Bubble Mk 2 PJ. CONVERSION Rayburn MF 19-12-05 Service manual

1
Mk 2 PJ. CONVERSION ©
Rayburn MF 19-12-05
INSTALLATION INFORMATION ©
http://www.oilstoves.co.uk/

2
C ntents
1-8. See Separate Document. ____________________________________ 4
11. Fitting The it._____________________________________________ 4
1. Rem ving The Firebricks. ______________________________________ 4
1a. Rem ve The Thick Fr nt Firebrick Beneath The Fuel-L ading D r. ______ 5
2. Rem ve The Oven Side Bricks. __________________________________ 5
3. Rem ve The Opp site Oven Firebricks. ____________________________ 5
4. Rem ve Fuel L ading D r Inner Cast Ir n Pr tective Plate. ____________ 6
5. Rem ve The Ash pan. _________________________________________ 6
6. Rem ve the grate carrier. _____________________________________ 6
7 Rem ve The Riddling Grate Bars. _________________________________ 6
8. Rem ve The Riddling Grate Supp rt Frame._________________________ 7
9. Rem ve The Sec ndary Air Chamber Casting. _______________________ 7
10. Rem ve the sec ndary air chamber fasteners. ______________________ 7
11. Check The H t Plate Seal. _____________________________________ 8
12.Rem ve The Flue B x Damper Plate. ______________________________ 8
13. L ck The Air Valve Open. _____________________________________ 8
12. Fitting The Boards And Burner Components._______________________ 8
4. Start Fitting The First B ards. _________________________________ 9
5. Fit The Cl sure Plate._________________________________________ 9
6. Fit Opp site Oven Over Cl sure Plate B ard._______________________ 10
7. Fit Primary Cl sure Plate B ard And Primary Fr nt B ard. _____________ 10
8. Fit Sec ndary Fr nt B ard. ___________________________________ 10
10. Fit The Fuel L ading D r Access C ver Plate. _____________________ 10
11. Fit Burner Base Plate. _______________________________________ 11
12. Fit C mbusti n Head. _______________________________________ 11
13. Fit The Air H se T The C mbusti n Head. _______________________ 11
14. Fit The Fuel Pump. _________________________________________ 12
15. Tighten The Fuel H se. ______________________________________ 12
16. Fit The C ntr l M dule. _____________________________________ 12
12b. Services Into The Burner. __________________________________ 13
1. Oil Feed. _________________________________________________ 13
2. Oil Is lati n Valve.__________________________________________ 14
3. Oil Pipew rk T Pressure Jet Burners. ___________________________ 14
4. P wer In._________________________________________________ 14
5. Fit the baffle kit. __________________________________________ 14
6. Fit ver ven baffle _________________________________________ 14
13. Commissioning._____________________________________________ 15

3
1. Setting the Burner Up. _______________________________________ 15
2. Heat Balancing the System. ___________________________________ 15
3. Lighting. _________________________________________________ 15
3.1. T Bleed The Pump. ________________________________________ 15
3.2. Set The C ntr l Stat. ______________________________________ 15
3.3. Set The Time Cl ck. _______________________________________ 15
3.4. Check The Burner Air Shutter. _______________________________ 16
3.6. Ignite The Burner. ________________________________________ 16
3.7. Fit The Baffle B x. ________________________________________ 16
3.9. T Set F r G d C mbusti n._________________________________ 16
3.10. C mbusti n Air. __________________________________________ 16
3.11. T Adjust The Pump Pressure. _______________________________ 17
4. Final Checks. ______________________________________________ 17
4.1. Fuel Tank. _______________________________________________ 17
4.2. Fuel. ___________________________________________________ 17
4.3. Filter.__________________________________________________ 17
4.4. Site Glass r Tank Gauge. ___________________________________ 17
4.5. Oil line._________________________________________________ 17
4.6. Fire valves. ______________________________________________ 17
4.7. Thr ugh Wall Sleeving. _____________________________________ 17
4.8. Is lati n valve. ___________________________________________ 17
4.9. Electrical. _______________________________________________ 17
4.10. Ventilati n. _____________________________________________ 17
4.11. Chimney System. _________________________________________ 18
4.12. Check c ntr ls Functi n. ___________________________________ 18
4.14. Vent the Ashpan D r. _____________________________________ 18
14. Warranty . _______________________________________________ 18
1. Items N t C vered Under the Warranty __________________________ 19
2. Lab ur. __________________________________________________ 19
3. Travelling time. ____________________________________________ 19
4. C nsequential l ss r damage. __________________________________ 19
5. N zzles. _________________________________________________ 19
6. Baffle kits and Insulati n B ards._______________________________ 19
7. Damage t the Fuel Pump._____________________________________ 19
15. Fault Finding. _____________________________________________ 19
16. Servicing. ________________________________________________ 19
18. Illustrations ______________________________________________ 19
1. Secti nal Details ___________________________________________ 20
2. B ard Details______________________________________________ 20

4
3. Ventilate Ashpit D r _______________________________________ 21
4. Opti nal Oven Stat Details____________________________________ 22
5. Oven stat sensing p siti n. ____________________________________ 23
6. Wiring and c ntr l lay ut _____________________________________ 23
7. Wiring Diagrams (All stat details)_______________________________ 24
8. Chimney terminal details. _____________________________________ 25
19. Parts and packing list _______________________________________ 26
1
1- -8 8. . S S
E
EE E
S
S
E
EP PA AR RA AT TE E
D
D
O
OC CU UM ME EN NT T
.
.
T ls Required
1. 60mm h le saw
2. High temp silic ne adhesive
3. M10 nut driver r suitable s cket
1
11 1. . F F
I
IT TT TI IN NG G
T
T
H
HE E
I
IT T
.
.
Bef re starting any w rk, check ff
the c ntents f the packing list with
the kit c ntents and make sure that
everything is c mplete.
Clean chimney, check and adjust the
chimney vacuum (0.02" - 0.06" w.g.)
and pr vide a cleaning access (min
diameter 5" f r linings.)
If applicable, check ut the existing
h t water system.
Install fuel tank and run a fuel line up
t the fireb x side f the appliance.
If necessary, m dify the electrical
supply.
Fit suitable ventilati n int the
appliance site.
Rem ve the h t plate
1
1. . R R
E
EM MO OV VI IN NG G
T
T
H
HE E
F
F
I
IR RE EB BR RI IC C S S
.
.
Fig 1 Sh ws the internals f a typical,
left hand ven MF, the pp site ven
fire bricks are still in situ and the
ven side casting is badly damaged.
This appliance is typical f the degree
f damage which can be inflicted by
inc rrect use and lack f adequate
maintenance.
This appliance was used f r
ph t graphic purp ses nly and was
n t in a g d en ugh c nditi n t be
rec mmissi ned.
Fig 1

5
1
1
A
A
.
. R R
E
EM MO OV VE E
T
T
H
HE E
T
T
H
HI IC C
F
F
R
RO ON NT T
F
F
I
IR RE EB BR RI IC C
B
B
E
EN NE EA AT TH H
T
T
H
HE E
F
F
U
UE EL L
-
-L L
O
OA AD DI IN NG G
D
D
O
OO OR R
.
.
(This is a time c nsuming j b, d n't
rush and take care n t t apply t
much pressure as the fr nt casting f
the appliance is nly thin and can be
easily br ken.)
2
2. . R R
E
EM MO OV VE E
T
T
H
HE E
O
O
V
VE EN N
S
S
I
ID DE E
B
B
R
RI IC C S S
.
.
Damaged pp site ven firebrick
Fig 2
3
3. . R R
E
EM MO OV VE E
T
T
H
HE E
O
O
P
PP PO OS SI IT TE E
O
O
V
VE EN N
F
F
I
IR RE EB BR RI IC C S S
.
.
These firebricks sh uld be fitted f r
summer time c king nly and
rem ved in wintertime t all w m re
heat fr m the fire t the water
heating.
Many users are unaware f this and
leave the firebricks permanently in
situ.
Scale build up behind them and makes
the rem val very time c nsuming and
difficult, if y u enc unter this
situati n, take great care n t t
damage the b iler during the rem val
pr cess.
Typical Damaged and scaled up,
pp site ven firebrick.
Fig 3
Damaged ven side casting
Fig 4

6
4
4. . R R
E
EM MO OV VE E
F
F
U
UE EL L
L
L
O
OA AD DI IN NG G
D
D
O
OO OR R
I
I
N
NN NE ER R
C
C
A
AS ST T
I
I
R
RO ON N
P
P
R
RO OT TE EC CT TI IV VE E
P
P
L
LA AT TE E
.
.
Fig 5
Rem ve the fuel-l ading d r and
rem ve the cast ir n pr tecti n plate
attached t it.
(N te it may be necessary t drill the
head ff the ld fastener and use
stills ns n the stub t rem ve it.)
Clean the d r inner surface and paint
it with heat resistant matt black
paint.
5
5. . R R
E
EM MO OV VE E
T
T
H
HE E
A
A
S
SH H P PA AN N
.
.
6
6. . R R
E
EM MO OV VE E T TH HE E G GR RA AT TE E C CA AR RR RI IE ER R
.
.
View thr ugh ash pit d r sh wing
damaged grate assembly in p siti n
Fig 6
7
7 R R
E
EM MO OV VE E
T
T
H
HE E
R
R
I
ID DD DL LI IN NG G
G
G
R
RA AT TE E
B
B
A
AR RS S
.
.
Fig 7.

7
Fig 8. Rem ve the grate bars by
lifting them up fr m the back supp rt.
8
8. . R R
E
EM MO OV VE E
T
T
H
HE E
R
R
I
ID DD DL LI IN NG G
G
G
R
RA AT TE E
S
S
U
UP PP PO OR RT T
F
F
R
RA AM ME E
.
.
Fig 9.
9
9. . R R
E
EM MO OV VE E
T
T
H
HE E
S
S
E
EC CO ON ND DA AR RY Y
A
A
I
IR R
C
C
H
HA AM MB BE ER R
C
C
A
AS ST TI IN NG G
.
.
Fig 10.
View thr ash pit d r sh wing
sec ndary air casting attached t
fr nt plate.
1
10 0. . R R
E
EM MO OV VE E T TH HE E S SE EC CO ON ND DA AR RY Y A AI IR R
C
CH HA AM MB BE ER R F FA AS ST TE EN NE ER RS S
.
.
There are tw fasteners, ne at the
ven side and ne at the pp site ven
side.
If it is n t p ssible t unscrew them,
it may be necessary t grind the
heads ff.
Fig 11.

8
Fig 12. Sec ndary air chamber casting
rem ved.
Vac The Debris Out.
Th r ughly vacuum ut all the dust
and debris fr m the appliance and the
ash pan area.
Fig 13. Rem ve the ash pit base plate
casting.
1
11 1. . C C
H
HE EC C
T
T
H
HE E
H
H
O
OT T
P
P
L
LA AT TE E
S
S
E
EA AL L
.
.
Make sure that the ceramic r pe seal,
n t which the h tplate sits, is in
g d c nditi n and n t ver
c mpressed, if it is n t f rming a
g d airtight seal with the cl sure
plate, renew it.
1
12 2. .R R
E
EM MO OV VE E
T
T
H
HE E
F
F
L
LU UE E
B
B
O
OX X
D
D
A
AM MP PE ER R
P
P
L
LA AT TE E
.
.
Rem ve the sliding damper in the flue
b x and seal the pening left by the
sliding damper with fire cement.
Check that there are n p tential f r
air leaks in r ar und the flue b x.
Check the rear utlet c ver plate, as
these are pr ne t leaking.
1
13 3. . L L
O
OC C
T
T
H
HE E
A
A
I
IR R
V
V
A
AL LV VE E
O
O
P
PE EN N
.
.
It is essential that as much c ling
and c mbusti n air as p ssible be
all wed t circulate ar und the
burner.
A permanent free air supply must be
established, as the burner cann t
functi n c rrectly with ut it.
T achieve this it is necessary t fully
pen the spin valve which is l cated in
the ash pan access d r and l ck it
permanently in this p siti n by use f
either a l ck nut, r a (suitably
p siti ned) drilled h le and split pin.
1
12 2. . F F
I
IT TT TI IN NG G
T
T
H
HE E
B
B
O
OA AR RD DS S
A
A
N
ND D
B
B
U
UR RN NE ER R
C
C
O
OM MP PO ON NE EN NT TS S
.
.
Bef re permanently fitting the
b ards, try a dummy run, t make sure
everything fits bef re final
permanent fitting and fire cementing.
It will be necessary t trim the ashpit
side lining b ards, the fr nt b ards
and the pp site ven under and ver
cl sure plate b ards t fit.
(The b ards can be cut and shaped
with w d w rking equipment.)
Start fitting the b ards as per Fig 4

9
1. Ash pit Base Oven Side Lining
B ards x 2.
2. Opp site ven cl sure plate supp rt
b ard.
3. The ven side b ard.
These b ards will have t be cut
trimmed t fit flush up t the side f
the ashpit castings and will f rm the
ven side supp rt t the cl sure plate.
4
4. . S S
T
TA AR RT T
F
F
I
IT TT TI IN NG G
T
T
H
HE E
F
F
I
IR RS ST T
B
B
O
OA AR RD DS S
.
.
Fig 4
Use silic ne t attach the b ards t
the side castings.
The b ards as sh wn in Fig 4 are held
in place by the angle brackets n the
underside f the cl sure plate.
5
5. . F F
I
IT T
T
T
H
HE E
C
C
L
LO OS SU UR RE E
P
P
L
LA AT TE E
.
.
The cl sure plate is fitted with the
angles d wn.
Fig 6
The cl sure plate has retaining angles
attached t the underside; these are
used t h ld the side supp rt b ards
in situ.
View fr m ab ve sh wing cl sure plate
fitted.
Fig 7

10
6
6. . F F
I
IT T
O
O
P
PP PO OS SI IT TE E
O
O
V
VE EN N
O
O
V
VE ER R
C
C
L
LO OS SU UR RE E
P
P
L
LA AT TE E
B
B
O
OA AR RD D
.
.
Fig 8
Fig 8a
7
7. . F F
I
IT T
P
P
R
RI IM MA AR RY Y
C
C
L
LO OS SU UR RE E
P
P
L
LA AT TE E
B
B
O
OA AR RD D
A
A
N
ND D
P
P
R
RI IM MA AR RY Y
F
F
R
RO ON NT T
B
B
O
OA AR RD D
.
.
Fig 8b
8
8. . F F
I
IT T
S
S
E
EC CO ON ND DA AR RY Y
F
F
R
RO ON NT T
B
B
O
OA AR RD D
.
.
Fig 8c
Sec ndary fr nt b ard in place.
9. When the sec ndary fr nt b ard is
fitted, fix it t the fr nt b ard by
the use f 4 x 35mm w d screws.
Screw thr ugh fr m the fr nt b ard
int the sec ndary b ard.
1
10 0. . F F
I
IT T
T
T
H
HE E
F
F
U
UE EL L
L
L
O
OA AD DI IN NG G
D
D
O
OO OR R
A
A
C
CC CE ES SS S
C
C
O
OV VE ER R
P
P
L
LA AT TE E
.
.
and use it as a template t mark the
centre f the viewing p rt.
Fig 14
Rem ve the plate and drill thr ugh
with a 60mm diameter h le saw.
Using the viewing glass as a template,
mark a further c ncentric circle
ar und the 60mm h le.

11
Using a sharp chisel, c untersink a
flat b tt med recess, t accept the
depth f the glass.
Silic ne the glass panel int the
s cket and screw the stainless c ver
plate t the fr nt b ard t sandwich
the glass panel int place.
Neatly seal ar und the edge f the
stainless c ver plate with silic ne t
finish ff.
1
11 1. . F F
I
IT T
B
B
U
UR RN NE ER R
B
B
A
AS SE E
P
P
L
LA AT TE E
.
.
With Fan Attached.
Fig 16
The burner base plate has a levelling
screw in each c rner t make sure
that it can sit flat in the base f the
c ker.
Fig 17
1
12 2. . F F
I
IT T
C
C
O
OM MB BU US ST TI IO ON N
H
H
E
EA AD D
.
.
with the high pressure flexi il pipe
pre fitted t it and c nnect the Air
H se
View fr m under side f cl sure plate
Fig 19
1
13 3. . F F
I
IT T
T
T
H
HE E
A
A
I
IR R
H
H
O
OS SE E
T
T
O
O
T
T
H
HE E
C
C
O
OM MB BU US ST TI IO ON N
H
H
E
EA AD D
.
.
and then fit the Upper Supp rt Plate
t carry the fuel pump and c ntr l
b x.
The upper supp rt plate is fastened
t the burner base plate by tw M5
fasteners. This ph t graph

12
1
14 4. . F F
I
IT T
T
T
H
HE E
F
F
U
UE EL L
P
P
U
UM MP P
.
.
Fig 20
Fit the fuel pump and c nnect the
flexi il feed fr m the c mbusti n
head t the s len id utlet as per fig
21.
Fig 21 Sh ws the high pressure flexi
being attached t the s len id pri r
t fitting the fuel pump int p siti n
n the supp rt plate.
1
15 5. . T T
I
IG GH HT TE EN N
T
T
H
HE E
F
F
U
UE EL L
H
H
O
OS SE E
.
.
Fig 22
1
16 6. . F F
I
IT T
T
T
H
HE E
C
C
O
ON NT TR RO OL L
M
M
O
OD DU UL LE E
.
.
Bef re fastening the c ntr l m dule
nt the upper supp rt plate c nnect-:
1. HT leads t the c mbusti n head.
2. The fan m t r c nnect r
3. The fuel pump c nnect r
4. The s len id c nnect r
5. Plug the Ph t Cell int the
c mbusti n head.
Lay the c nnected wiring as neat as
p ssible and gently push the c ntr l
m dule int place.
Fix in place with 2 x M5 fasteners.
WHEN YOU ARE HAPPY WITH THE
DUMMY RUN, PROCEED AND FIT
EVERYTHING PERMANENTLY, FIRE
CEMENTING THE BOARDS IN
PLACE AND FILLING ANY GAPS
WITH FIRE CEMENT OR ROPE AS
YOU GO.

13
1
12 2
B
B
.
. S S
E
ER RV VI IC CE ES S
I
I
N
NT TO O
T
T
H
HE E
B
B
U
UR RN NE ER R
.
.
1
1. . O O
I
IL L
F
F
E
EE ED D
.
.
T get the il feed pipe w rk thr ugh
the side f the appliance it will be
necessary t mark ut and drill
thr ugh the inner and uter skins f
the appliance, this is an awkward j b
requiring s me patience.
H le saw thr ugh the uter panel and
then self tap the adapt r plate t the
side panel.
Mark thr ugh nt the inner cast ir n
panel and drill thr ugh t gain access
f r the il feed, p wer, and stat link.
The 90 deg C KBB fire-valve phial will
have t fitted n the inside f the
ashpit d r via a suitable clip.
The ashpit d r cast sealing face will
have t be gr und away t pr vide
access f r the phial capillary.
N te t make the drilling easier, drill
a small pil t h le first and f ll w
thr ugh with a larger diameter drill.
Fig 23
Adapt r plate fitted
Fig 24 is a view sh wing access h les
drilled thr ugh the inner casting.
Fig 24
Fig 25 is a view sh wing s me critical
items
1. P wer in plug
2. Oil bleed tap
3. Flexi air h se.
4. Fuel pressure test p int
5. Fuel pressure adjuster screw.
6. C ntr ller l ck ut reset butt n.
7. Therm stat live link ut.
Fig 25
1
2
3
4
5
6
7

14
Fit the flexi il feed pipe and the
rem te fire valve phial and capillary
thr ugh the cable supp rt in the l wer
plastic plug ready t c nnect up.
2
2. . O O
I
IL L
I
I
S
SO OL LA AT TI IO ON N
V
V
A
AL LV VE E
.
.
Fit the il is lati n valve pri r t the
KBB firevalve.
3
3. . O O
I
IL L
P
P
I
IP PE EW WO OR R
T
T
O
O
P
P
R
RE ES SS SU UR RE E
J
J
E
ET T
B
B
U
UR RN NE ER RS S
.
.
Fig 26
Because there is a m t r and a fan in
the burner unit, s me vibrati n may
be transmitted thr ugh the pipew rk.
If the pipew rk is in c ntact with any
sharp edges fretting can ccur, t
prevent this apply silic ne sealant at
any p tential hazard p ints.
Check that the il supply line has a
suitable filter, firevalve and d es n t
have the p tential f r air l cking.
4
4. . P P
O
OW WE ER R
I
I
N
N
.
.
Fit the mains feed cable thr ugh the
cable supp rt ready t c nnect up t
the plug supplied.
5
5. . F F
I
IT T T TH HE E B BA AF FF FL LE E I IT T
.
.
The baffle kit c mprises f tw
c mp nents.
1. A circular stainless steel tube
with a ceramic b ard lid and cut uts
in the vertical sides f the tube.
The cut uts all w h t gasses t be
directed t the ven side and b iler
side.
It is fitted c ncentrically ver the
flame tube and the spikes are pressed
d wn int the t p b ard t prevent
m vement.
It can be r tated t a variety f
different p siti ns relative t the
users requirements.
2. A simple angle plate designed t
st p the flue gasses g ing diag nally
acr ss the ven t p and directly up
the chimney.
The plate is fitted in the right angle
c rner f the h t plate cut ut
cl sest t flue utlet; it diverts the
flue gasses t wards the fr nt f the
appliance and then ut f the
appliance.
6
6. . F F
I
IT T O OV VE ER R O OV VE EN N B BA AF FF FL LE E
Left hand ven sh wn.

15
1
13 3. . C C
O
OM MM MI IS SS SI IO ON NI IN NG G
.
.
C mmissi ning takes the f rm f
three separate activities-:
1. Setting the burner up.
2. Heat balancing the appliance t the
users system.
3. Final check f the c mplete
installati n.
1
1. . S S
E
ET TT TI IN NG G T TH HE E
B
B
U
UR RN NE ER R
U
U
P
P
.
.
1a. N zzle .4 x 60 Deg S lid
1b. Pump Pressure 9 Bar
1c. Gr ss Output 14 kW
1d. Net Output 10.5kW
1e. Flue Gas Fl w .0027 m/s.
2
2. . H H
E
EA AT T
B
B
A
AL LA AN NC CI IN NG G T TH HE E
S
S
Y
YS ST TE EM M
.
.
Adjusting the p siti n f the r und
baffle t give the c rrect distributi n
f heat between the b iler and ven.
If there is n b iler fitted then
adjust the baffle t get the balance
between the h t plate and ven.
3
3. . L L
I
IG GH HT TI IN NG G
.
.
Make sure the appliance is fully
assembled, d n t fit the baffle b x,
as it is necessary t view the flame.
Carry ut electrical safety tests in
line with IEEE and OFTEC
requirements
P larity.
Sh rt circuiting.
Earthing.
Turn the oil on and check for oil
leaks.
3
3. .1 1. . T T
O
O
B
B
L
LE EE ED D
T
T
H
HE E
P
P
U
UM MP P
.
.
1. Take great care when bleeding the
pump, it is a single cylinder
recipr cating device and if repeated
l ck uts ccur, due t lack f fuel
caused by air l cking, it can s n be
damaged.
If the pump runs with ut il it will
make a quite l ud and rapid rattling
n ise and permanent damage in the
f rm f a subdued rattling will ccur.
2. Turn the il n and make sure that
the is lati n valve and KBB fire valve
are turned int the n p siti n.
3. Turn the perating stat d wn s
that it is n t calling.
4. G t the burner and und the
bleed tap 2 Fig 25.
5. Y u will need an assistant t turn
the p wer n and quickly ff at y ur
c mmand.
6. Put plenty f tissues ar und the
bleed tap and ask y ur assistant t
turn the p wer n but be ready t
turn it ff quickly.
7. Turn the p wer n and watch until
il is vented ff thr ugh the tap.
When this ccurs quickly p wer ff
and tighten the bleed tap.
M p up any spillage.
3
3. .2 2. . S S
E
ET T
T
T
H
HE E
C
C
O
ON NT TR RO OL L
S
S
T
TA AT T
.
.
Turn the stat fully ff.
3
3. .3 3. . S S
E
ET T
T
T
H
HE E
T
T
I
IM ME E
C
C
L
LO OC C
.
.
Make sure that the time cl ck is
calling.

16
3
3. .4 4. . C C
H
HE EC C
T
T
H
HE E
B
B
U
UR RN NE ER R
A
A
I
IR R
S
S
H
HU UT TT TE ER R
.
.
The burner air shutter has been set
at the fact ry and sh uld be
satisfact ry f r test firing.
T adjust the burner air the c ntr l
m dule will have t be eased ut f
the ashpit t all w access f r y u
hand int fan assembly.
The air slide is l cked in place with an
m5 plastic headed screw n the side
plate.
3
3. .6 6. . I I
G
GN NI IT TE E
T
T
H
HE E
B
B
U
UR RN NE ER R
.
.
The viewing p rt is plugged with
ceramic w l which sh uld be rem ved
t view the flame during
c mmissi ning and replaced after.
Turn the stat ON and viewing thr ugh
the p rt y u will see the burner g
thr ugh an igniti n sequence and
ignite.
Failure t ignite will cause the flame
failure butt n n the c ntr ller t
illuminate, after a sh rt time push the
butt n in t reset the c ntr ller and
repeat the pr cess again until igniti n
ccurs.
3
3. .7 7. . F F
I
IT T
T
T
H
HE E
B
B
A
AF FF FL LE E
B
B
O
OX X
.
.
When y u are happy with the flame
picture, turn the burner ff and
is late the mains electricity bef re
y u fit the baffle b x.
Make sure that the baffle is set up t
suit the users requirements.
The baffle is fitted ver the flame
tube as illustrated.
There are tw rectangular cut uts in
the vertical sides f the baffle which
can be p siti ned t p int t -:
1. The rear and left hand side f r
intensive water heating r wintertime
running
Or
2. The fr nt and right hand side f r
intensive c king r summer time
running.
Or
3. T the right and rear f r
intermediate running.
It can be set up t bias the flame t
the ven r the b iler r an
intermediate p siti n.
3
3. .9 9. . T T
O
O
S
S
E
ET T
F
F
O
OR R
G
G
O
OO OD D
C
C
O
OM MB BU US ST TI IO ON N
.
.
Because f the ven vent all wing
excess air int the flue gasses it will
be difficult t take accurate flue gas
analysis readings.
C upled with this, these appliances
are n t air tight and further air will
ingress int the flue gasses.
The best plan is t use a sm ke pump
and set the burner at between 0-1
sm ke.
3
3. .1 10 0. . C C
O
OM MB BU US ST TI IO ON N
A
A
I
IR R
.
.
C mbusti n air is adjusted via the air
c ntr l damper n the fan unit which
when set can be l cked in place.

17
Because the burner is a tight fit in
the ashpit area it will be necessary t
ease the c ntr l m dule ut f the
ashpit n t a suitable temp rary
stand t all w access in t adjust the
air slide.
3
3. .1 11 1. . T T
O
O
A
A
D
DJ JU US ST T
T
T
H
HE E
P
P
U
UM MP P
P
P
R
RE ES SS SU UR RE E
.
.
There are tw type f pump fitted t
Flexaflame burners.
Nipp n and Taisan
The il pump pressure n the Nipp n
pump is adjusted via the screw t the
left f the fuel entry p siti n. The
burner is set at the fact ry at a
pressure t suit the appliance being
c nverted.
Fully in and three quarters f a turn
ut is equal t 10 Bar, each quarter f
a turn ut is equal t ne bar
reducti n. If y u l se y ur p siti n
with the adjustment, get back t the
10 bar start p int.
Taisan
The il pump pressure n the Taisan
pump is adjusted via the setscrew and
l cknut t the Right f the fuel entry
p siti n.
The burner is set at the fact ry at a
pressure t suit the appliance being
c nverted.
4
4. . F F
I
IN NA AL L
C
C
H
HE EC C S S
.
.
C mmissi ning checks sh uld be
carried ut n the f ll wing-:
4
4. .1 1. . F F
U
UE EL L
T
T
A
AN N
.
.
Check f r leaks-stability-height-
p siti n-vent.
4
4. .2 2. . F F
U
UE EL L
.
.
Fuel- check f r c rrect grade
4
4. .3 3. . F F
I
IL LT TE ER R
.
.
Is it fitted?
Check f r functi n and leaks.
4
4. .4 4. . S S
I
IT TE E
G
G
L
LA AS SS S O OR R
T
T
A
AN N
G
G
A
AU UG GE E
.
.
Check f r functi n and leaks.
4
4. .5 5. . O O
I
IL L L LI IN NE E
.
.
Check f r functi n, p siti ning,
material suitability and leaks.
Make sure that a leak test is carried
ut after the burner has been running
f r at least half an h ur, make sure
that there is n il dripping fr m the
c mbusti n head.
4
4. .6 6. . F F
I
IR RE E V VA AL LV VE ES S
.
.
Check f r functi n and leaks.
4
4. .7 7. . T T
H
HR RO OU UG GH H
W
W
A
AL LL L
S
S
L
LE EE EV VI IN NG G
.
.
Check that it is fitted and sealed
4
4. .8 8. . I I
S
SO OL LA AT TI IO ON N V VA AL LV VE E
.
.
Check f r functi n, c nvenience f
p siti ning and leaks.
4
4. .9 9. . E E
L
LE EC CT TR RI IC CA AL L
.
.
Check f r c rrect fusing, l cati n and
specificati n f any is lati n devices.
4
4. .1 10 0. . V V
E
EN NT TI IL LA AT TI IO ON N
.
.
Make sure that adequate ventilati n is
pr vided.

18
4
4. .1 11 1. . C C
H
HI IM MN NE EY Y
S
S
Y
YS ST TE EM M
.
.
Chimney system sh uld be checked t
make sure that it c mplies with the
relative standards, regulati ns and all
ther instructi ns given.
4
4. .1 12 2. . C C
H
HE EC C C CO ON NT TR RO OL LS S
F
F
U
UN NC CT TI IO ON N
.
.
Check c rrect h t c nditi n
functi ning f water heating system
and all c ntr ls.
4.13. Instruct User.
Ensure that the cust mer is
instructed n the basic use f the
appliance, timers, c ntr ls and il /
electrical is lati n devices if fitted.
The imp rtance f regular
maintenance and regular checking f r
il leaks.
C mmissi ning sh uld n t be signed
ff unless the c mmissi ning engineer
is satisfied that all the w rk d ne
c mplies with the relative standards
and regulati ns detailed within this
d cument.
4
4. .1 14 4. . V V
E
EN NT T T TH HE E
A
A
S
SH HP PA AN N
D
D
O
OO OR R
.
.
This w rk sh uld n t be carried ut
unless the cust mer is 100% happy
with the c nversi n.
Once the w rk has been carried ut it
is n t p ssible t c nvert the
appliance back t s lid fuel, sh uld
the need ever arise.
The bjective f the activity is t
all w a c ling stream f air t pass
vertically up behind the ashpit d r
and st p the build up f h t air in the
ashpit.
This will have a beneficial effect n
the l ngevity f the burner, as it will
be perating in a much c ler
envir nment.
The d r sh uld be rem ved and
placed up n a bubble pack supp rt t
prevent damage t the enamel
surface.
Using a 4inch disc grinder set up with
a flap wheel, grind away an area as
detailed in Fig 29 and refit the d r.
1
14 4. . W WA AR RR RA AN NT TY Y. .
Ensure that the warranty registrati n
d cumentati n is returned t
Harw rth Heating Ltd.
It will not be possible to deal with
any warranty claims unless we hold
on our Data Base, details from a
correctly filled in warranty
commissioning form.
The f rm must arrive back at ur
w rks within tw weeks f the burner
being c rrectly c mmissi ned.
When the warranty f rm is received
at ur w rks details fr m it will be
entered n t ur warranty
registrati n Data Base.
This information will form part of a
record of the installation and will be
the first point of reference by our
staff, for any claims made under
the equipment warranty.

19
The warranty c vers PARTS ONLY
f r a peri d f ONE YEAR and is
c nditi nal up n all the requirements
f ur installati n and c mmissi ning
instructi ns being fully adhered t .
1
1. . I I
T
TE EM MS S
N
N
O
OT T
C
C
O
OV VE ER RE ED D
U
U
N
ND DE ER R T TH HE E
W
W
A
AR RR RA AN NT TY Y
2
2. . L L
A
AB BO OU UR R
.
.
3
3. . T T
R
RA AV VE EL LL LI IN NG G T TI IM ME E
.
.
4
4. . C C
O
ON NS SE EQ QU UE EN NT TI IA AL L L LO OS SS S O OR R D DA AM MA AG GE E
.
.
5
5. . N N
O
OZ ZZ ZL LE ES S
.
.
6
6. . B B
A
AF FF FL LE E I IT TS S A AN ND D
I
I
N
NS SU UL LA AT TI IO ON N
B
B
O
OA AR RD DS S
.
.
Damaged due t faulty installati n and
r faulty c mmissi ning f the
appliance.
7
7. . D D
A
AM MA AG GE E T TO O T TH HE E
F
F
U
UE EL L
P
P
U
UM MP P
.
.
Caused by air l cks in the fuel line r
lack f fuel.
If the fuel pump runs with ut il it
will make a l ud and rapid rattling
n ise.
If this ccurs permanent damage in
the f rm f a subdued rattling will
ccur.
1
15 5. . F F
A
AU UL LT T
F
F
I
IN ND DI IN NG G
.
.
Fault finding pr cedures are c vered
under a separate sheet.
1
16 6. . S S
E
ER RV VI IC CI IN NG G
.
.
Servicing sh uld be carried ut at six
m nthly intervals
Service engineers sh uld request a
c py f the servicing schedule fr m
ur sales desk.
Schedules will als be available fr m
ur web site.
www. ilst ves.c .uk
1
18 8. . I I
L
LL LU US ST TR RA AT TI IO ON NS S
Additi nal inf rmati n f ll ws in the
f rm f illustrati ns

20
1
1. . S S
E
EC CT TI IO ON NA AL L
D
D
E
ET TA AI IL LS S
Fig 27
2
2. . B B
O
OA AR RD D
D
D
E
ET TA AI IL LS S
Fig 28