Boulter eco-system User manual

Eco-System
Boiler
Boulter Boilers Ltd
Magnet House
30 White House Road
Ipswich
IP1 5JA
Tel: [phone]
Fax: [phone]
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: [phone]
Fax: [phone]
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
☎[phone].
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
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
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
D
50.00
50.00 50.00
* 20mm ET KNOCKOUT

BOULTER BOILERS Eco-System PAGE 9
3:6 COMMISSIONING DATA
12/19 19/26
Maximum Temperature of Adjustable Controls Control Stat 85oC +/- 2oC
Limit Stat 110oC +0/-6oC
Maximum Emissions Limit (Class 1) NOx 250 mg/kWh-CO 125 mg/kWh
Range of Temperature Control Control Stat 0 - 85oC
Exit Flue Gas Mass Flow Kg/Sec x 10-3
Heat Input (Full Load) kW (based on Net 22.1 29.0
efficiency of 91%)
Heat Output (Full Load) kW 19 26.4
1. There are two columns in the table for
combustion gas temperature:-
FLUE EXIT temperature, and
BOILER TEST POINT temperature.
2. Where possible CO2, smoke and flue gas
temperatures should be sampled from the FLUE
EXIT (i.e. external balanced flue discharge, or from
the test point provided in the conventional flue
adaptor)
3. These figures may be used to calculate
combustion efficiency.
4. Alternatively (where the forgoing is impractical
such as vertical BF) gases can be sampled at the
BOILER TEST POINT inside the casing.
Because the gas temperatures at this point are
significantly higher it should not be used to
calculate or measure efficiency.
5. If the BOILER TEST POINT temperature agrees
with the data in Table 3:6.1, then use the
appropriate FLUE EXIT temperature from the table
to calculate the combustion efficiency.
6. On conventional flue only - flue draught should
be measured at the flue exit test point.
3:6.1 Class C2, Kerosene Oil
RIELLO BURNER
Model
12/19
19/26
Output Riello
RDB
TYPE
Nozzle
Danfoss
Delevan
US/GPH
Pump
Pressure
kW Btu/h
x1000
11.7
16.1
19
19
23.4
26.4
40
55
65
65
80
90
0.4x60oES
0.5x60oES
0.6x60oES
0.6x60oES
0.75x60oW
0.85x60oW
7.0
8.0
7.6
7.6
7.2
8.0
100
115
110
110
105
115
BAR psi
Boiler
Test Point
Temp oC
215-245
260-285
295-320
280
304
335
Flue Exit
Temp oC
Gross
165-195
180-225
180-245
180
200
204
Smoke
No.
C02
%
483T50
484T50
101.08
111.49
121.76
101.76
112.17
122.41
0-1
0-1
0-1
0-1
0-1
0-1
Fuel
Rate
Kg/h
LOW 6.69 9.61
MID 8.46 11.84
HIGH 9.24 12.79

BOULTER BOILERS Eco-System PAGE 10
4:1 STANDARDS & REGULATIONS
The installation of the Boiler must comply with the
latest edition of :
BS 5410 Oil Installations
Pt 1 up to 44kW;
Pt 2 and over 44kW
BS 5449 Forced circulation hot water central
heating systems for domestic premises.
BS 4543 Pt. 1 & 3 Factory made insulated
chimneys.
BS 7593 Code of practice for the treatment of
water in domestic hot water central heating
systems.
BS 7671 (1992) Electrical Wiring Regulations.
BUILDING REGULATIONS.
Part J&L England and Wales
Part F Section III Scotland
Part L Northern Ireland
The Control of Pollution (Oil) Regulations
Oil boilers should be installed in accordance with
good practice as recommended by OFTEC (Ref.
2:3 Commissioning page 6).
4:2 THE HEATING SYSTEM
This should be installed in accordance with current
good practice as advised by HVCA. It is not the
purpose of the manual, nor is it possible, to
adequately deal with the subject in this manual.
When designing and installing the controls of the
heating system, it must be remembered that if the
control system is such that the water circulation
through the boiler can be totally or substantially
reduced whilst the oil burner can still fire, the water
in the boiler will reach very high or boiling
temperature before the boiler thermostat can
sense it and switch off the Burner.
If this condition is likely wire the controls so that the
electrical supply to the burner is switched off
simultaneously with the stopping of circulating
pumps or the closing of motorised valves.
On existing heating systems where a Boiler is
replaced, ensure that the system is chemically
cleaned.
The system should contain clean water and be free
from leaks. Suitable inhibitors against limescale
and corrosion should be added to the system.
Refer to BS 7593.
Kettling and system noises can be avoided by
suitable pre-treatment (i.e. Chemical Cleaning) at
the onset.This is essential when fitting a new boiler
to an existing system.
4:3 SITING & POSITIONING
The noise level from Eco boilers is quite low and
kitchen installations have not given rise to
complaints. Consideration must be given however,
to the following points.
1. Noise may be accentuated by the installation in
small rooms or recesses with hard or hollow stud
wall surfaces. Due consideration to the siting of
boilers should be given.
Further advice from BOULTER BOILERS should
be sought where any doubt exists.
2. Some individuals may be particularly sensitive to
even low noise levels and this should be discussed
before installation.
3. The type of chimney, position relative to the
boiler and whether a draught stabiliser is to be
fitted may affect sound level in the room.
4. The 12/19 & 19/26 Boiler models are serviced
from the front. A space of 450mm (18”) in front
should be available.
4:4 THE HEARTH
The Eco boilers have a Hearth Temperature of less
than 85°C. The boiler requires a level hearth on
which to stand which should comply with the
Building Regulations.
If the Boiler is to stand on a floor made of
combustible material then protection between the
Boiler and the floor should be provided by means
of non combustible material.
Consideration should be given to the Weight of the
Boiler and the Building Regulations regarding floor
loading.
The filled Boiler weight can be found in 3:5.
Advice should be sought from your local Building
Control Office if there are any doubts regarding the
floor supporting the Boiler.

BOULTER BOILERS Eco-System PAGE 11
4:5 THE CHIMNEY - (FLUE Ø 4” OR 5”)
CONVENTIONAL CHIMNEY INSTALLATION ONLY.
VERY IMPORTANT
All Eco boilers are supplied in Balanced Flue
Form.
To connect either size of boiler to a
conventional chimney you must use The
Conventional Flue adaptor FC4CF.
This includes all parts necessary to make the
connection to the boiler. A test point is also
provided for ease of installation and
commissioning. Secure the air duct in the clip
provided.
The use of this adaptor is essential for safe
performance and is a condition of the
guarantee that this must be fitted.
The boiler requires a minimum stable draught of
0.1 mbar (0.04w.g.).
If the chimney exceeds 6m (20 feet) in length, it
may produce a draught exceeding 0.37 mbar
(0.15” w.g.) and a draught stabiliser should be
fitted.
The chimney should comply with the latest edition
of the Building Regulations and BS 5410: Part 1.
Factory built chimneys must comply with the
Building Regulations and BS 4543 Parts 1 and 3.
Compliance with the Building Regulations does not
indicate that the chimney is satisfactory in respect
of draught conditions, or is positioned so that ‘down
draughts’ will not occur.
Special pots and cowls which might restrict the flow
of gases must not be fitted and should be removed.
A brick chimney must be fitted with a suitable
stainless steel liner. Insulation between the liner
and an exposed chimney may be necessary to
avoid condensation.
A flexible liner should be the same diameter as the
Flue Offtake size of the boiler - 4”(100mm) or 5”
(125mm). (see page 8)
The Flue pipe, connecting the boiler to the chimney
adaptor should be the same diameter as the Boiler
Flue Offtake and should not be more than 1.8m
(6’-0”) long. Flue Pipes when fitted should satisfy or
be ‘deemed to satisfy’ the Building Regulations.
Flue pipe bends - 90° bends must not be used -
use 135° bends. Bends with soot doors should be
used where necessary
FOR BALANCED FLUE INSTALLATIONS SEE
SECTION 6.
4:6 AIR SUPPLY
CONVENTIONAL CHIMNEY INSTALLATION ONLY
A permanent adequate supply of air is required for
combustion and correct operation of a draught
stabiliser, if fitted.
This air enters the Boiler through the back panel. At
least 15mm clearance is required at the rear of all
boilers.
When the boiler is situated in a confined space or
chamber a permanent adequate supply of air is
required for ventilation to prevent over heating.
4:6.1 Opening Sizes
The clear opening required for combustion only
should be based on a requirement of 550mm2/kW,
(or 1in2per 4000 Btu/h) above 5kW
When a draught stabiliser is fitted to the flue pipe
or chimney in the room in which the boiler is
situated the clear air intake should be
1100mm2/kW.
When the boiler is situated in a confined space with
Combustion or Ventilation air from outside - Allow
550mm2/kW at low level and in addition
550mm2/kW at high level;
When Combustion and Ventilation air is taken from
a heated adjoining space the allowance should be
1650mm2/kW at low level and in addition
1100mm2/kW at high level. Ensure that the heated
adjoining space itself has an adequate supply of
air.
When the Boiler is installed in a basement or low
level boiler house where air can enter only from
high level, the incoming air supply for Combustion
and Ventilation should be ducted to low level. A
high level outlet should be provided for ventilation.
Gasket
(foil face
up)
Test Point
Air Duct
Securing Clip
Nuts
Conventional
Flue Adaptor
Fig 3

BOULTER BOILERS Eco-System PAGE 12
4:7 OIL STORAGE
4:7.1 Oil Tank
Consideration to the access by fuel delivery lorries
should be given when positioning the oil tank.
Tank positioning should be in accordance with BS
5410 Part 1 and OFTEC Technical Book 3.
In the interest of most economical deliveries the Oil
Tank should be of 3,000 litres (600 gallons)
capacity.
It should be complete with the following:
1. Sludge Cock - on steel tanks.
2. Outlet Valve.
3. Contents Indicator.
4. Screw fill connection and independent vent. The
Fill and Vent should be suitably capped to prevent
ingress of water or fitted with return bends.
4:7.2 Steel Tanks
Tanks should be mounted on suitable supports, if
these are of brick or blocks, a damp proof
membrane should be inserted between the tank
and its supports.
Tanks should slope 20mm per 1m of length
downwards from the Oil Outlet to the Sludge Cock
situated at the opposite end.
4:7.3 Plastic Oil Tanks
Tanks made from plastic are now available. These
should be UV stabilised for protection against
sunlight, and coloured green. Plastic tanks do not
need to stand on piers, but should be supported
across the entire base area, ideally on 50mm thick
garden slabs or a concrete base. As there is only
one tapped outlet they are more suited to single
pipe feed as gravity supply or with a Boulter 3K Oil
Loop Deaerator where suction lift is required. (Part
No. BS 03060)
4:8 OIL SUPPLY
The oil entry holes in the boiler casing are shown
in the diagram in Section 3:5 of this manual.
Flexible Hoses supplied with the Boiler MUST NOT
pass through these holes.
All joints in the Oil Lines must be oil tight and the
Oil Line should be flushed clean before connecting
to the burner.
Note that no soldered joints are permissible in the
oil line.
4:8.1 Oil Filter
An Oil Filter is supplied with the Boiler.
Connections are 1/4 BSP Female, see fig. 4:8c.
It is essential for reliable operation that the Oil
Filter is fitted in the Oil Pipe supplying Oil from
the Tank to the Burner. It should be fitted as
close to the Boiler as practicable, but NOT
inside the Boiler casing.
It is a condition of the guarantees that the Filter
is fitted correctly.
4:8.2 Fire Check Valve (Not Supplied)
A Remote acting FIRE VALVE* must be fitted in the
suction line at the time of installation - see BS
5410: Part 1.
The valve must be fitted external to the Boiler,
preferably at point where the Oil Pipe enters the
building. The sensor should be located above the
Burner in the clip provided, see figs. 4:8b, 4:8d
& 4:8f.
The entry point for the Fire Valve Sensor should be
through any of the 20mm ET knockouts located at
the top of the rear casing, or side panels.
To prevent damage to the capillary always pass the
sensor through the blind grommet (supplied), it will
be necessary to cut across the diaphragm.
*Remote Acting Fire Valves are available from
Boulter, through your merchant or installer e.g.
Ref: Operating Capillary
Temperature Length
RAF9015C 90oC 1.5m
RAF9030C 90oC 3.0m
RAF9060C 90oC 6.0m
RAF9090C 90oC 9.0m
4:8.3 Single Pipe System
Fig. 4:8b
If the bottom of the Oil Tank is above the oil Burner,
install a 10mm copper supply pipe to the Burner
incorporating the correct Filter, Shut Off Valve and
Fire Check Valve.
Ensure that the Burner Oil Pump is correctly set for
‘Single Pipe’ operation. (See 4:9.2).
4:8.4 Two Pipe System
Fig. 4:8d
When the bottom of the Oil Tank is below the level
of the Oil Pump on the Burner it is necessary to
install an additional 10mm return pipe.
The Oil Filter, Shut Off Valve, spring loaded Non-
Return Valve and Fire Check Valve are always in
the suction line supplying oil from the Tank to the
Burner.
The Non-Return Valve must be fitted to allow the

BOULTER BOILERS Eco-System PAGE 13
Fig. 4.8a
Flexible Oil Pipes and Fire Check Valve
Flexible Hose
Ball Valve Burner
flow in the correct direction and prevent drain back
to the Tank, see fig. 4:8e.
Ensure that Valves are NOT fitted in the Return
Line. The Return Line must be unobstructed at
all times.
Ensure that the Burner Oil Pump is correctly set for
‘two Pipe’ operation. (See 4:9.1)
4:8.5 Deaerator Oil Pipe System
Fig. 4:8f
An alternative two pipe arrangement can be
achieved using a 3K-Oil Loop Deaerator which
removes the air from the oil feed on a single pipe
lift. The Burner Pump is piped to the Deaerator,
which should be positioned close to the burner, but
NOT inside the Boiler Case. A Non-Return Valve
is not required in the return line.
The advantage of this system is gained where a
two pipe run from the oil supply tank is long or
difficult to achieve.
Boulter 3K Deaerators are available as an optional
extra from your merchant (Part No. BS 03060).
4:8.6 Water Separator Oil Filter
For changeover applications, the use of a Water
Separator Oil Filter, available from BOULTER
BOILERS is recommended (BS03052).
4:8.7 Flexible Oil Pipes
The Flexible Oil Pipes are fitted inside the Boiler
casing and are of adequate length to enable the
Burner to be removed without disconnecting. When
fitted correctly the pipes should be curved round
the Burner as shown in Fig.4:8a.

BOULTER BOILERS Eco-System PAGE 14
OIL CONNECTIONS SEE BELOW
FIRE CHECK VALVE
ALTERNATIVE FILTER POSITION
TOTAL PIPE LENGTH ‘L’
FIRE
CHECK
VALVE
SENSOR
FILTER
SLUDGE
COCK
OIL TANK
SCREW
FILL
20mm / metre
FALL
INDEPENDENT
VENT
H
4 Metres MAXIMUM
SINGLE PIPE OIL SYSTEM - TANK OUTLET ABOVE BURNER
DO NOT FIT PUMP BYPASS SCREW TO BURNER - SEE 4.9.2
H METRES 0.5 1.0 1.5 2.0
Burner to supply 20 40 80 100
KEROSENE
10mm OD
PIPE
TABLE GIVING MAXIMUM PIPE LENGTH 'L' METRES
Fig. 4:8b Single Pipe Oil System.
RIELLO BURNER PUMP
NO BYPASS SCREW
FITTED
SINGLE PIPE OIL SYSTEM - OIL CONNECTIONS
Items 1 - 5 NOTsupplied with Boiler
ITEM PART QTY CODE
1 Filter 25I 1 BS 00496
2 Ball Valve 1 BS 03041
31/4'' BSP x 10mm Coupling 1 FS 00151
4 Longlife Hose 900mm 1 BS 03101
5 Grommet 3 RP00610
BOILER CASE
10MM DIAMETER
SUPPLY TUBE
LH & RH FUEL ENTRY AVAILABLE (LH SHOWN)
SCHEMATIC DIAGRAM FIT HOSE AS SHOWN IN FIG. 4:8a
PLUG
Fig. 4:8c Schematic Oil Pipe Connectors
Camray 5
Camray 5 Utility
1
5
4
3
2

BOULTER BOILERS Eco-System PAGE 15
RETURN PIPE
NON RETURN VALVE
ALTERNATIVE FILTER POSITION
SUCTION PIPE ‘L’ MAX
FIRE
CHECK
VALVE
SENSOR
FILTER
OIL TANK
SCREW FILL
INDEPENDENT VENT
H
TWO PIPE OIL SYSTEM - TANK OUTLET BELOW BURNER
FIT PUMP BYPASS SCREW TO BURNER
FIRE CHECK
VALVE
SAW CUT OR SMALL
HOLE IN RETURN PIPE
INSIDE TANK TO
PREVENT SYPHON
H METRES 0.5 1.0 1.5 2.0
Burner to 100 100 90 70
supply
KEROSENE
10mm OD
PIPE
TABLE GIVING MAXIMUM PIPE LENGTH 'L' METRES
Fig. 4:8d Two Pipe Oil System.
RIELLO BURNER PUMP
WITH BYPASS SCREW
FITTED
TWO PIPE OIL SYSTEM - OIL CONNECTIONS
Items 1 -5 are supplied with the Boiler. See Fig 4:8c.
BOILER CASE
10MM DIAMETER
SUPPLY TUBE
LH & RH FUEL ENTRY AVAILABLE (LH SHOWN)
SCHEMATIC DIAGRAM FIT BOTH HOSE AS SHOWN IN FIG 4:8a
10MM
DIAMETER
RETURN
TUBE
Fig. 4:8e Schematic Oil Pipe Connectors
Items 6 -10 NOT supplied with boiler.
ITEM PART QTY CODE
6 Non Return Valve 1 BS 00538
8 Longlife Hose 900mm 1 BS 03103
9 Washers 2 FS 00159
10 3/8'' BSP x 10mm Coupling 3 FS 00157
Camray 5
Camray 5 Utility
1
5
4
8
5
3
2
10
10 9
69
10
0
100

BOULTER BOILERS Eco-System PAGE 16
3K OIL DEAERATOR MUST BE
INSTALLED UPRIGHT OUTSIDE
BUILDING
DO NOT FIT NON-RETURN VALVE
TOTAL PIPE LENGTH
FIRE CHECK VALVE SENSOR
FILTER
OIL TANK
SCREW FILL
INDEPENDENT VENT
H
DEAERATOR OIL SYSTEM - TANK OUTLET BELOW BURNER
FIT PUMP BYPASS SCREW TO BURNER
FIRE CHECK
VALVE
Fig. 4:8f. Deaerator Oil Systems
DEAERATOR PIPE OIL SYSTEM - OIL CONNECTIONS
LH & RH FUEL ENTRY AVAILABLE (LH SHOWN)
SCHEMATIC DIAGRAM FIT BOTH HOSE AS SHOWN
IN FIG 4:8c
Fig. 4:8g Schematic Oil Pipe Connections.
ITEMS 7, 8, & 10 ARE AVAILABLE AS A KIT NO. BS 03058C.
The table right shows total Pipe Length ‘L’ metres 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
6 242119161311 8 6
8 100 100 93 84 71 59 46 33
10 100 100 100 100 100 100 100 100
Pipe
Size
mm
O/D
Lift - H metres (3.5m Max)
3K OIL
DEAERATOR
ITEM PART QTY CODE
6 3K Oil Loop 1 BS 03060
71/4'' BSP x 10mm Coupling 3 FS 00151
8 Longlife Hose 900mm 1 BS 03103
10 3/8'' x 10mm Coupling 1 FS 00157
Camray 5
Camray 5 Utility

BOULTER BOILERS Eco-System PAGE 17
4:9 OIL BURNER
The Burner makers’ technical leaflet is supplied
with this manual and provides supplementary
information not included in this manual.
4:9.1 Burner Pump for Two Pipe and Deaerator
System
For two pipe oil systems the Burner Oil Pump has
to be fitted with the Bypass Screw supplied. Boilers
are despatched with the Bypass Screw in a
labelled envelope attached to the Burner. This
socket screw is inserted into the return port as
shown in Fig. 4:9a.
4:9.2 Burner Pump for Single Pipe System
The burner is supplied set for single pipe operation.
The return port is plugged and the Bypass Screw
is not fitted. See Fig. 4:9b.
Fig. 4.9a Burner Pump for Two Pipe Operation
Fig. 4.9b Burner Pump for Single Pipe Operation
ONLY USE BYPASS SCREW FOR ALLEN KEY (2.5MM).
DO NOT USE SLOTTED SCREW
ALLEN KEY
BYPASS
SCREW
FLOW
RETURN
FLOW
BYPASS SCREW
NOT REQUIRED
RETURN PLUGGED

BOULTER BOILERS Eco-System PAGE 18
5:1 BALANCED FLUE BOILERS
A range of Balanced Flue Kits are available as
optional extras.
Balanced Flues permit considerable choice of
siting of the Boiler. Boilers may be installed in
situations where no chimney exists, where the
chimney is unsatisfactory or in outhouses.
It is important that care is exercised in
choosing a suitable location for the Boiler and
Flues. It is to be expected that with the help of
this manual and the application of caring
engineering experience and common sense
unreasonable liberties will not be taken.
It is a mandatory requirement that:-
1. The terminals of balanced flues which can be
touched are to be fitted with a guard.
Any proposed installation which deviates from the
details provided or gives rise to any doubt should
be referred to BOULTER BOILERS LTD. who will
be pleased to consider and discuss it.
5:1.1 Balanced Flue Types
Three types are available
1. Low Level Horizontal - Rear & Side
- Discharge L/R
2. High Level Horizontal - Rear & Side
- Discharge L/R
3. Vertical (Flat or Pitched Roof)
Only Kerosine fuel may be used when the Low
level Horizontal flues are installed.
5:2 HORIZONTAL BALANCED FLUES
The Terminals of Horizontal Balanced Flues should
be installed on a plain surface of wall preferably not
less than 900mm from internal corners of the
building and away from any recesses and any
projections on the wall face that could affect wind
flow across it.
Listed are the general restrictions as to the
positioning of Horizontal Balanced Flue Terminals.
Refer to Fig 5:4a
1. Positions should be avoided where the exhaust
of combustion products could cause nuisance.
2. Terminals must be situated more than 600mm
distance from any opening in the building.
3. Avoid close proximity to internal corners where
products of combustion may not freely disperse
and may enter the air intake to the boiler.
4. Avoid positions such as narrow passageways,
especially with a closed end, where easy
dispersion could be adversely affected.
5. Avoid positions where the terminal may be
discharging close to and in the direction of a near
neighbouring dwelling or exhausting immediately
over adjoining property.
6. Avoid positioning immediately under openable
windows.
7. Care should be taken to ensure that there is
clearance between the outer surface of the flue and
any combustible material.
8. Positioning the Flue terminal within a CAR
PORT is not recommended.
5:3 VERTICAL BALANCED FLUES
Vertical Balanced Flues enables boilers to be
installed in single storey outhouses or utility rooms
where it may not be convenient for it to be sited
near an outer wall. It may also be employed to
exhaust vertically to avoid nearby windows or
doors.
Vertical Balanced Flues may also be preferred in
cases where close proximity to adjoining houses or
property dictates minimum exhaust noises.
5:3.1 Positioning of Vertical Flues
Listed are general restrictions as to the positioning
of Vertical Balanced Flues. Refer to Fig. 5:4a.
1. Avoid positions where Vertical Flues will exhaust
adjacent to a higher wall.The minimum distance for
operation from a higher vertical wall must be
600mm.
2. Ensure Vertical Flues do not exhaust below the
level of any openable window less than 2300mm
horizontally from the terminal (see BS 5410:1).
3. Care should be taken to ensure that there is
clearance between the outer surface of the flue and
any combustible material.