Boulter Eco-system Manuel utilisateur

Eco-System

Boiler

Boulter Boilers Ltd

Magnet House

30 White House Road

Ipswich

IP1 5JA

Tel: 01473 241555

Fax: 01473 241321

Manual Part No. PL 49021

Issue No 1

Date April 2002

INFORMATION FOR THE INSTALLER AND SERVICE ENGINEER.

Under the Consumer Protection Act 1987 and the Health and Safety at Work Act 1974,

it is a requirement to provide information on substances hazardous to health (COSHH

Regulations 1988).

The Company takes every reasonable care to ensure that these products are designed

and constructed to meet these general safety requirements, when properly used and

installed.

To fulfil this requirement products are comprehensively tested and examined before

despatch.

This appliance may contain some of the materials below.

When working on the appliance it is the Users/Engineers responsibility to ensure that

any necessary personal protective clothing or equipment is worn appropriate to parts

that could be considered as being hazardous to health and safety.

INSULATION & SEALS

Glass Rope, Mineral Wool, Insulation Pads, Ceramic Fibre, Fibre Glass Insulation.

May be harmful if inhaled. May be irritating to the skin, eyes, nose or throat. When

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

face masks and eye protection.

After handling wash hands and other exposed parts. When disposing, reduce dust with

water spray, ensure parts are securely wrapped.

GLUES, SEALANTS & PAINT

Glues, Sealants and Paint are used in the product and present no known hazards when

used in the manner for which they are intended.

KEROSENE & GAS OIL FUELS (MINERAL OILS)

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

2. The lighter fractions also remove the protective grease normally present on the

surface of the skin rendering the skin dry, liable to crack and more prone to

damage caused by cuts and abrasions.

3. Skin rashes (oil Acne). Seek immediate medical attention for any rash, wart or sore

developing on any part of the body, particularly the scrotum.

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

nated with mineral oil.

5. Never breath any mineral oil vapours. Do not fire the Burner in the open i.e. out of

the Boiler as a miss fire will cause unburnt oil vapours.

6. Barrier cream containing lanolin such as Rosalex Antisolv, is highly recommended

together with a strict routine of personal cleansing.

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

HEALTH AND SAFETY

Due to a policy of continual development Boulter Boilers

reserves the right to alter or amend the design of its prod-

ucts without prior notice.

OFTEC Code of Practice OCP/1: 1995 For the Safe Installation, Commissioning, Maintenance and Fault

Rectification of Oil Firing Equipment should be consulted.

BOULTER BOILERS

Boulter Boilers Limited

Magnet House,

30 White House Road,

Ipswich IP1 5JA

Telephone: (01473) 241555

Fax: (01473) 241321

A member of the Bullough Group of Companies

BOULTER BOILERS Eco-System PAGE 1

CONTENTS - Part 1

SECTION 1 - USER GUIDE

1:2 Safety Notices

1:5 Operating Instructions

1:5:1 Boiler Control Thermostat

1:5:2 Boiler Overheat/Limit Thermostat

1:5:4 Lockout Indicator

1:5:5 Starting your Boiler

1:5:6 Switching off Temporarily

1:5:7 Shutting Off for Summer

1:5:8 Sealed System Central Heating

1:5:9 Frost Protection

1:5:10 Oil Delivery

1:5:11 Maintenance/Troubleshooting Guide

1:5:12 Option Programmer

SECTION 2 - INTRODUCTION

2:1 Introduction

2:2 Flue Options

2:3 Commissioning

2:4 Safety

SECTION 3 - TECHNICAL DATA

3:1 Fuels

3:2 Boiler Technical Details

3:3 Burner Details

3:4 Electric’s

3:5 Dimensions

3:6 Commissioning Data

SECTION 4 - INSTALLATION

4:1 Standards and Regulations

4:2 The Heating System

4:3 Siting & Positioning

4:4 The Hearth

4:5 The Chimney

4:6 Air Supply

4:7 Oil Storage

4:8 Oil Supply

4:9 Oil Burner

SECTION 5 - BALANCED FLUES

5:1 Balanced Flue Boilers

5:2 Horizontal Balanced Flues

5:3 Vertical Balanced Flues

5:4 Positioning the Boiler

5:5 Terminal Guards

5:6 Horizontal Flue Terminal

5:7 Blanking Plates

SECTION 6 - BALANCED FLUE

INSTALLATION

6:1 Notes on Installation

6:2 Low Level Horizontal Flue

6:3 High Level Horizontal Flue

6:4 Vertical Flues

6:5 High Level Flue Length Alteration

6:6 Quick Fit Flue Systems

SECTION 7 - COMMISSIONING

7:1 Commissioning

7:2 Responsibility

7:3 Reporting

7:4 Recommended Commissioning Check

List

7:5 Recommended Commissioning Tests

SECTION 8 - MAINTENANCE

8:1 Maintenance

8:2 Air Shutter Adjustment

8:3 Baffle Arrangement

SECTION 9 - SPARES & ACCESSORIES

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

9:4 Burner Parts

SECTION 10 - FAULT FINDING

10:1 Fault Finding

10:2 Fault Finding Chart

BOULTER BOILERS Eco-System PAGE 2

1:2 IMPORTANT SAFETY NOTES

To obtain the best possible performance and

trouble free operation from your Boiler, it is

important that you read these instructions carefully.

Your Eco Boiler has built-in safety features, which

are detailed in the relevant section of this manual.

1:2.1

The heating system must comply with the latest

editions of British Standard 5410 and The Building

Regulations.

Please note: It is essential in the interest of the

Boiler efficiency and reliable performance that

once the Boiler has been installed it is first

commissioned by a competent and preferably

an O.F.T.E.C.* registered engineer. It is the

responsibility of the installer to ensure that the

Boiler is commissioned.

If an engineer is not known, Boulter Boilers will

be pleased to provide details of commissioning

and servicing engineers from their register.

*The Oil Firing Technical Association for the

Petroleum Industry - Banstead, Surrey 01737

373311.

◆If it is known or suspected that a fault exists on

the Boiler, it MUST NOT be used until the fault has

been corrected by a competent engineer (see

Failure to Start).

◆It is essential that the instructions in this

booklet are strictly followed for safe and economic

operation of the Boiler. Failure to observe these

instructions may invalidate your right to free

breakdown cover during the guarantee period.

We recommend that you keep these instructions in

a place near your appliance for easy reference.

1:2.2 Air Supply to Boiler -

Conventional Flue

Where your Boiler is used on an open conventional

flue system, a permanent air supply is required for

combustion. Clearances provided at the sides and

rear of the appliance for air entry must be kept free

of obstruction. For further explanation please refer

to section 4.6 of this installation manual.

Your Eco Boiler should be connected to an

electrical supply complying with the Electrical

Wiring Regulations (BS7671): as well as an oil

supply complying with BS5410 Pt.1; and an

appropriate flue system.

◆ALWAYS SWITCH OFF THE ELECTRICAL

SUPPLY before removing any of the covers for

cleaning.

◆If any part of the Boiler or its flue is modified,

then the guarantee/warranty will be invalidated.

1:5 OPERATING INSTRUCTIONS

1:5.1 BOILER CONTROL THERMOSTAT

The Boiler Control Thermostat is also the ON/OFF

switch for the Boiler. To Switch the Boiler off, turn

the Thermostat to the ‘OFF’ position and isolate at

the mains isolating switch.

The Boiler Control Thermostat also controls the

water temperature within the Boiler.

The recommended Control Thermostat settings are

as follows:

WINTER HEATING & HOT WATER No. 4

SUMMER HOT WATER ONLY No. 2

The Boiler Control Thermostat automatically

switches the Burner ON and OFF to maintain the

selected temperature. The Burner is lit by an

automatic ignition system and therefore there is no

pilot flame.

The Boiler should not be operated below 60°C as

this will cause corrosion which will reduce the life of

the Boiler (Summer position).

1:5.2 BOILER OVERHEAT/LIMIT THERMOSTAT

The Boiler is fitted with a safety overheat/limit

thermostat. This will interrupt the power supply to

the Boiler and shut it down completely in the

unlikely event of overheating.

Should this occur, wait for the Boiler to cool, and

then reset the thermostat by pressing the limit

thermostat reset button located at the rear of the

Control Panel.

If this problem still persists, turn off the Boiler and

consult your installer.

BOULTER BOILERS Eco-System PAGE 3

1:5.4 LOCKOUT INDICATOR

In the unlikely event of a Burner malfunction, it will

automatically shutdown, and the red lockout

indicator on the Control Panel will be lit.

To restart the Burner, wait for a period of at least 45

seconds. Remove the front door panel (as

illustrated) and press the lockout reset button

located on the front of the Burner (see fig 2). If the

Burner immediately goes to lockout again, wait

three minutes and then repeat the procedure, once

more only, by pressing the reset button again.

If this problem still persists, turn off the Boiler and

consult your engineer.

1:5.5 STARTING THE BOILER

1. Ensure that all external controls, e.g.

programmer, timer, room thermostat etc., are

turned on and calling for heat.

2. Make sure the Boiler Control Thermostat is set

within the recommended range 2 to 4 and that the

mains electricity and oil are turned on.

1:5.6 SWITCHING THE BOILER OFF -

TEMPORARILY

The Boiler may be stopped by turning the boiler

control thermostat to the OFF position on the

standard Control Panel, or the programme switch

to the OFF position on the optional programmer.

Alternatively, the Boiler may be stopped by:

1. Turning off the mains switch controlling the

Boiler, or

2. Turning the programmer (if fitted to the heating

system) to its off position.

1:5.7 SHUTTING OFF FOR THE SUMMER

If the Boiler is to be shut off for the summer, it is

advisable to have it thoroughly serviced. Thorough

cleaning will minimise corrosion during the idle

period. Remember, when the Boiler is required, to

ensure that the oil supply is open before switching

on.

1:5.8 SEALED SYSTEM CENTRAL HEATING

It is important that the correct operating system

pressure is maintained. Your Installer should give

guidance on this.

1:5.9 FROST PROTECTION

If there is any danger that your Boiler may freeze

up during severe weather conditions, it is

recommended that you consult your installer who

will be able to advise you on an appropriate course

of action, either by installing a frost thermostat or

the addition of system anti-freeze.

1:5.10 OIL DELIVERY

Where possible, it is advisable to temporarily

switch the Boiler off when your oil supply is being

replenished. This is to allow any sediment to settle

and not be drawn into the Boiler. If not this could

result in an inconvenient break down.

We advise that you keep your Boiler off for one

hour after the oil is delivered to your tank. Please

ask your supplier, or the driver to notify you before

the oil is discharged.

1:5.11 MAINTENANCE AND TROUBLE

SHOOTING GUIDE

1:5.11.1 MAINTENANCE

For normal cleaning of the outside casing, simply

wipe with a dry cloth. To remove stubborn marks

and stains, wipe with a damp cloth and finish off

with a dry cloth. DO NOT use abrasive cleaning

materials.

The Boiler must be serviced at regular intervals by

a qualified service engineer. Failure to have the

Boiler serviced at the recommended intervals will

BOULTER BOILERS Eco-System PAGE 4

Fig. 2

REMOVING

FRONT

DOOR

LOCKOUT

RESET

invalidate the guarantee/warranty.

Using Kerosine Class C2 fuel, the Boiler should be

serviced at twelve monthly intervals to ensure that

the efficiency and performance of your boiler is

maintained.

Please also note that on conventional flue models,

it is possible for the air intake at the rear of the

Boiler casing to become blocked with household

debris.This air intake must remain clear at all times

and so it is advisable to inspect and clean this area

regularly. Please refer to section 1:2.2 in this

booklet.

Flue Terminal Pluming

Due to the high efficiency of the Eco range white

water vapour from the flue discharge - called

pluming may be observed from time to time under

certain weather conditions. This is perfectly normal

and should be no cause for concern.

1:5.11.2 FAILURE TO START

If the Burner fails to start, adopt the following

procedure:

1. Check that there is oil in the tank and that the

supply valve is open.

2. Check the programmer or time switch to

ensure that it is operating and set to the correct

time to be “ON”.

3. Check that the Boiler Control Thermostat is set

high enough to be “ON” or calling for heat.

4. Check whether the limit thermostat has tripped.

Press the reset button once the temperature has

dropped sufficiently.

5. Check whether the burner has gone to lockout

and the indicator lamp on the control box is lit.

Press the reset button on the Control box, when

released, the lights will go out and the Burner will

again attempt to start. If the Burner does not run

and again goes to lockout with red indicators

glowing:

◆Wait three minutes.

◆Repeat the procedure by pressing the button.

◆Failure to start on the second attempt indicates

a fault requiring attention.

◆Switch off the mains supply and call your

service engineer.

BOULTER BOILERS Eco-System PAGE 5

2:1 INTRODUCTION

This Manual covers Installation, Commissioning

and Maintenance of the Eco Boilers.

The Eco boiler is:

1. Designed for Central Heating and Hot Water.

2. Not suitable for open vented systems.

3. Suitable for sealed Central Heating systems

which are within the maximum permitted working

pressure. All Boilers are supplied with a manual

reset limit thermostat.

4. Suitable for new installations and for replacing

existing boilers.

Eco Boilers offer greater freedom to select the

most suitable position for siting and the opportunity

to install the boiler in a suitable outbuilding if

required.

All models are supplied as standard with low level

horizontal firing Oil Burner, they are suitable for

connection to a conventional chimney or any of the

Camray 5 Balanced Flue options. Note: The nozzle

on this appliance is only covered by a 1 year

guarantee.

2:2 FLUE OPTIONS

Eco Boilers are designed to operate with high

efficiency, clean combustion and low noise level.

They offer unique versatility and can be used in the

following modes:

1. Low level rear outlet balanced flue.

2. High level rear outlet balanced flue.

3. Vertical outlet balanced flue. (Insulated

balanced draught chimney).

4. High level side outlet balanced flue.

5. For connection to a conventional chimney (via

conventional Flue Kit, 12/26 Part No. FC4CF).

6. Other options maybe available. Please contact

Boulter Boilers.

The tested balanced flue terminals and

connections afford an adequate supply of air for

combustion and equalisation of pressure between

exhaust and intake as required for operation under

unfavourable wind conditions.

Balanced flues are supplied in a carton which

includes ALL parts for balanced flue installation.

The horizontal terminals are designed to avoid the

possibility of staining outer walls through which

they pass.

2:3 COMMISSIONING

It is essential in the interest of boiler efficiency and

reliable performance that once the boiler has been

installed it is first commissioned by a qualified

engineer.

If an engineer is not known, Boulter Boilers will be

pleased to provide details of commissioning and

servicing engineers from their register.

See Section 7 for Commissioning Procedure.

It is the responsibility of the installer

to ensure that the boiler is

commissioned by a competent engineer,

preferably an OFTEC* Registered

Commissioning Engineer.

*The Oil Firing Technical Association for the

Petroleum Industry, Banstead, Surrey

☎(01737) 373311.

2:4 SAFETY

READ HEALTH AND SAFETY INFORMATION

ON INSIDE FRONT COVER OF THIS MANUAL.

IMPORTANT

Should you wish to remove or

dismantle any covers or parts of the

boiler for cleaning or maintenance

ALWAYS FIRST SWITCH OFF THE

ELECTRICITY SUPPLY.

1. On no account should any part of the Boiler or its

Flue be modified with the exception of flues which

require adjusting to length to suit site conditions, as

detailed in this manual.

2. The wiring of the control panel should be as the

wiring diagrams included in this Manual. Wiring

should not be tampered with, modified or changed

for any reason.

3. Only use Boulter replacement parts.

Non compliance with the above will invalidate the

Guarantee.

BOULTER BOILERS Eco-System PAGE 6

IMPORTANT

BOULTER BOILERS Eco-System PAGE 7

3:1 LIQUID FUELS

Eco Boilers will burn liquid fuels complying with BS2869 Part 2 1988 Class C2 as specified in the Code

of Practice for Oil Firing BS5410 Part 1.

Class C2 (Kerosine)

This fuel is suitable for all Eco models. Burners are supplied with the appropriate nozzle and pump

pressure as standard for this fuel. They are set for mid-range output. Details of all nozzle sizes and pump

pressure for all outputs are shown on section 3.6.

3:2 BOILER TECHNICAL DETAILS

Maximum Boiler working pressure 3 Bar - 30.6m Water Head

Minimum recommended return water temperature 60°C

Maximum hearth temperature less than 85°C.

Maximum side panel temperature less than 35°C above room temperature.

Minimum Conventional flue draught at boiler flue outlet 0.035”w.g. (8.75N/m2).

Maximum Conventional flue draught at boiler flue outlet 0.15”w.g. (37.5N/m2).

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

with 11°C temperature rise across the

boiler.

3:3 BURNER DETAILS

Burner type - RIELLO 484T50, 483T50 or 487T50

Pressure Jet - supplied as standard. Manually

adjustable air regulator.

The burner must be set to details given in section

3.6.

For further details of the burner, refer to the burner

data sheets supplied in the literature envelope.

3:4 ELECTRIC’S

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

The Electrical Installation of this

appliance must be performed by a

suitably qualified electrical

engineer/installer.

All wiring to supply and all system components

external to boiler must comply with the latest

edition of BS7671:1992 formerly IEE Wiring

Regulations.

This appliance must be effectively earthed and

connection to the supply must be through a double

pole isolating switch fused 5 amp.

The isolating switch must have all pole contact

separations at least 3mm

IMPORTANT

BOULTER BOILERS Eco-System PAGE 8

3:5 DIMENSIONS

Model

12/19

19/26

Output

kW Btu/h

x 1000

11.7/

19 40/65

19/

26.4 65/90

ABCDEFGHJ

Flue

K* L

mm mm mm mm mm mm mm mm mm ø

ins

860 596 446 130 121 540 55 65 92 4" 1

BSP

860 596 446 130 121 540 55 65 92 4" 1

BSP

Weight

Empty

Kgs

112

114

Water

Content

Filled

Weight

Kgs

130

135

Litres

17.5

21.0

* Conventional Flue Size

FLOW

CONNECTION

RETURN

CONNECTION

RETURN

CONNECTION

FLOW

CONNECTION

*15.00 *15.00

50.00

50.00 50.00

20mm ET KNOCKOUT

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