.g. (8.75 N/m²) Minimum 0.16 "w.g. (40.0 N/m²) Maximum
110 °C (230 °F) Manual Reset
Less Than 35 °C Above Room Temperature
Less Than 30 °C Above Room Temperature
230V 1 Phase 50Hz Fuse 5A
30 °C
50 °C
Store Capacity
Time to Achieve Storage Temperature
kW
25
20
24
24
Flowsure+
40 Litres
12 Minutes (From Cold)
Table 1
Part No. 5102478
Technical Data 13
Boiler Dimension & Clearances
45/50, 50/70
70/90
90/110
System
Flowsure
Flowsure+
A
B
C
D
E
F
G
H
850
390
565
100
100
569
97
59
850
490
565
100
125
569
97
59
850
490
565
100
125
569
97
59
850
490
565
100
125
850
490
565
100
125
850
590
565
100
125
97
59
97
59
97
59
J
1" B.S.P
1" B.S.P
1" B.S.P
1" B.S.P
1" B.S.P
K
1" B.S.P
1" B.S.P
1" B.S.P
Model
Height
Width
Depth
Centre of flue from rear
Flue Diameter
Height between connections
Height of bottom connection
Distance of conn. from wall
mm
mm
mm
mm
mm
mm
mm
mm
Return Connections 2off
1 off
Flow connections
2off
1 off
1" B.S.P
22mm
Cold Mains Inlet
DHW Outlet
System Fill
22mm
22mm
15mm
15mm
15mm
15mm
15mm
15mm
Weight empty
Water content
Water content
Oil Supply Connection
kg
ltr
Imp
BSP
105
18.2
4.0
¼"
122
20.5
4.5
¼"
128
22.5
5.0
¼"
130
20.5
4.5
¼"
145
20.5
4.5
¼"
170
60.0
13.2
¼"
Installation
Clearances
mm
mm
mm
mm
610
12
6
25
610
12
6
25
610
12
6
25
610
12
6
25
610
12*
6
25
610
12*
6
25
Front
Top
Sides BF
Sides CF
* If mounted under a worktop, the top needs to be removed
Table 2
14 Technical Data
Part No. 5102478
Flue Options:
Low Level Horizontal
Flue Kits 1, 2, 5, & 6
Suitable for all Models
(System, Flowsure &
Flowsure + Rear Flue Only)
High Level Horizontal
Flue Kits 3, 5, 6, 7, & 8
Suitable for all Models
High Level Vertical
Flue Kits 3, 4, 5, 6, 9 & 10
Suitable for all Models
Kits 7 & 8
Kits 1 & 2
Kits 5 & 6
(if required)
Kits 5 & 6
(if required)
Intersection
With Roof
Kit 3
2.150m Min.
4.550m Max.
Kits 9 or 10
Kits 5 & 6
(if required)
Kit 3
1.6m Min.
2.1m Max.
770mm
Floor
Level
Floor Level
For Flue Lengths see tables
Flue
Outlet
Kit 4
D
Flue
Outlet
Floor
Level
For Flue Lengths see table
For Flue Lengths see tables
Flue
Outlet
D
Low Level Riser
Flue Kits 12, 5, 6, 7, & 8
Kits 7 & 8
C
D
Flue
Outlet
20mm
Kits 5 & 6
(if required)
Kit 12
D
990mm
B
K
Floor
Level
A
For Flue Lengths see tables
Boiler
Dimensions
F
12mm
Min.
H
6mm or
25mm
Min.
ST00125E
J
G
Knock-out Blanks
For Cables
And Fuel Pipes
6mm
or
25mm
Min.
610mm
Min.
Minimum
Boiler
Clearances
Fig. 8
Part No. 5102478
Technical Data 15
2 - Pre-Installation Requirements
As with all building services, the oil fired
systems have to be installed so as to ensure
safe and efficient operation. The following notes
provide a guide to current best practice. It is
important that documents relating to Building
Regulations and Standards are studied.
In addition we also recommend the following
OFTEC publications:Technical Information Book 3
Installation requirements for oil
fired boilers and oil storage tanks.
Technical Information Book 4
Domestic heating systems
These books are available from OFTEC, Century
House, 100 High Street, Banstead, Surrey SM7
2NN.
Training
Baxi have several training centres around the
country, for details of courses for oil firing telephone
01926 430481. OFTEC also hold training courses
on oil fired central heating.
Regulations and Standards
The installation of oil fired boilers is covered by the
requirements of the Building Regulations which are
statutory instruments and must be complied with.
Those for England and Wales are made by the
Department of the Environment in London.
The Building Standards (Scotland) Regulations are
made by the Scottish Office. Part F of the Technical
Standards to the Regulations covers heat producing
appliances and fuel storage.
The Building Regulations (Northern Ireland) are
made by the Northern Ireland Department of the
Environment. Heat producing appliances, including
oil heating appliances, are covered by Technical
Booklet L.
The Isle of Man has its own Building Bye-laws. In
the Channel Islands, Jersey and Guernsey have
their own separate Building Bye-laws.
The British Standard covering oil fired boiler
installation is BS5410. This is issued as Part 1:1977
for installations up to 45 kW and Part 2:1978 for
larger installations. This standard also covers oil
storage tank installations.
Additional standards and regulations
Fig. 9
16 Pre-Installation Requirements
•
BS 5449: 1990 Forced circulation hot water
Part No. 5102478
•
•
•
•
central heating systems for domestic
premises.
BS 7074: Pt.1:1989 Application, selection
and installation of expansion vessels and
ancillary equipment for sealed systems.
BS 7671 Requirements for electrical
installations. IEE wiring regulations 16th
edition.
Control of pollution (oil) regulations.
Local water undertakings bye-laws.
Chimney
Every Baxi boiler has a very high
efficiency and care must be taken to ensure
that the chimney is suitable.
Chimneys may have been already built and
completed before a choice of appliance has
been made. Alternatively, chimneys may
be installed to suit the particular appliance
chosen.
A factory made insulated chimney
complying with the requirement of BS4543
may be considered as an alternative to a
conventional structural chimney for both
new and existing buildings. A further
alternative may be a suitable form of
insulated flue pipe normally positioned on
a wall outside a building.
Capacity
The chimney or flue must have a crosssectional area throughout its whole length,
that is at least the area of the flue outlet of
the boiler and must be sealed at the boiler
with fire clay or other suitable compounds.
As few bends as possible should be used
and, where necessary, 135° bends are
recommended.
Height
The chimney or flue should be of sufficient
height to provide a minimum draught of
0.035" w.g. measured above the boiler.
Draught conditions that are excessive i.e.
above 0.16" w.g. due to chimney height or
location, should be controlled by means of
a draught stabiliser fitted to the chimney.
External Flues
All external flues of metal or other materials
should have cleaning facilities, and be well
insulated to maintain the correct draught
conditions.
Fig. 10
Part No. 5102478
Pre-Installation Requirements 17
Internal Flues
The exposed flue pipe between the boiler flue off-take
and the chimney proper (either internally or externally)
must not be of asbestos. Vitreous Cast Iron, Steel or
similar materials should be used.
Note: When installing the boiler into a chimney
previously fitted with a liner, the liner must be replaced
and made weather-tight.
Choice of Materials
The materials used in the construction of chimneys
and flues must always be suitable for the application.
Their construction must be durable, non-combustible,
able to resist the range of temperatures expected; and
also resistant to external as well as internal corrosion.
This is particularly important due to the Statesman's
high thermal efficiency, where correct choice of
materials will prevent problems likely to be caused by
condensation.
If you are in any doubt, you should seek advice of a
reputable manufacturer of chimneys, names should
be available from your local stockist.
Combustion & Ventilation Air for Open Flue Oil Fired
Boilers
General. A sufficient permanent air supply to an
appliance will be required.
a) For proper combustion of fuel and effective
discharge of combustion products to the open air.
b) For the ventilation of any confined space in which
an appliance is installed to prevent overheating of
the appliance and any equipment in and near the
appliance.
c) For the satisfactory operation of any draught break
or stabilizer which may be fitted.
Air for Combustion
This requirement will be satisfied if the room or space
in which the appliance is installed has an opening or
duct which is designed to allow the passage of air at
all times equivalent, in total free area, to 550 mm2/kW
(2.5 in2 per 10,000 btu’s) of the appliance rating.
If the space containing the appliance has an extract
ventilation fan fitted, the supply of air should be such
that the operation of the appliance and flue is
unaffected when the windows and doors are closed
and the extractor fan is running.
Air for Ventilation
For an appliance in a confined space, care shall be
taken to provide air for ventilation. A working guide to
the minimum free area of openings to be provided in
addition to that for combustion air is as follows:
a) Where the air is taken from a heated space, 1100
mm2/kW at high level and 1100 mm2/kW (5.0 ins2
per 10,000 Btu’s) at low level.
b) Where the air is taken from outside, 550 mm2/kW
at both high level and low level (2.5 in2 per 10,000
btu’s) at low level.
The above requirements are essential, in particular
for appliances which are installed with a low level
discharge. The warranty for such boilers could be
affected if proper free air requirements are not
provided.
FREE AREAS OF GRILLES ARE MM2 PER KW
OF APPLIANCE RATING (OUTPUT)
Fig. 11
18 Pre-Installation Requirements
Part No. 5102478
Extract Fans
Draught Breaks
If the room in which the appliance is located also has an
extract fan the performance of the appliance must be
unaffected when the fan is running with all doors and
windows closed.
When an appliance with a draught break is fitted in a room
add 550mm2/kW to the free area of the combustion air
inlet.
When an appliance with a draught break in a compartment
which is ventilated as noted above, no additional allowance
is required.
Combustion & Ventilation Air for Balanced Flue Oil Fired Boilers
FREE AREAS OF GRILLES ARE mm2 PER/KW OF APPLIANCE RATING (OUTPUT)
Fig. 12
Balanced Flue
Boilers fitted with balanced flues must only fire Kerosine and will not operate satisfactorily unless the free air requirements
have been satisfied.
Consideration should be given to the texture of the wall onto which the low level flue terminal is fixed. As with all heat
emitting devices the warm air from the terminal will encourage the accumulation of dirt which will at some time require
removal with a detergent based cleaning fluid.
Clearances Required Around Balanced and Low Level Discharge Flues Fitted to Oil Fired Boilers
See Fig. 13
A
B
C
D
E
F
Below a gutter or sanitary pipework
Horizontal from opening, airbrick window etc.
Above ground or balcony level
Below eaves or balcony
From an internal or external corner
From a terminal facing a terminal
Part No. 5102478
G From a surface facing the terminal
H Vertical from terminals on the same wall
I Horizontal from terminals on the same wall
J Below an opening, airbrick, window etc.
K From vertical sanitary pipework
Pre-Installation Requirements 19
Table Showing the Balanced Flue Clearance Dimensions
A
B
C
D
E
F
G
H
I
J
K
England & Wales 1991
-
600
-
-
600
-
-
-
-
600
-
Scotland 1990 Balanced*
Low Level*
600
1000
-
600
600
600
1000
600
600
600
600
600
600
1500
1500
600
600
600
600
600
1000
Northern Ireland 1990
-
600
-
-
600
-
-
-
-
600
-
600
600
300
600
300
1200
600
1500
750
600
300
Building Regulations
BS 5410 Part 1 1997
Table 3
British Standard
Fig. 13
*
Where the terminal is within 1 metre of any plastic material, such material should be protected from the effects
of combustion products.
There are additional general requirements in most Regulations and Standards that the flue must be positioned so
that it does not cause a nuisance and permits the dispersal of combustion products.
If the terminal is less than 2 metres above ground level, balcony or place to which any person has access, the
terminal must be protected by a guard, (Flue Guard Part No. 26000045).
20 Pre-Installation Requirements
Part No. 5102478
Tank Support
Steel tanks are normally supported on masonry piers.
These have to maintain the tank at a sufficient height to
enable access to be gained for painting.
Requirements for Tank Accommodation
Reference should be made to the relevant building
regulations, bye-laws, etc. in order to achieve a satisfactory
degree of safety in relation to the methods of protection.
Underground tanks are also referred to in BS 5410:Pt.1.
BS 5410:Pt.2 gives more detailed guidance on the burying
of steel tanks.
The Scottish Building Standard requirements for
underground tanks are the same as those of BS 5410:Pt.1.
Methods of Tank Protection
It is considered unlikely that a fire will originate from the
stored oil and it is the purpose of these recommendations
to ensure that a fire which may originate from a building
or other external source is not transmitted to the tank
contents.
Adequate safety may be achieved in a number of ways,
for example:
a) Protecting the tank by a physical barrier or isolating
the tank by sufficient space;
b) Enclosing the tank by non-combustible fire resisting
construction; i.e., putting the tank underground.
Oil Storage Tank & Supply Installations
Oil Tank Types
Steel Tanks
Steel tanks should be constructed so as to comply
with BS 799:Pt.5:1987. Galvanised steel pipework or
valves must never be used for oil storage or supply
systems.
Plastic Tanks
Tanks made from plastics material are now available.
Oil should never be stored in translucent plastic
containers.
Fig. 14
Part No. 5102478
Pre-Installation Requirements 21
Storage Requirements and Tank Sizes
end of the vent is fitted with a return bend and an open
wire mesh balloon.
Tanks are available in a wide variety of sizes and
capacities. For boilers of up to 13 kW (45,000 Btu/h)
tanks with a capacity of 1200 litres (250 gallons) are
satisfactory. Above that size of boiler a larger capacity
tank should be considered.
Some typical tank sizes and capacities are noted below
Length
Metres
Width
Metres
Height
Metres
Capacity
Litres
1.22
0.61
1.22
1.22
0.61
1.22
1.22
1.22
1130
1360
2700
3650
1.36
1.25
1.36
1150
1250
2500
Steel Tanks
1.52
1.83
1.83
2.44
A mushroom type vent may be fitted provided its free
area is at least equal to the cross sectional area of the
fill pipe. The vent should normally rise no higher than
600 mm above the top of the tank.
If the vent pipe rises more than 600 mm above the
tank a pressure relief outlet must be provided in the
vent at the 600 mm level. This is normally a horizontal
branch off the vent with a flap at its end. This is hinged
at the top and fitted so that it is normally closed but
will open easily if oil rises up to the level of the branch.
Isolating Valve
A valve is fitted in the tank outlet in an accessible
position so that the oil supply to the burner can be
shut off if required.
Polythene Tanks
2.03
1.37
2.02
0.69
1.06
1.36
The valve must be of a type suitable for use with oil.
The outlet from the tank must be above the level of the
bottom of the tank to prevent water and sediment being
drawn in to the oil supply pipe.
Drain Valve
Tank Fittings
TANKS REQUIRE TO BE PROVIDED WITH THE
FOLLOWING FITTINGS:
In order to enable the sediment and water to be
removed from the tank a gate valve and plug are fitted
in the bottom plate of the tank.
Fill Pipe
Contents Gauge
A 50 mm diameter black steel fill pipe terminating with
a 50 mm male BSP thread hose coupling connection
and non ferrous screw cap and chain.
The most commonly used gauge is the sight tube type.
These are simple and have some advantages for
domestic use. An isolating valve must always be
provided and is often incorporated in the gauge
connection. The top of the gauge must be fixed to the
top of the tank and provided with a cap to protect the
oil from foreign matter. Integral gauges using internal
floats are also available. These are less likely than sight
gauges to give rise to leaks.
Extended Fill Pipe
Extended fill pipes can be used when the location of
the tank is such that access for filling would be difficult
for a delivery tanker carrying 30 metres of hose.
Extended fill lines must be run in 50 mm diameter black
steel tube with proper support. They must be arranged
so as to be self draining, preferably in to the tank.
Where tanks are located lower than their filling
connection care must be taken to ensure that the
pressure head of oil applied during filling is not
excessive.
Where the use of an extended fill pipe means that the
delivery driver cannot see the oil tank, an audible alarm
should be fitted to indicate that the tank is nearly full.
Vent Pipe
A separate vent pipe with an internal diameter at least
equal to that of the fill pipe must be fitted. The open
22 Pre-Installation Requirements
Overfill Alarms
Audible alarms can be fitted in tanks to indicate that
they are nearly full. These are an essential requirement
when the delivery point and tanker access are remote
from each other.
Oil Supply Pipe Layout
Oil can be run from the storage tank to the burner by a
single pipe gravity flow if there is a sufficient height
difference between the bottom of the tank and the
burner. Otherwise a two pipe system is needed.
a) Single Pipe Supply Systems - Tanks serving
Part No. 5102478
appliances with pressure jet burners by means of
a single pipe need to be positioned so that they will
apply the 300 mm minimum required head of oil to
the burner when the fuel level is at its lowest point.
The fittings and layout are shown in Fig. 16.
Pipe Dia
I/D in mm.
Figures for
Kerosine Only
8
10
0.5
1.0
10
20
20
40
1.5
2.0
40
60
80
100
Table 4
'A' Metres Length in Metres
b) Two Pipe Supply Systems - If the tank base is
below the level at which gravity feed to the burner
can be maintained, a two pipe oil supply system
can be adopted. The fittings and layout are shown
in Fig. 17. The non return valve in the supply line of
the two pipe system is required to prevent oil
running back from the burner and un-priming the
oil pump. The non return valve in the return line is
only required if the top of the tank is above the
burner. Its purpose is to prevent oil running back
through the burner during maintenance.
Pipe Dia
I/D in mm.
8
10
Figures for
Kerosine Only
100
100
100
100
100
100
100
90
Oil Line De-Aerating Devices
These may be used in conjunction with Statesman
boilers. It is recommended that they are fitted outside
the dwelling. It is not permissible to fit plastic
components in fuel lines within dwellings or boiler
rooms. The manufacturers instructions should always
be followed, particularly when the oil tank may be
situated at low level. The fittings and layout are shown
in Fig. 16.
Oil Filter
An oil filter should always be fitted in the oil supply
line. Facilities should be provided to enable it to be
serviced without draining down the oil supply system.
Fire Valves
A fire valve is an essential part of the oil supply system.
It should be capable of cutting off the flow of oil outside
Part No. 5102478
It is essential that these devices conform to current
Standards and Regulations. When they are
installed, their manufacturers recommendations
must be adhered to.
Copper Tube and Fittings
Copper tube for oil lines should be to BS.2871:Part 1:
Table Y. It can be obtained in coil form or half hard for
use with bending machines. This pipe can be obtained
with protective plastic sheathing applied. Copper tubes
for oil lines must not be soldered.
Note: Galvanised pipes must not be used.
Floor Temperatures
Table 5
100
100
100
100
100
80
55
5
The valve should be located just outside the building
at the point where the oil supply line enters. It must be
activated by a remote sensor located over the burner
but in a position clear of any direct radiation or
excessive heat. Weight operated valves connected to
a sensor by wires and pulleys have been used for this
purpose. It is preferable, however, to use a valve with
a capillary connection between its sensor and the oil
cut off mechanism. The use of fusible head isolating
valves is not recommended.
Fittings for copper pipe should be of the flared
manipulative type to BS.864:Part 2:1983. Steel pipe
should be to BS.1387:1985. Fittings for steel pipe
should be to BS.1740:Part 1:197271 with taper threads.
'B' Metres Length in Metres
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
the building in the event of a fire starting up within the
boiler.
The thermal insulation provided in the boiler base
ensures the floor temperatures is kept below 80 °C
and as such, a non combustible hearth is not required.
The floor should always be smooth and flat and capable
of supporting the installed weight of the boiler, including
its water content. If constructed by a material which is
softened by oil, it is advisable to install an additional
metal tray underneath the boiler for protection against
accidental damage.
The Heating System
When fitting into an existing installation the system
should be chemically cleaned, and a suitable inhibitor
added to keep it in good condition.
SYSTEM, FLOWSURE AND FLOWSURE +
System Requirements: These boilers are specifically
designed for Sealed Systems but will operate on open
vented systems. When used on a sealed system the
central heating system should be in accordance with
the relevant recommendations given in BS 5449 Pt 1
and BS 7074 Pt 1.
Pre-Installation Requirements 23
The appliances incorporate a circulating pump, no
other pump is required. The appliances will operate
satisfactory on a two pipe small bore or micro bore
system using thermostatically controlled radiator
valves. When employing a central heating system
where primary water flow may be prevented during a
pump overrun situation (i.e. by using thermostatic
radiator valves on all radiators), a bypass valve should
be fitted between flow and return pipes.
It is strongly recommended that isolating valves are
fitted to the central heating flow and return pipes, this
will allow the boiler and heatstore tank (Flowsure + ) to
be drained for service work without having to drain down
the whole central heating circuit.
On the Flowsure and Flowsure + a drain point should
be provided in the domestic hot water pipework at any
point below the height of the domestic hot water heat
exchanger. Provision should also be made to allow air
to be vented from the domestic hot water pipework at
any high points.
Sealed Primary System
A manual reset overheat thermostat is located on the
underside of the electrical control panel and is
accessible by removing the boiler front casing panel. If
a boiler overheat condition arises the burner will remain
inoperative until the thermostat button is reset. See
the Users Instructions.
The pressure relief valve operates at 3 bar (45 lb/in²).
Install a pressure relief valve discharge pipe, not less
than 15 mm diameter and connect to the pressure relief
outlet connection using a 15 mm compression fitting.
The pipe run should be as short as possible, run
continuously downwards and discharge to the outside
of the building, where possible over a drain. The
discharge point must be such that it will not be
hazardous to occupants or cause damage to external
electrical components or wiring.
Note: It must not discharge above an entrance, or
window, or any type of public access. The installer
must consider that the overflow could discharge
boiling water. See Fig. 15.
Fig. 15
increased by simply pumping up the vessel with a
standard type pump and checking the pressure with a
tyre gauge. A schraider type valve is provided on the
vessel for this purpose. The air charge should not
exceed a pressure of 1.5 bar (22 p.s.i.).
With an initial system pressure of 0.5 bar, a system
capacity of about 120 litres (26.4 gals), can be
accommodated. A check should be made to ensure
the system volume comes within this capacity but if it
is greater, than an additional expansion vessel will be
needed. This should be fitted in ether the flow or return
pipes, as close as practicable to the boiler. Refer to BS
7074 Pt 1 for more information.
Note: The values given in Table 6 are the total system
volumes. The primary water capacity given in Table 2
should be deducted from the total system volume when
calculating the volume for the radiators, pipework etc.
Safety Valve Setting (bar)
Initial System Pressure (bar)
0.5
Total Water Content of System
VESSEL VOLUME (L)
litres
25
50
75
100
125
150
175
200
225
250
The combined temperature /pressure gauge indicates
the system pressure, which must be maintained, and
the primary water temperature in the boiler shell.
The 10 litre expansion vessel is charged to 0.5 bar and
is suitable for a static head of 5 metres (16.5 ft), i.e. the
vertical distance between expansion vessel and highest
point of system, usually the top of bedroom radiators.
If the static head is greater than 5 metres, then the air
charge in the vessel must be increased to equal this
greater higher static pressure. The pressure can be
24 Pre-Installation Requirements
3.0
For system volumes other than
those given above, multiply the
system volume by the factor
across
1.0
1.5
litres
2.1
4.2
6.3
8.3
10.4
12.5
14.6
16.7
18.7
20.8
litres
2.7
5.4
8.2
10.9
13.6
16.3
19.1
21.8
24.5
27.2
litres
3.9
7.8
11.7
15.6
19.5
23.4
27.3
31.2
35.1
39.0
0.0833
0.109
0.156
Deduct from the value given in the table the 10 litre expansion vessel supplied.
Table 6
Part No. 5102478
The automatic air vent automatically expels any airreleased from the water and thereby keeps the boiler
fully charged.
Filling and Make-up Loop
A connection must be incorporated into the central
heating system to facilitate filling. There must be no
direct connection to the mains water supply, even
through a non-return valve, without the approval of the
Local Water Authority. The filling point must be at low
level, water loss must be replaced. The connection
should be made in the central heating return as close
to the boiler as possible.
Permissible methods of filling
Direct method - A detachable flexible hose is connected
to a stop valve fitted to an outlet on the service main.
The other end of the hose is connected to a second
stop valve and a double check valve. The double check
valve is fitted to an inlet connection on the central
heating return pipe. The hose should be disconnected
after filling. Where the mains pressure is excessive a
pressure reducing valve shall be used to make filling
easier.
Note: On the Flowsure and Flowsure+, this method is
recommended, and the associated components are
supplied with the boiler. A pressure reducing valve is
not required as the stop valve incorporates a flow
restrictor. (restricted to 10 l/m).
Booster pump method - The system may be filled
through a self contained unit comprising a cistern,
pressure booster pump and if necessary, an automatic
pressure-reducing valve or flow restrictor. The pressure
booster pump must be capable of pressurising the
system to a minimum of 1.0 bar (14 p.s.i.) measured at
the appliance. The cistern should be supplied through
a temporary connection from a service pipe or cold
water distributing pipe. The unit may remain
permanently connected to the heating system to
provide limited water make-up.
Provision should be made for replacing water loss
from the system by re-pressurisation of the system
Flowsure and Flowsure+
The final 600 mm of the mains cold water connection
to the boiler should be made in copper tubing to BS
2871 Pt 1, which is recommended for water carrying
pipework and must be used for pipework carrying
potable water. All capillary joints in the D.H.W. pipework
must be joined with a lead free solder.
The boiler is suitable for mains cold water supply having
a maximum pressure of up to 10 bar (145 lb/in²). A
pressure reducing valve must be fitted if the mains
pressure exceeds 10 bar.
If there are long pipe runs to the taps or shower. It is
suggested that they be insulated to prevent the rapid
cooling of residual hot water in the pipes after the tap
has been turned off.
Taps and Valves - Hot and cold taps and mixing valves
used with these boilers must be suitable for operating
at a mains pressure of up to 10 bar (145 lb/in²).
Showers (Fixed head type) - No anti-syphonage
arrangements are necessary. Thermostatically
controlled shower valves will give extra comfort and
guard against flow of water at too a high a temperature.
Showers (Loose or flexible head type) - A loose head
shower hose must be fixed so that the head cannot fall
closer than 25 mm (1 in) above the top edge of the
bath to prevent its immersion in bath water. Alternatively
the shower must incorporate or be fitted with an antisyphonage device at the point of the flexible hose
connections.
Bidets - The supply of hot and cold mains water direct
to a bidet is permitted (subject to local Water Company
requirements) provided that the bidet is of the over-rim
flushing type. The outlet(s) should be shrouded and
unable to have any temporary hand held spray attached.
No anti-syphonage arrangements are necessary.
Use in Hard Water Areas
If the area of installation is recognised as a hard water
area, (above 200 p.p.m.) it is essential that a suitable
water treatment device of an electronic, magnetic or
galvanic type be installed in the mains water supply.
Domestic Hot Water
System
The domestic hot water cylinder (where fitted) must be
of the indirect coil type and suitable for working at a
gauge pressure of 0.35 bar above the safety-valve
setting, i.e. 3.65 bar.
Part No. 5102478
To assess water hardness, immerse the test strip
supplied, for about one second in a water sample (NOT
IN RUNNING WATER) so as to moisten all the zones.
Inspect the strip after 1-2 minutes, check the zones, if
two or more zones have changed colour the hardness
of the water is above 200 p.p.m. and a water treatment
device will be required.
Pre-Installation Requirements 25
Single Pipe Supply System
Fire Valve
Sensor
Max. Oil Level 4 metres
Above Burner
Shut Off
Valve
Filter
Fire Valve
Max.
Head 4m
Pump
'A'
Fire Valve
Sensor
De Aeration
Device
Fire Valve
Oil Tank Below
or Level
with Burner
Isolating
Valve
Oil Supply
Pipe
Pump
Isolating
Valve
Filter
Fig. 16
Non-Return Valve
Fire Valve
Filter
Oil Return Pipe
Oil Tank
Below Burner
Non-Return
Valve
Pump
Fire Valve
Sensor
Shut Off
Valve
'B'
150mm
ST00203A
Oil Supply
Pipe
Twin Pipe Supply System
Fig. 17
26 Pre-Installation Requirements
Part No. 5102478
3 - Installation & Commissioning
Low Level Horizontal - Kits 1 & 2 With Extensions
Low Level Horizontal - Kits 7, 8 & 12
Kit 5
950mm
Kit 6
Max. kit 5 + 6
Kits 5 & 6 (Extensions)
Kits 7 & 8
(Terminal)
300mm
Max.
Kits 1 & 2 (Flue)
175 Min.
225 Max.
Kits 5 or 6
(Extension)
Max. Kit 5 + 6
126
Kit
12
Kits 1 & 2
(Terminal)
The terminal can be extended
between these markers
12
Kit 6
300mm
Casing
175 Min.
225 Max.
Wall Width
Min.
Kit 5
950mm
990
Casing
Kit 5
103
Wall
Kit 6
Width
12 Min.
All Dimensions in mm
Floor Level
Floor Level
All Dimensions in mm
Low Level Rear
ALL Models
Low Level Left/Right
50/70 Models
Low Level Rear
ALL Models
Low Level Left/Right
70/90 90/110 Models
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
100 - 275
1
100 - 250
1
100 - 200
1
225 - 600
2
125 - 500
2
100 - 450
2
600 - 900
2+6
500 - 800
2+6
450 - 750
2+6
900 - 1,200
2+6+6
800 - 1,100
2+6+6
750 - 1,050
2+6+6
Low Level Left/Right
45/50 50/70 Models
2+5
1,100 - 1,450
2+5
1,050 - 1,400
2+5
1,550 - 1,850
2+5+6
1,450 - 1,750
2+5+6
1,400 - 1,700
2+5+6
Low Level Right
Flowsure + Model
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
100 - 275
12 + 7
100 - 175
12 + 7
100 - 125
12 + 7
Not Suitable
12 + 7
225 - 525
12 + 8
125 - 425
12 + 8
100 - 375
12 + 8
100 - 275
12 + 8
525 - 825
12 + 8 + 6
425 - 725
12 + 8 + 6
375 - 675
12 + 8 + 6
275 - 575
12 + 8 + 6
825 - 1,125
12 + 8 + 6 + 6
725 - 1,025
12 + 8 + 6 + 6
675 - 975
12 + 8 + 6 + 6
575 - 875
12 + 8 + 6 + 6
1,125 - 1,225
12 + 7 + 5
1,025 - 1,125
12 + 7 + 5
975 - 1,075
12 + 7 + 5
875 - 975
12 + 7 + 5
1,225 - 1,475
12 + 8 + 5
1,125 - 1,375
12 + 8 + 5
1,075 - 1,325
12 + 8 + 5
975 - 1,225
12 + 8 + 5
1,475 - 1,775 12 + 8 + 5 + 6
1,200 - 1,550
Low Level Left/Right
70/90 90/110 System
Flowsure Models
Flowsure + Left Only
1,375 - 1,675 12 + 8 + 5 + 6
1,325 - 1,625 12 + 8 + 5 + 6
1,225 - 1,525 12 + 8 + 5 + 6
ST00192A
770
With Extensions
Dress Plate (Outer Wall)
Dress Plate (Inner Wall)
Kits 7 & 8
(Elbow)
All Dimensions in Tables ± 5mm
High Level Horizontal - Kits 3, 7 & 8 With Extensions
Kits 7 & 8
All Dimensions in Tables ± 5mm
Kits 7 & 8
(Terminal)
(Elbow)
With Extensions
High Level Vertical - Kits 3, 4, 9 & 10
Kit 4
Kit 4
1000mm
to wall
or chimney
1000mm to wall,
or chimney
Pitched
Roof
Kit 9
300 Min.
175 Min.
225 Max.
Kits 5 or 6
(Extension)
Max. kit 5
Flat Roof
Flashing
300
Min.
Kit 5
Wall
Kit 5
950mm
Width
1600 Min.
2100 Max.
Kit 6
300mm
Kit 3
All Dimensions in mm
Kit 10
Kit 4
Flashing
Pitched Roof
Kit 6
Flat Roof
Kit 6
All Dimensions in mm
12
Kit 4
300
Casing
103
Kit 5
950
950
Floor Level
High Level Vertical
ALL Models
Roof
Height
Min.
Max.
2,150
2,650
2,450
2,750
Kit
Numbers
950
Roof
Height
Fit Dress Plate
to the Ceiling
(if required)
High Level Rear
ALL Models
High Level Left/Right
50/70 Models
High Level Left/Right
70/90 90/110
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
Wall
Width
Kit
Numbers
100 - 275
3+7
100 - 175
3+7
100 - 125
3+7
3+4
Wall
225 - 525
3+8
125 - 425
3+8
100 - 375
3+8
2,950
3+4+6
Kit 3
525 - 825
3+8+6
425 - 725
3+8+6
375 - 675
3+8+6
3,250
3+4+6+6
825 - 1,125
3+8+6+6
725 - 1,025
3+8+6+6
675 - 975
3+8+6+6
3,100
3,600
3+4+5
1,125 - 1,225
3+7+5
1,025 - 1,125
3+7+5
975 - 1,075
3+7+5
3,400
3,900
3+4+5+6
3,700
4,200
3+4+5+6+6
1,225 - 1,475
3+8+5
1,125 - 1,375
3+8+5
1,075 - 1,325
3+8+5
4,550
3+4+5+5
4,050
Casing
Floor Level
All Dimensions in Tables ± 5mm
Part No. 5102478
103mm
All Dimensions in Tables ± 5mm
ST00181B
Kits 5 or 6
Two
Max.
Kit 5
Fig. 18
Installation & Commissioning 27
Installation & Commissioning
It is possible to install the boiler without removing
the casing sides but care should be taken not to
damage the panels when connecting the water
pipes.
Fitting a Balanced Flue
Refer to the Instructions supplied with the flue.
Fitting a Conventional Flue
Local Building Regulations and Bye Laws should
be consulted for details of the chimney, use a 135°
bend. 90° bends must not be used, due to their
flow resistance and baffling characteristics.
Ensure that flue pipe entering a brick chimney is
cut off flush with the inside surface or at a small
inclined angle to prevent droppings entering the
flue connection. Provision for cleaning the
chimney should be made below the flue entry.
Refer also to Section 2 of these Instructions.
a) Unpack the boiler.
b) Select the desired oil feed position and remove
the appropriate knockout in the base using a
suitable drift.
c) Position boiler.
d) Lift off top casing panel.
e) Carefully remove knockout panel in top
casing panel using gentle manipulation.
f) Seal flue pipe to boiler with fire cement.
g) Re-fit top casing panel.
Connecting the Electricity Supply
Electrical Connections:
All electrical wiring must be carried out by a
qualified electrician in accordance with current
I.E.E. Regulations and any Local Regulations that
may apply.
Earthing: It is essential that the appliance is
earthed.
Fig. 19
Cable Entry: The cable should be heat resisting
and routed either along the top side of the casing
or run from the bottom side through the knock
out holes in the base tray, making sure they do
not come in contact with the heat exchanger.
Fusing: The mains electrical supply should be
taken from a double pole isolating switch (fused
5 amp) situated near the boiler.
28 Installation & Commissioning
Part No. 5102478
Wiring Diagrams: Refer to wiring diagrams in
Section 1 of these Instructions. The mains inlet
plug is provided in the bag of fittings supplied.
Note: A permanent live supply must be made,
to allow the pump overrun device, as fitted to
the Flowsure and Flowsure+, to operate correctly.
Control Box
Assembly
Remove
Front Cover
To wire in external controls, open the door on
the right hand side of the facia panel, to expose
a blanking plate (Statesman, Statesman System)
or programmer plate (Flowsure, Flowsure+).
Control
Panel
Statesman, Statesman System: Remove the
blanking plate you will then see a plug-in terminal
block, remove the appropriate part, run wires
through hole in panel, wire into plug refit plug into
socket, pull through excess wires then refit
blanking plate.
Flowsure, Flowsure+: Remove the programmer
plate you will then see a plug-in terminal block,
remove the plug, run wires through hole in panel,
wire into plug refit plug into socket, pull through
excess wires then refit programmer plate.
Facia Door
A plastic facia door is incorporated into the
control panel. This door is designed to come
off if any undue pressure is exerted on it when
open but can easily be snapped back into
place. It may however become detached if the
appliance has been handled roughly during
transit. If you find the door is missing when
opening the carton, check to see if it is
amongst the packaging.
Control
Panel
Mains
Socket
Control Box
Assembly
Burner
Socket
Limit Thermostat
Reset Button
Fuel Pipes
Refer to Section 2, Figs. 14, 16, 17 plus Tables
4 and 5.
Part No. 5102478
Earth
Main Supply
Connection
E L
Neutral
ST00209A
The flexible fuel pipe should be connected to
the burner and the other end to the fuel line
via the isolation valve (supplied). At this stage
the connection should be left finger-tight as
it will have to be disconnected before the
burner is started in order to vent air from the
line after the fuel has been turned on. Couple
a filter to the rigid pipe and run pipework from
the inlet of the filter to the tank. The filter
should not be installed inside the boiler.
continued on page 34.
Live
N
Before connecting a flexible hose to the burner
draw off a small quantity of oil, approximately
two pints, into a suitable container, check that
fuel is clean.
Fig. 20
Installation & Commissioning 29
Fig. 21
30 Installation & Commissioning
Part No. 5102478
Fig. 22
Part No. 5102478
Installation & Commissioning 31
Fig. 23
32 Installation & Commissioning
Part No. 5102478
Room Stat Or Programmable Stat.
1
2
3
Detail With Room Stat/Frost Stat
gy *
y
S/L
HW
ON
g/y
br
L
L
br
Clock
Electro-mech.
o
w
N
b
S/L
CH
ON
p
Boiler
Terminal Socket
p
N
Press / Temp
Terminal Plug
b
ST00129C
Frost Stat
Remove Link
*
Only
COLOUR CODING
b = Blue
br = Brown
gy = Grey
w = White
y = Yellow
o = Orange
p = Pink
g/y = Green/Yellow
Fig. 24
Part No. 5102478
Installation & Commissioning 33
An Isolation Valve should be placed on the tank side
of the filter, so that the oil supply can be isolated when
servicing is required.
Ensure that the filter is positioned correctly and that it
is easily accessible with sufficient clearance below it
for cleaning or replacing the filter element.
It is vital that all joints are completely oil-tight, leaks
may cause air locks in the fuel supply pipe, and will
almost certainly lead to complaints of oil odour.
Fit the fire valve in the oil line, as detailed in Section 2,
Page 26.
Where the tank position provides a gravity flow of oil
to the burner, THE SINGLE PIPE SYSTEM should
be used. The difference in “head”, i.e., the distance
vertically between the pump and the outlet of the tank,
dictates the maximum length of oil supply pipe,
including horizontal and vertical runs (see Section 2).
When the tank outlet is below the level of the burner
fuel pump, THE TWO PIPE SYSTEM MUST BE
USED (See Fig. 17). Here a return line is piped from
the pump back to the tank, finishing at least 150 mm
above the bottom. This section of pipe must end at
the same level in the tank as the suction as to prevent
loss of prime.
The ends of the two pipes should be well separated
so that no sludge is disturbed by the return, and will
not be pulled into the suction pipe. An elbow at the
end of the return will ensure that the discharge is away
from the suction. A non-return valve should be fitted
as close as possible to the tank and at the lowest
available point in the suction line. Avoid having the
bottom of the tank more than 3 m (10') below the burner.
The difference in levels between the pump and the
suction and the return lines in the tank controls the
maximum length of pipe, including horizontal and
vertical runs.
It is necessary to enable the pump to raise the oil out
of the tank. Problems can be encountered, with air
collecting on shut down, if the fuel pump is situated at
the highest point in the system.
System and Flowsure:
Return connections are provided on each side of the
boiler at low level. A flow connection is provided at
high level at the top rear of the boiler. Connect the
pipework to the selected connections and blank off
the unused ones.
Flowsure+:
A flow connection is provided at high level at the top
rear of the boiler and one return connection is provided
at low level to the left side of the boiler.
Note: If the pipes are to be reduced down from 22
mm, eccentric adaptors should be used to prevent air
being trapped in the boiler, see Fig. 25.
On the Flowsure and Flowsure+, domestic hot and cold
water connections are provided at the top rear of the
boiler.
Caution: On the Flowsure care should be taken if
solder connections are made to the hot water outlet
pipe, disconnect the DHW limit thermostat from the
pipe prior to applying heat.
Filling and Make-Up Loop
On the Flowsure and Flowsure+ the flexible hose
provides the means for initial filling of the system from
the mains supply and also for subsequent make-up. It
is fitted with a double check valve to ensure system
water cannot feed back whilst filling and a shut-off valve
is provided for mains isolation. IT IS IMPORTANT THAT
FILLING IS DONE SLOWLY AND THE HOSE IS
DISCONNECTED WHEN NOT IN USE.
On the System boiler a filling and make-up loop will
need to be provided.
Retarders
There is an access door above the burner,(behind the
expansion vessel on the System, Flowsure and
Flowsure+), remove and check the retarders are sound
and in position.
Most models have three retarders above a baffle plate.
The 45/50 has three retarders only and the 90/110
has six retarders and two baffle plates.
Water Connections
Thermostats
Statesman:
Flow and return connections are provided on each side
of the boiler, comprising two high level flow connections
and two low level return connections. Connect the
pipework to the selected connections and blank off
the unused ones, it is always preferable to connect
the flow and return pipe diagonally opposite if at all
possible.
Check that all thermostats are secure in their pockets.
On the 45/50, 50/70, 70/90 and 90/110 models it is
recommended that on fully pumped systems the
boiler stat phial is on the side nearest the flow
outlet. If hot water is by gravity circulation fit the
boiler stat phial on the gravity flow side.
Commission the boiler - See page 36.
34 Installation & Commissioning
Part No. 5102478
Fig. 25
Part No. 5102478
Installation & Commissioning 35
Commissioning
9.
It is strongly recommended that the boiler/burner is
commissioned by a qualified technician, preferably
OFTEC trained and registered.
10.
Burner
11.
1. Unless already removed, remove the top casing
panel, front casing panel and burner cover.
2. Temporally disconnect the fuel hose from the
burner, run off the oil into a container to purge air
from the fuel line.
3. Re-connect oil line and check for leaks.
4. Connect a pressure gauge to the oil pump.
5. Check that the water system is filled and vented.
6. Check that all controls are calling for heat.
7. Switch on electricity supply.
8. Turn on boiler thermostat. The burner will start and
should light within 20 seconds. If the flame is not
established during this time the burner lock out
neon will light, wait about a minute before pressing
the reset button to re-commence the lighting
sequence.
12.
13.
Continuous failure to light is almost certainly due
to air remaining in the fuel supply.
Start and stop the burner two or three times until
the flame cuts off sharply - this indicates any
remaining air has been dispersed.
When the burner is operating check the fuel supply
pressure, adjust if necessary to give the required
output.
Switch off the boiler, remove the pressure gauge
and re-fit the plug.
Re-fit the burner cover and boiler casing panels,
Switch the boiler on. Allow the burner to run for
about 15 minutes. The flue gas sampling point
should be used whilst adjusting the air to give clean
combustion. See the Burner Information
Instructions for correct CO2 reading.
Boiler and system preparation
1. Remove the boiler top and front casing panels.
2. Check that all controls are not calling for heat.
3. Check that all water connections throughout the
system are tight.
Models: 50/70, 70/90, System,
Flowsure & Flowsure+. 90/110 has 6 Retarders
3 Retarders
Control
Thermostat
Front
Access
Door
Baffle
Plate
Front
Access
Door
Baffle
Plates
For Model
90/110
Shell
Front
Access
Door
Remove
Front
Cover
3 Retarders
(No Baffle Plate)
ST00210A
Model: 45/50
Slot The Plate
Into Position
Baffle Plate
Lift Out
For Model
The Plate
50/70, 70/90
With These
Holes
Baffle Plate For Models
System, Flowsure & Flowsure+
Fig. 26
36 Installation & Commissioning
Part No. 5102478
4. Having completed the necessary water connections,
those connections not utilised should be plugged.
5. Check that the central heating system has been fully
flushed out at installation using a flushing agent. If
not, add a suitable flushing agent to the system and
fill the system. Then drain the system while hot and
immediately refill adding a suitable proprietary
corrosion inhibitor (such as Fernox).
If the pressure indicated on the pressure gauge is
greater than 2.5 bar when operating at the maximum
central heating temperature, an extra expansion vessel
must be fitted to the system as close as possible to
the boiler central heating return connection.
Any extra vessel fitted must be pressurised to the same
figure as the integral vessel.
Domestic Hot Water System (Flowsure/Flowsure+)
The following procedures should be used when filling
the sealed system boilers.
6. Set the diverter valve to the mid position by moving
the manual lever to the left hand side and locking in
position (Flowsure/Flowsure+). Open all radiators
and lockshield valves and remove and discard the
automatic air vent cap.
7. Fill the system and check that air is being discharged
from the automatic air vent.
8. Vent each radiator in turn to remove the air from the
system.
9. Bleed any air from the boiler pipework using the
manual air vents provided (Flowsure/Flowsure+).
10. Disconnect the burner at the control box by pressing
the connecting plug locking tab and pulling the plug
free.
11. When the system has been completely vented, set
the controls to call for heat. The pump will now operate
and any remaining air can be purged from the system
using the appropriate bleed points.
12. Set all controls to stand-by and reconnect burner
electrical plug to control box.
13. Return the diverter valve lever to the normal right
hand position (Flowsure/Flowsure+).
Set the Expansion Vessel Pressure
The charge pressure of the expansion vessel as
dispatched is 0.5 bar, which is equivalent to a static
head of 5 metres (16.5 ft). The charge pressure must
not be less than the static head at the point of
connection. A schraider type valve is fitted to the
expansion vessel to allow the charge pressure to be
increased if necessary.
Set the System Pressure
1. Check that the mains water supply has been fully
flushed out at installation. If not, disconnect the
cold water inlet pipe from the boiler and flush the
cold supply thoroughly
2. Set the boiler to hot water mode.
3. Fully open the hot water tap.
4. With a suitable water measuring container, check
the water flow rate, see Table 1 (page 13).
5. The flow rate can be manually adjusted at the
mains cold water inlet isolating valve if the flow
rates as indicated in Table 1 cannot be achieved.
6. Set the mixer valve for optimum hot water
temperature, See the Users Instructions for
adjustment (Flowsure+only).
7. Fully close the hot water tap.
Note: Max flow rate for Flowsure, 13 ± 1.5 litres/minute
and Flowsure+, 17.5 ± 1.5 litres/minute.
Completion of Commissioning
If the boiler is being passed over to the user
immediately, advise the user of the precautions
necessary to prevent damage to the system and to
the building in the event of the system remaining
inoperative during frost conditions. Advise the user that
for continued efficient and safe operation of the boiler,
it is important that adequate servicing is carried out
by a qualified engineer at least once a year for boilers
using kerosene and twice a year if using gas oil. Set
the system controls to the user’s requirements.
If the boiler is to be left inoperative, set all controls off.
Turn off oil supply at the isolating valve and switch off
the electricity supply. If there is any possibility of the
boiler and system being left inoperative during frosty
conditions then drain the boiler and system.
Fill the system until the pressure gauge shows 1.5 bar
(21.5 lb/in²) and check for water soundness. Release
water from the system until the system design pressure
is obtained, up to a maximum of 1.5 bar.
System design pressure in bar = static head of the system
in bar + 0.3
Note: 1 bar is equivalent to 10.2 metres (33.5 ft) of
water. Set the movable pointer giving a permanent
record of the set system pressure when cold.
Part No. 5102478
Installation & Commissioning 37
Model: 45/50
Remove The 3 Retarders, Examine For
Damage, Replace if Necessary
Models: 50/70, 70/90, System,
Front
Flowsure & Flowsure+
Access
90/110 has 6 Retarders
Door
Lift Out
The Plate
With These
Holes
Examine The
Interior Of
The Boiler
And If Necessary
Clean Carbon Off
Baffle Plate
For Models:
50/70, 70/90 System,
Flowsure
& Flowsure+
Boiler Shell
Baffle Plates
For Model
90/110
Top
Cover
Remove
The Baffle
Plate &
Examine
For Damage,
Replace If
Necessary
Thermostat
Pocket
Examine The
Interior Of
The Flue
And If Necessary
Clean Inside
Burner
Lead
Thermostat
Flue Gas
Sampling
Remove
Front
Cover
Remove
Front
Access
Door
Disconnect
Flange
Disconnect Burner
Air Supply Pipe
Clean
Combustion
Head
(LD2SH Model
Shown)
Remove
Burner
Clean
Ignition
Electrodes
ST00211A
Replace
Nozzle
With One
Of Identical
Type
Disconnect
Burner Plug
Disconnect
Suction Line
Fig. 27
38 Installation & Commissioning
Part No. 5102478
4 - Servicing & Maintenance
•
If the balanced flue is dismantled for any reason and
the flue seals disturbed, new seals must be fitted.
Refer to the Parts Catalogue for part numbers.
Servicing
•
•
To maintain the boiler’s high thermal efficiency and
reliable operation, it should be serviced annually by a
qualified engineer preferably OFTEC trained and
registered. If Gas Oil is the fuel two visits per year are
advised.
Operate the boiler and system. Note any faults which
may need to be corrected during the service. It is
advised that a set of combustion results are first
obtained before undertaking any work.
•
Switch off the electricity supply at the main isolating
switch to the boiler. Turn off the fuel supply.
•
Pull off front cover and disconnect the burner oil
pipe(s), flexible air tube and burner plug, refer to
the Burner Information Instructions.
•
Remove expansion vessel assembly and lay to one
side (where fitted).
•
Undo burner retaining nut and withdraw burner from
boiler, remove combustion head. Clean combustion
head, making sure all slots and holes are clean. Clean
ignition electrodes, examine for signs of damage.
•
Remove nozzle and replace with one of identical
type. Under no circumstances should the nozzle
be stripped into component parts and never
attempt to clean the nozzle tip.
•
Remove burner cover, pull out and clean photocell.
•
Remove air intake assembly and right hand side of
fan casing and check impeller for deposits - clean
blades as necessary.
•
Remove end cap from oil pump and take out filter. Wash
clean with kerosene and replace. (Caution - the oil
pump contains a small amount of fuel, which will be
released, when the end cap is removed).
•
Re-assemble burner and check dimensions, refer to
Burner Information Instructions. Note: Check all seals
and replace if damaged.
•
Remove access door on front of boiler, remove
retarders and baffle plate (not 45/50) noting their
positions. Brush off all deposits, if they show signs of
damage replace.
Part No. 5102478
•
Examine interior of boiler and if necessary clean.
Remove any loose debris from the combustion
chamber.
•
Check the condition of the refractory base and repair
any minor cracks with fire cement.
•
When satisfied refit retarders and baffle plate (not 45/
50) and refit access door making sure that seals and
gaskets are correctly fitted.
•
Refit burner to boiler, connect flexible air tube, oil
pipe(s) and refit burner lead.
•
With all controls calling for heat, turn on fuel and switch
on electricity. Allow burner to run for several minutes
and then carry out combustion tests, refer to the Burner
Information Instructions and if necessary, adjust to
obtain best results.
•
On completion of combustion tests, replace front cover
and expansion vessel assembly (where fitted).
Note: It is advisable to replace flexible fuel pipes
every five years.
Maintenance
•
•
•
To ensure trouble-free heating and hot water, it is most
important that the boiler and burner are correctly
serviced.
This is best carried out by entering into a Service
Contract with your Installer.
Conditions of operation will vary, but with normal usage
the following is strongly advised:
At the end of winter
• Switch off main switch.
• Close all stop valves in the oil supply pipes.
• Clean the flueways and all inside surfaces of the
boiler.
• Clean flue and chimney.
• Clean all boiler internal surfaces.
At the end of summer
• Isolate elctrical supply to the boiler.
• Switch off main switch.
• Close all stop valves in the oil supply pipes.
• Clean the flueways and all inside surfaces of the
boiler.
• Clean flue and chimney.
• Clean all boiler internal surfaces.
Also,
• De-sludge the fuel tank(s)
There should be a sludge valve fitted to the tank(s).
• Replace/clean cartridge in main filter
If a paper microbic cartridge has been in service
Servicing & Maintenance 39
for more than one heating season, a
replacement should be fitted. If a metal fine
microbic filter is fitted then this should be
cleaned with kerosene. Ensure that the filter
bowl is thoroughly cleaned out before
replacement.
Sight
Gauge
Isolating
Valve
Steel Tank
Draw Off
Pipe
Clean Or Replace
Oil In-line Filter
•
Remove the burner
Service the burner, refer to the Burner
Information Instructions.
•
Clean the boiler
This is required as follows if the boiler was not
cleaned at the end of the heating season:
Remove the expansion vessel assembly (if
fitted) and the front access door from the boiler
Remove the retarders and baffle plate (not
45/50), clean any soot and any hard deposits
from the boiler surface.
•
Gaskets
It is advisable to replace all gaskets which have
been disturbed unless it is certain that they
are in excellent condition.
•
Check all thermostats
Test all thermostats to ensure that they are
working correctly. Remove all dust with a soft
brush and make sure that accessible contacts
are clean.
•
Water system (Sealed system boilers only)
The system water should be topped up as
necessary using the filling system provided.
Drain Off Sludge
In Tank
Clean Out Boiler & Check Gaskets For Damage.
Replace If Not In Perfect Condition
Check
Thermostat
Disconnect
Burner
Air Supply
Pipe
Filling must be carried out with the system cold
so that the pressure can be brought up to the
original cold fill reading indicated by the red
pointer. A careful watch should be kept on the
pressure gauge during filling and the mains
pressure valve opened slowly.
Remove
Burner
Topping up may, by arrangement, be a part of
the annual service contract.
Clean
Combustion
Head
(LD2SH Model
Shown)
Replacement of Parts
Disconnect
Burner Plug
Disconnect
Suction Line
Clean
Ignition
Electrodes
ST00212A
Replace
Nozzle
With One
Of Identical
Type
Isolate the boiler from the Electricity, Oil and
Water supplies before replacing any
components.
On the sealed system boilers it should be
remembered that the boiler is under system
pressure and, as such, before disconnecting
any parts that enter the water shell, the system
pressure must be reduced and the boiler
drained.
Fig. 28
40 Servicing & Maintenance
Part No. 5102478
Replacement of Thermostats
(Statesman & System)
1. Remove the front cover.
2. Pull off the temperature control knob.
3. If a clock is fitted un-clip from the facia and
disconnect the plug at the back. On the System
boiler disconnect the rear electrical connecter.
4. Remove the facia retaining screws at the base
of the facia.
5. Lift off the facia and disconnect the indicator
lights plug.
6. Remove the controls assembly securing
screws.
7. Lift away the controls assembly and un-clip
both sensors and temperature bulb (where
fitted) from their pockets.
8. Remove the retaining screws and split the
controls box assembly apart.
Limit Thermostat
1. Remove the limit thermostat by disconnecting
the electrical connections. Then unfasten the
retaining nut at the base of the control box and
remove.
2. Fit the new limit thermostat in reverse order to
the above ensuring correct location.
7
Remove
Sensor
From
Pocket
5
Lift Off The
Facia &
Disconnect
The Indicator
Lights Plug
Replacing
Thermostats
(Front Access)
3
Control
Box
Assembly
1
2
Remove The
Temperature
Control Knob
Caution
Disconnect
Clock
(If Fitted)
Remove
Front Cover
4
Remove
Facia
Securing
Screws
The Side
Casing
Avoid Over
Bending
Boiler Control Thermostat
1. Remove the boiler thermostat by disconnecting
the electrical connections and removing the
locknut securing the spindle to the controls
assembly. Pull away the sensor from the
control box front cover.
2. Fit the new boiler thermostat in reverse order
to the above ensuring correct location.
9
Remove The
Retaining Nut
& Boiler Stat
(If Required)
Rear View
Of Control
Box Assembly
9 Remove Retaining
Nut & Limit Stat
(If Required)
ST00213A
8
Remove The Two
Retaining Screws
And Split The
Controls Box
Assembly Apart
66
Remove
The
Controls
Box
Assembly
Screws
Fig. 29
Part No. 5102478
Servicing & Maintenance 41
Replacement of Thermostats
(Flowsure/Flowsure+)
1. Remove the front and top covers.
2. Pull off the temperature control knob.
3. Un-clip the programmer assembly and push into the
controls assembly.
4. Remove the facia retaining screws at the base of the
facia.
5. Lift off the facia and disconnect the indicator lights
plug.
6. Disconnect the inside and rear electrical connectors.
7. Remove the controls assembly lid securing screws
and remove the lid.
Note which way the electrical connectors fit before
removing any of the thermostats.
Re-assemble in reverse order unless stated otherwise.
Boiler Control Thermostat
1. Disconnect the electrical connections.
2. Remove the clip and withdraw the sensor
from its pocket.
3. Remove the locknut securing the
thermostat spindle to the controls
assembly.
Limit Thermostat
1. Disconnect the electrical connections.
2. Remove the clip and withdraw the
temperature gauge bulb and limit
thermostat sensor from its pocket.
3. Remove the locknut securing the
thermostat to the controls assembly. On reassembly insert the thermostat sensor
before the temperature gauge bulb.
Pump Overrun Thermostat
1. Disconnect the electrical connections.
2. Unscrew the two screws securing the
thermostat to the controls assembly.
3. Remove the clip and withdraw the sensor
from its pocket.
Tank Limit Thermostat (Flowsure+)
1. Disconnect the electrical connections.
2. Unscrew the two screws securing the
thermostat to the controls assembly.
3. Remove the clip and withdraw the sensor
from its pocket.
DHW Overheat Thermostat (Flowsure)
1. Disconnect the electrical connections.
2. Unscrew the two screws securing the
thermostat to the bracket on the pipe.
Heatstore Thermostat (Flowsure+)
1. Disconnect the electrical connections.
2. Unscrew the two screws securing the
thermostat to the bracket on the pipe.
Automatic Air Vent
1. Drain the boiler using the boiler drain point
provided.
2. Unscrew the automatic air vent and fit a
new one in the reverse order.
3. Fill the system as described in Section 2Pre - installation Requirements.
Fig. 30
42 Servicing & Maintenance
Part No. 5102478
Pressure Relief Valve
1. Drain the boiler using the boiler drain point provided.
2. Undo the compression fitting connecting the
discharge pipe to the relief valve.
3. Undo the pressure gauge sensor retaining nut and
withdraw sensor from the relief valve, taking care
not to lose the fibre washer seal.
4. Undo the union nut at the rear of the relief valve
and pull the relief valve clear of the pipework, taking
care not to lose the fibre washer seal.
5. Fit a replacement valve in the reverse order.
6. Fill the system as described in Section 2 - PreInstallation Requirements.
Circulating Pump
1. Remove the pump electrical cover and disconnect
the electrical leads taking note of the wire positions.
2. Turn off the isolating valves mounted on the inlet
and outlet of the pump. Undo the two union nuts
and remove the pump from between the pipework.
Note: A residue of water will remain in the pump.
3. Fit a replacement pump with new sealing washers.
Note: The direction flow indicator on the pump
should point from left to right.
4. Open all valves and fill the system as described in
Section 2 - Pre-Installation Requirements.
5. Un-clip the temperature/pressure gauge from its
bracket, remove gauge, carefully withdrawing
sensor and bulb capillary tubes through bracket
assembly.
6. Fit a replacement gauge in the reverse order.
7. Open the valves and fill the system as described in
Section 2 - Pre-Installation Requirements.
Diverter Valve ( Flowsure/Flowsure+)
1. Drain the boiler using the boiler drain point provided.
2. Turn off the isolating valves mounted on the inlet
and outlet of the pump.
3. Disconnect the electrical lead from the connection
plug, mounted on the rear of the control box, taking
note of the wire positions.
4. Undo the two screws, retaining the central heating
flow pipe to diverter valve, gently pull pipe away
from diverter valve.
5. Undo the two screws, retaining the DHW flow pipe
to diverter valve, gently pull pipe away from diverter
valve.
6. Undo the two screws, retaining the pump to diverter
pipe, remove diverter valve from pipe assembly.
7. Fit a replacement diverter valve in the reverse order,
taking care to check and replace if necessary the
“O” ring seals, fitted to the pipe tail ends.
8. Open the valves and fill the system as described in
Section 2 - Pre-Installation Requirements.
Expansion Vessel
Flow Switch (Flowsure/Flowsure+)
1. Drain the boiler using the boiler drain point provided.
2. Undo the nut connecting the vessel to the flexible
pipe from the boiler.
Take care not to lose the fibre washer seal.
3. Undo the two nuts retaining the expansion vessel
assembly bracket to the boiler, lift bracket up and
out, remove from boiler.
4. Remove top retaining arm, lift vessel up and out off
bracket assembly.
5. Fit a new expansion vessel in reverse order to
above.
6. Fill the system as described in Section C - PreInstallation Requirements.
System Pressure/Temperature Gauge
1. Drain the boiler using the boiler drain point provided.
2. Turn off the isolating valves mounted on the inlet
and outlet of the pump.
3. Undo the nut retaining the pressure gauge sensor
from the pressure relief valve. Remove sensor,
check fibre seal, replace if damaged on
replacement of new sensor.
4. Remove the clip and withdraw the temperature bulb
from its pocket.
Part No. 5102478
1. Close the mains water isolation valve to boiler.
2. Close the domestic service cock on the mains inlet
pipework of the boiler.
3. Drain the residual water from the hot water
pipework.
4. Disconnect the flow switch electrical lead from the
connection plug, mounted on the rear of the control
box, taking note of the wire positions.
5. Undo the nut connecting the flow switch to domestic
service cock pipework.
6. Undo the nut connecting the flow switch to water to
water heat exchanger pipework.
7. Pull the nuts back and extract the flow switch.
8. Fit new flow switch and new fibre washers in the
reverse order, ensuring the flow switch head is
inclined at least 15° above horizontal and will not
foul the top casing panel. The direction flow
indicator on the flow switch head should point in
the direction of the water to water heat exchanger.
9. Open the domestic service cock and mains water
isolation valve, turn on hot water tap, check
connections are sound.
Servicing & Maintenance 43
Domestic Service Cock (Flowsure/Flowsure+)
7. Fit a new plate heat exchanger in reverse order,
ensuring to replace any damaged fibre washers.
1. Close the mains water isolation valve to boiler.
2. Drain the residual water from the hot water
pipework.
3. Undo the nut connecting the domestic service cock
to mains inlet pipework.
4. Undo the nut connecting the domestic service cock
to flow switch pipework.
5. Pull the nuts back, gently ease out the domestic
service cock from the pipework.
6. Fit new domestic service cock in reverse order,
ensuring the direction flow indicator on the domestic
service cock points to flow switch.
7. Open mains water isolation valve, turn on hot water
tap, check connections are sound.
Flowsure+:
1. Undo both nuts retaining the mixer valve and flow
switch assembly to the plate heat exchanger.
Remove assembly, and place aside, ensuring
electrical lead is not strained.
2. Undo both nuts retaining the primary return pipe,
from PHE outlet and shell top return connections.
Remove pipe assembly and place aside.
3. Slacken nut on tank outlet connection, pipe to PHE
inlet. Undo nut retaining pipe and slide to one side.
Remove plate heat exchanger.
4. Fit a new plate heat exchanger in reverse order,
ensuring to replace any damaged fibre washers.
Note: A flow restrictor and filter is fitted in the outlet of
the domestic service cock, ensure the correct colour
flow restrictor is fitted for the correct boiler model,
see Table 1 (page 13).
Open all isolation valves, fill the system as described
in Section 2 - Pre-Installation Requirements. Vent air
from the domestic hot water pipework. Open hot water
tap check for correct operation of system.
Flow Restrictor
The flow restrictor cannot be replaced due to its
location inside the domestic service cock, it is
suggested that the domestic service cock be replaced
when required. Follow instructions on replacement in
paragraph covering the domestic service cock above.
Note: After the replacement of components, always
check for soundness of connections. Always carry
out a full functional check of the system.
Domestic Hot Water Plate Heat Exchanger
(Flowsure/Flowsure+)
1. Drain the boiler using the boiler drain point provided.
On the Flowsure+ drain approximately one litre of
water from the heatstore tank using the tank drain
point provided, this will prevent excessive residual
spillage from the pipework when disconnecting.
2. Close the mains water isolating valve to the boiler,
drain the residual water from the hot water
pipework.
Flowsure:
1. Remove the electrical spade connectors from the
DHW overheat thermostat.
2. Remove the flow switch, refer to paragraph, flow
switch replacement in this section.
3. Undo nut on cold inlet pipe feed to PHE, remove
pipe.
4. Undo nut on hot water outlet pipe from the PHE,
remove pipe.
5. Slacken the two screws retaining the DHW flow pipe
to the diverter valve. Undo the nut retaining the
DHW flow pipe to PHE inlet and swing pipe up and
away.
6. Undo the nut retaining the primary return pipe, from
the PHE outlet. Slide the plate heat exchanger back
and out of the boiler.
44 Servicing & Maintenance
Part No. 5102478
Fig. 31
Part No. 5102478
Servicing & Maintenance 45
Fig. 32
46 Servicing & Maintenance
Part No. 5102478
5 - Fault Finding
SYMPTOM
Burner Does Not
Start, Motor Does
Not Run
SYMPTOM
Boiler Starts,
No Flame
Established,
No Oil To Burner
Part No. 5102478
CHECK LIST
ACTION
1. Mains switched on
Switch on
2. Fuse in switch
Fit a fuse
3. Fuse blown
Replace fuse
4. All external controls call for heat
Set to call for heat
5. Boiler stat calls for heat
Set to an “ON” position
6. Limit stat tripped - Light on
Reset limit stat
7. Boiler at lock out - Light on
Reset
8. Faulty external wiring
Repair if necessary
9. Faulty external controls
Check that they are operating
10. Burner control box faulty
Check by fitting spare box
11. Boiler control panel wiring faulty
Check & refer to wiring diagram
Section 1
12. Burner motor seized
Remove and check ease of rotation
CHECK FOR
ACTION
1. Oil in the tank
Re-Fill
2. All valves open from tank to burner
Open valves
3. Fire valve correctly set
Set as per manufactures instructions
4. Filter blocked
Clean and replace elements
5. Air lock in fuel lines
Bleed burner
6. Nozzle blocked
Replace nozzle
7. Pump pressure correct
Set to correct pressure refer to
Burner Instructions
8. Pump rotates:- Is it correct
for either one or two pipe
Dismantle pump from Motor
and check freedom of rotation
9. Pump drive coupling faulty
Remove pump and examine
coupling for signs of wear and
damage, refer to Burner Instructions
10. Solenoid valve not opening
Check operation of the solenoid
valve
Fault Finding 47
SYMPTOM
CHECK FOR
ACTION
1. Signs of fuel in boiler
Check as for 2 to 8 below
2. Correct combustion head settings
Set correctly refer to Burner
Instructions
3. Electrodes clean and not damaged
Clean
4. Nozzle blocked
Replace nozzle
5. If two pipe system, check pipe
work is correct
Amend as necessary
6. Faulty Transformer
Replace control box if no spark
is suspected
7. Electrode leads shorting out
Check leads for signs of shorting
if found replace. Refer to Burner
Instructions
8. Faulty pump solenoid
Replace pump assembly
SYMPTOM
CHECK FOR
ACTION
Burner Starts,
Flame Established
But Goes To
Lock Out After
15 Seconds
1. Intermittent oil supply
Check for dirt in filters or oil in fuel
lines
2. If two pipe system, that pipework
is correct
Refer to Table 5, Page 23
3. Combustion head settings correct
Refer to Burner Instructions
4. Photocell not fitted correctly
Replace correctly
5. Photocell circuit faulty
Replace
6. Dirty Photocell
Clean and replace
POSSIBLE CAUSE
ACTION
1. Combustion air setting too high
Re-set and confirm by measuring
CO2 refer to Burner Instructions
2. Air collects in system overnight
Examine all joints and if suspect
re-make
3. Faulty non return valve 2 pipe system
Replace faulty valve
Burner Starts,
No Flame But
Oil To Burner
SYMPTOM
Locks Out In
Morning Only
48 Fault Finding
Part No. 5102478
SYMPTOM
CHECK FOR
ACTION
Flame Established
But Not
Maintained
1. Air in fuel line
Check for joints for increases of air
rectify as necessary, bleed burner
and restart
2. Combustion settings incorrect
Adjust settings and confirm by flue
gas analysis
3. Wrong grade of oil
Obtain correct grade of fuel or in
case of conventional flue models
adjust burner for correct grade.
4. Combustion products leaking
Check all seals, particularly the
gasket between burner and boiler
5. Combustion products re-circulating
into balanced flue terminal
Insert CO2 probe and check
CHECK FOR
ACTION
1. Correct grade of fuel used
Either adjust for fuel used or drain
and refill tank correctly
2. Correct nozzle fitted
Refer to Burner Instructions and
fit correct nozzle
3. Correct oil pressure
Refer to Burner Instructions and set
correct pressure
4. Correct air settings
Do combustion checks and re-set
5. Air in fuel lines
Bleed air from lines
SYMPTOM
Burner Runs But
Smoke, and or
Smell, and or
Pulsation
6. Adequate access for combustion air Refer to Section 2
Part No. 5102478
7. Adequate ventilation
Refer to Section 2
8. One sided flame
Remove burner, clean and re-check
settings, refer to Burner Instructions
Clean or replace the nozzle
9. Oil leak within burner.
Remove burner and examine for
leakage, repair suspect joints
10. Oil leak to burner within boiler
Suspect pump solenoid, replace
pump assembly
11. Flue plus boiler resistance too high
Check retarders & baffle plate
positions, check for obstructions
12. Defective nozzle
Replace nozzle with one of same
specification
Fault Finding 49
SYMPTOM
SYMPTOM
Other Problems
POSSIBLE CAUSE
ACTION
13. Bad oil cut off
Bleed air from pump or replace pump
assembly
14. Dirt collecting on fan
Remove burner and clean
15. Combustion products leaking
Check all joints, replace suspect
seals
POSSIBLE CAUSE
ACTION
1. Boiler frequently tripping on
limit stat
Replace limit stat
2. Limit stat calibration too low
Boiler stat max temperature
too high
Check outlet temp of boiler and if
necessary replace
3. Lack of flow through boiler.
If possible try circulating pump on
higher setting (Statesman only)
4. Condensation from Chimney
Could take place in cold weather due
to high efficiency of boiler.
Check system complies with
Standard
5. Noisy Motor
Look for signs of oil leaking from
pump, motor and coupling
6. Pump pressure oscillating
Air in oil, Dirt in pump regulating
valve
Defective pump coupling
Faulty gauge
7. Faulty pump cut off:oil in boiler
Defective Solenoid valve
Air in fuel lines
A Burner Fault Finding Guide is incorporated within the
Burner Information Instructions.
50 Fault Finding
Part No. 5102478
Notes
Part No. 5102478
Notes 51
6 - Short Spares
Drg.
Ref.
Description
Model - see key
Makers Part
Number
1
2
3
4
5
7
8
9
10
11
12
13
14
15
Boiler thermostat
Thermostat knob
Limit thermostat
Mains inlet plug
Retarder
Retarder
Retarder
Retarder Assembly
Baffle Plate
Baffle Plate
Baffle Plate
Baffle Plate
Front plate seal
Viewing glass
Viewing glass gasket
Air duct tube
Jubilee clips
Red neon
Amber neon
Viewing glass gasket
Green neon
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B
C
D
E, F, G
B
C
D
E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
A, B, C, D, E, F, G
26009018
26002014
26009097
26009004
26001224
26001361
26001283
26001157
26001149
26001361
26001284
26001152
26001158
10/17500
5000726
26003019
26009029
26009009
26009010
10/17499
26009011
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Expansion Vessel
Expansion Vessel Flexible Hose
Drain Elbow - Boiler
Automatic Air Vent
Pressure Safety Valve
Circulating Pump
Pressure/Temperature Gauge
Diverter Valve
Double Check Valve
Flow Switch
Switch - 2 Position
Pump Overrun Thermostat
Plate Heat Exchanger
Plate Heat Exchanger
DHW Thermostat
Tank Thermostat
Tank Limit Thermostat
Drain Elbow - Tank
Mixer Valve
Manual Bleed Valve
Isolator Valve (System Fill)
Flexible Hose (System Fill)
Cold Main Isolator Valve (System Fill)
Switch - 3 Position
Timer - ElectroMechanical
Domestic Service Cock
Domestic Service Cock
Relay
E, F, G
E, F, G
E, F, G
E, F, G
E, F, G
E, F, G
E, F, G
F, G
F, G
F, G
F, G
F, G
F
G
F
G
G
G
G
F, G
F, G
F, G
F, G
F, G
F, G
F
G
F, G
26009157
26009158
26009109
26009104
404S601
405/0317
26009159
26009160
26009144
26009166
26009090
26009156
26009107
26009146
10/18763
10/18763
26009156
26009149
26009148
10/18944
10/11066
26009161
10/20142
404S684
10/19114
10/20141
26009168
26009126
6
Key: A = 45/50. B = 50/70. C = 70/90. D = 90/110. E = System. F = Flowsure. G = Flowsure +
52 Spare Parts
Part No. 5102478
6
(System
Flowsure
Flowsure +)
1
3
5 (90/110)
5
6
(50/70
70/90)
9
12
13
15
8
6
(90/110)
14
19
11
10
24
35
7
20
Not Spared
21
23
4
11
3
bar
C
O
M
PACT
25
28 / 29
38
26
37
39
36
42
25A
43
2
16
33
ST00160C
7 6 5 43
98
1716
18
9
17
40
2
2 124 322
01
221
18
41
22
41
115
27
32
30
31
110
12
3
34
Fig. 33
Part No. 5102478
Spare Parts 53
7 - Flue Kit Options
KIT 1
Horizontal Low Level Telescopic
(Short Wall) 100 - 275mm
Dress Plate
(Inner Wall)
Fasteners Pack
Instructions
4 - wood screws
4 - wall plugs
Inner Seal
Outer Seal
Gasket
KIT 2
Horizontal Low Level Telescopic
225 - 600mm
Dress Plate (Outer Wall)
Dress Plate
(Inner Wall)
Fasteners Pack
Instructions
4 - wood screws
4 - wall plugs
Inner Seal
Gasket
54 Flue Kit Options
Dress Plate (Outer Wall)
ST00139C
Outer Seal
Part No. 5102478
Kit 5
Kit 4
Horizontal and Vertical
Flue Extension
950mm
Vertical
Through
The
Roof
Terminal
Inner Seal
Outer Seal
Kit 6
Horizontal and Vertical
Flue Extension
300mm
Inner Seal
Outer Seal
Clamping
Plate
Kit 7
Horizontal
High Level
Telescopic
(Short Wall)
100 - 275mm
Inner Seal
Outer Seal
Kit 11
Kit 8
Terminal Guard
(Supplied
with Kits
1, 2, 7 & 8)
Horizontal
High Level
Telescopic
225 - 525mm
Inner Seal
Outer Seal
Kit 12
Kit 3
Low Level Riser
Instructions
Fasteners Pack
4 - Wall Plugs
4 - Wood Screws
Inner Seals
(1 off)
Vertical High Level Riser Telescopic
Fasteners Pack
Outer Seals
(1 off)
Instructions
4 - Wall Plugs
4 - Wood Screws
3 - Self Tapping Screws
Dress Plate
(Inner Wall)
Dress Plate
(Outer Wall)
Kit 9
Flashing Flat Roof
Dress Plate
(Outer Wall)
Gasket
Kit 10
Flashing Pitched Roof
22˚ to 45˚
Outer Seals
(2 off)
Dress Plate
(Inner Wall)
Dress Plate
(Case Top)
Part No. 5102478
ST00140C
Dress Plate
(Case Top)
Inner Seals
(2 off)
Gasket
Flue Kit Options 55
Sales Enquiries:
Sales Operations
Eastern Avenue,
Team Valley Trading Estate,
Gateshead.
Tyne & Wear. NE11 0PG.
Tel:
Fax:
08706 060 403
0191 491 7568
Service Enquiries:
Service Operations
Brooks House,
Coventry Road,
Warwick. CV34 4LL.
Tel:
Fax:
08706 096 096 *
01926 410006
Spares Enquiries:
Spare parts are available nationwide via the
Interpart Stockists network.
For your local stockist consult Yellow Pages under
Central Heating
Trade Support:
Trade Support
Brooks House,
Coventry Road,
Warwick. CV34 4LL.
Tel:
Tel:
Fax:
08706 049 049 - General *
01926 409135 - Oil Installer
01926 410006
Training Administration:
National Training Administrator
Tel:
0845 600 7402
Responsible for allocation and booking of all
courses and activities at all training facilities in the
UK
Brochure Hotline:
Tel:
08706 060 623
The Internet:
http://www.baxi.com
http://www.potterton.co.uk
http://www.oilboilers.co.uk
Registered Office:
Sceptre Way, Bamber Bridge, Preston. PR5 6AW.
Registered No. 3879156
All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes
and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold
subject to our standard Conditions of Sale which are available on request.
* To aid continuous improvement and staff training, calls to this line may be monitored or recorded.
Publication No. 5102478 - 01