Charnwood OLX User manual

CHARNWOODOLX
OilFired
HearthBoiler
Operating
and
InstallationInstructions
BishopsWay,Newport,IsleofWight,PO305WS
Tel:[phone] Fax: [phone]
E-Mail: [email protected] Internet:www.charnwood.com

CHARNWOODOLX45
OperatingandInstallationInstructions
BishopsWay,Newport,IsleofWight,PO305WS
TechnicalSupportTel: [phone] Fax: [phone]
E-Mail: charnwoo[email protected] Internet:www.charnwood.com
Page3
OLXV5.205.04
OperatingInstructions
InstallationInstructions
GeneralPoints........................................................4
Fuel..........................................................................4
ControllingTheBoiler............................................4
ElectricFlameEffectandFanHeater......................4
IfTheBurnerFailstoLight......................................4
Maintenance............................................................4
ReplacingtheFlameEffectBulb...............................4
Health&SafetyPrecautions....................................6
Standards&Regulations..........................................6
Performance...........................................................6
AirSupply...............................................................6
Chimney..................................................................6
Hearth&FireSurround..........................................8
OilSupply................................................................8
PreparationoftheFireplace....................................9
CentralHeatingSystem...........................................9
FittingTheFire.......................................................10
ElectricalConnection..............................................10
CombustionChamberAssembly............................10
FinishingTheInstallation.........................................11
Commissioning.......................................................12
OverallDimensions................................................12
Specifications..........................................................14
WiringDiagram......................................................15
ElectrodeSettings...................................................16
ExplodedPartsDrawing-Boiler.............................17
ExplodedPartsDrawing-Burner...........................18

CharnwoodOLXOilFiredHearthBoiler
OperatingInstructions
FlameEffect
andOptional
FanHeaterControl
Boiler
Thermostat
TurnHandle
Clockwise
ToOpen
Fig.1.Controls
GENERALPOINTS
CONTROLLINGTHEBOILER
Beforeusingtheboilerforthefirsttime,checkwiththe
installerthatithasbeencorrectlyinstalledand
commissioned.Donotattempttousetheboilerbefore
ithasbeencommissioned.
Theboilerissetuptoburn28sec.viscosityoil,thisis
commonlyknownasKerosene.DonotuseGasOil.
Theboileriscontrolledbythethermostatwhichison
thelefthandsideofthefire,itisthelowerofthetwo
controlknobs(seeFig.1.)Thissetsthetemperature
thattheboilerwilloperateat.ACentralHeatingTime
ClockorProgrammerwillnormallycontroltheheating
system.
Theelectricflameeffect operatescompletely
independentlyfromtheboilerandisswitchedonand
offbythetopcontrolknobonthelefthandsideofthe
fire(seeFig.1.)Turntheknobtoposition"1"to
operatetheflameeffect.Theflameeffectmaytakea
fewmomentstobecomeestablishedwhenfirst
switchedonafterlongperiodsofnotbeingused.
Position"2"isusedforthe1KWsettingoftheoptional
fanheateriffitted.Position“3”isthe2KWsetting.If
theroomtemperaturebecomesexcessive,theinternal
thermostatwillswitchtheheatertoblowcoolairuntil
thetemperaturefalls,whenitwillreverttoitsprevious
setting.
FUEL
ELECTRICFLAMEEFFECT&FANHEATER
IFTHEBURNERFAILSTOLIGHT
MAINTENANCE
IftheburnerfailstolightthentheResetlightonthe
BurnerResetButtonmaylightup(seeFig.2.)This
situationisknownas“Lockout”inwhichcasewaitfor
1minuteandpressthere-setbutton(locatedthrough
theholeinthefrontpanelbehindthedoors.)The
burnerwillthentrytoigniteagain.
Iftheburnercontinuallygoestolockout,thenthecause
needstobeestablishedandtheproblemputright.The
mostcommoncausesarelackoffuel,orairinthefuel
line.Checkthattheoiltankisnotempty,andthatall
valvesareopen.Thetroubleshootingguidegives
furthersteps,someofwhichwillrequireactionbya
trainedOilEngineer.Donotpresstheresetbutton
morethanfivetimesinarowasthiscancausedamage
tothepump.
Itisimportanttohavetheapplianceservicedeach
year.PleasearrangethiswithanOFTECapproved
Heatingengineer.Theflexibleoilsupplyhosemustbe
replacedevery2years
Replacingthebulbintheflameeffectisasimple
operationthatcanbecarriedoutwithoutusingany
tools.
Ensurethattheflameeffectisswitchedoffbefore
attemptingtoreplacethebulb.Openthedoorsand
ReplacingTheFlameEffectBulb
Page4
OLXV5.205.04
BurnerResetButton
LocatedThroughHole
InFrontPanel
Fig2.BurnerResetButton
SerialnumberLabel
Bottomplate
Innerplate

Fig.3.FlameEffectBulbReplacement
1)LiftBulbfromclip
2)RemoveBulbfromHolder
Holder
Sleeve
Clip
Bulb
Sleeve
removethecoals.LiftofftheFrontFence.Liftoutthe
fibreglasscoaleffect.Lifttheright-handendofthe
bulbandcoveroutofitsclip,seeFig.3,thenunplug
thebulb,movingittowardstheright.Slidethecover
offanddiscardtheoldbulb.Slidetheoldcoveronto
thenew bulbandinsertthebulbbaseintotheholder
ontheleft.Ensurethatthebulbispushedfully
home,thenlowertheright-handendandpressit
intotheclip.Replacethefibreglasscoaleffect,with
therearedgepassingjustunderthePerspex.Re-fit
thefrontfenceandreplacethecoals.
Page5
OLXV5.205.04

CharnwoodOLXOilFiredHearthBoiler
InstallationInstructions
Theairsupplyforcombustionistakenfromwithin
thebuildersopeningontheright-handsideofthe
HEALTHANDSAFETYPRECAUTIONS
STANDARDS&REGULATIONS
PERFORMANCE
AIRSUPPLY
Pleasetakecarewheninstallingtheappliancethatthe
requirementsoftheHealthandSafetyatWorkAct
1974aremet.
Sometypesoffirecementarecausticandshouldnot
beallowedtocomeintocontactwiththeskin.Incase
ofcontactwashwithplentyofwater.
Noasbestosisusedintheappliancebutifthereisa
possibilityofdisturbinganyasbestosinthecourseof
installationthenappropriateprotectiveequipmentmust
beused.
Whenhandlinginsulatingmaterialsasuitablefacemask
andprotectiveglovesshouldbeworn.
Takecarewhenhandlingfueloilwhichcancauseskin
irritation,avoidcontactwiththeskinorclothing,take
caretowashhandswellaftercontactwithfueloiland
beforeeating.Fueloilmustneverbetakeninternally.
Inadditiontotheseinstructionstherequirementsofthe
followingstandardsmustbefulfilled:
BS5410Pt1OilInstallationsUnder45kW
BS5449ForcedCirculationhotwatercentral
heatingsystemsfordomesticpremises
BS7671ElectricalWiringRegulations
LocalAuthorityBylawsandBuildingRegulations
regardingtheinstallationofOilBurningAppliances,
fluesandchimneysandTheControlofPollution(Oil)
Regulationsmustalsobeobserved.
Oilboilersshouldbeinstalledinaccordancewithgood
practiceasrecommendedbyOFTEC(TheOilFiring
TechnicalAssociationforthePetroleumIndustry,
Banstead,Surrey.Tel:[phone].)
Theoutputoftheboilerisadjustablebetween11-13
kW(38-44,000Btu/h),asmallamountofheatwillbe
givenouttotheroombutforpurposesofsizingthe
systemthisshouldbeignored.TheoptionalFanHeater
providesupto2KWofheattotheroom.
boilerandaductedairsupplymustbeprovidedtothe
righthandsideoftheboileratthispoint.Atwometre
lengthofflexibleductingandfixingclipsaresupplied
withtheappliancetoconnecttheairinputfromthe
appliancesilencertotherigidplasticducting.Theair
pipeshouldbesealedintotheapplianceusingasilicone
sealant.Theductingshouldberunin50mmdia.(2")
plasticpipeandmustterminateinfreeair-preferably
eitheroutsideorinaventilatedloftspace.Theendof
theductingmustbefittedwithasuitablecageto
prevententrybybirdsorsmallmammals.Theducting
shouldbeboxedinwhereitpassesthroughlivingareas.
Thelengthofductingshouldbekepttoaminimum,
andthemaximumrecommendedlengthis10metres
incorporatingupto4bends.(Onebendisapprox.
equivalentto1metreofstraightpipe).
Providedthattheductingterminatesasdescribed
abovethereisnorequirementforaseparate
combustionairsupplyintheroominwhichthe
applianceisinstalled.However,iftheducting
terminateswithinalivingspacethentheremustbean
adequateairsupplyintothatroomtotallingatleast55
sq.cm.(8.5sq.inches)toprovidecombustionair.
ThechimneyshouldcomplywithBS5410:Part1and
mustmeetBuildingRegulations.
Thediameterofthechimneymustnotbelessthan100
mm(4”)internaldiameter.
Astheboileroperatesathighefficiency,itisimportant
thatthechimneyiswellinsulatedinordertoprevent
condensationforming.
Brickorstonechimneysshouldbelinedwithasuitable
liner.Ifastainlesssteellinerisusedinabrickorstone
chimneythenitmustbeinsulatedbetweenthelinerand
thebrickworkinordertopreventcondensationthat
canreducethelifeofboththelinerandtheboiler.
Pumicelinerswillgivetherequiredlevelofinsulation.
Astheflueoutlettemperatureisbelow250°Cstainless
steelflexiblefluelinerssuitableforoilmaybefitted
directlyontotheappliance,althoughintheinterestsof
reducingfluenoiseitispreferabletousea600mm
lengthofrigidfluepipefromtheappliancetotheliner.
CHIMNEY
Page6
OLXV5.205.04

Page7
OLXV5.205.04

Iffluepipeisusedtoconnecttheappliancetothe
chimneyitmustbebetween100&125mm(4-5")
internaldiameter.
Thechimneyterminationmustnotbesubjectedto
downdraughts.Ifnecessaryananti-downdraughtcowl
maybefitted.Therequireddrawforthisapplianceis
0.17mbar(0.07inH2O).
Theboilerwaterwaystotallyenclosethecombustion
chamber.Thismeansthatthemaximumtemperature
belowtheboileris100°Candthereforea
constructionalhearthisnotrequired.
Thehearthandbasewithinthefireplaceopeningmust
bemadefromnon-combustiblematerialandmustbe
flatandlevel.Thehearthmustbeflattoalloweasy
fittingofpartsonthefire.Whenpositioningtheboiler
ensurethatthesideflangesontheboilercomelevel
withthefaceofthefiresurround.
Thefiresurroundshouldbemadefromnon
combustiblematerialandhaveopeningdimensions
showninFig.7.
TheCharnwoodOilBoilerissetuptoburnKerosene
28secondviscosityoiltoBS2869Part21988Class
C2.Itcomescompletewithaflexibleoillineandshut
offvalve,towhichtheoilsupplylineshouldbe
connected.
Whenconsideringwheretositetheoilstoragetank,
considerationshouldbegiventotheaccessrequiredby
fueldeliverylorries.Tankpositioningmustalsobein
accordancewithBS5410Part1andOFTECTechnical
Book3.
Oiltanksshouldhavethefollowingitems:
Avalvefittedtotheoutlet
Sludgevalve(onsteeltanks)
Oillevelindicator
Hingedfillandventcoverorseparatefill
connectionandvent.Thefillandventmustbe
eithersuitablycappedorhaveareturnbendto
keepoutdirtandwater.
Steeltanksshouldbemountedonsuitablesupports.If
theyaremountedonblocksorbricksthenadamp
proofmembraneshouldbefittedbetweenthe
supportsandthetank.Steeltanksshould slope20mm
HEARTHANDFIRESURROUND
OILSUPPLY
per1moflengthdownwardsfromtheoiloutlettothe
sludgecockfittedattheoppositeend
PlastictanksshouldbeUVstabilisedforprotection
fromsunlight.Theydonotneedtostandonpiersbut
shouldbesupportedacrosstheentirebase.Referto
themanufacturersinstructionsforfulldetails.
Beawareofpollutionpreventionregulationsandthe
needforbundingifthetankisclosetowatercourses
ordrains.
Inordertoensurequietnessofoperationofthe
CharnwoodOLXasinglepipesystemisused.Theoil
storagetankshouldideallybepositionedwiththebase
ofthetankhigherthanthebaseofthefire.Whenthe
storagetankisbelowtheleveloftheburnerthenanoil
liftermustbeused.
Anoilshutoffvalveissuppliedwiththeboilertoallow
theburnertobeeasilydisconnectedandminimiseoil
spillage.
Anoilfiltershouldalsobefittedoutsidethebuilding,
adjacenttotheoiltank.
Aprotectivefirevalvemustbefittedintheoilsupply
line.Thephialsensorshouldbemountedintheburner
chamberThefirevalveshouldhaveacutout
temperatureof90°C.
Solderedjointsarenotpermittedintheoilsupplyline,
andallconnectionsmustbeproperlysealedtoprevent
oilleakageandairingress.
Someschematiclayoutsofoilsupplysystemsareshown
inFigs.4&5.
Theoilsupplylineshouldentertheappliancefromthe
left-handsidebehindthesidepanel.Thefittingsupplied
withthefirefacilitatesthis.
Ifthesupplylineistoruninfrontofthefireplace
surroundthenitwillbenecessarytocutasectionfrom
theendofthebottomplateonthefiretogiveaccess
forthepipe.Itispreferabletobringthesupplyinfrom
behindthefiresurround.
Theoilsupplylinemaybeineither8or10mmdia.
copper,dependantonthelengthoftherun,however,
theconnectionontheapplianceisa10mm
compressionfitting.
.
ThesupplylineMUSTbeflushedoutinthefollowing
manner:-
Connectthesupplylinetothecompressionfitting
ontheservicevalveatthelefthandsideofthe
appliance,butdisconnecttheflexiblehosefromthe
othersideoftheservicevalve,andreplaceitwith
Page8
OLXV5.205.04

770mm
670mm
SurroundandOpening
Dim.A:
Dim.B:
Min.555mm(213/4")
Max.470mm(181/2")
Min.405mm(16")
Theshadedareaonthefaceof
thesurroundistheminimumflat
arearequired.
Fig.7LimitingDimensionsOf
Max.579mm(223/4")
Fig.6.TypicalInstalation
usingflexibleflueliner
rightdowntoAppliance.
ClosurePlate
Rockwoolinfill
aroundflexible
lineraboveclosure
Rockwool
insulation
around
Appliance
Vermiculiteinfill
aroundFlexible
Liner
Firesurroundwith
removablemetal
closurepanels
100mmidsingleskin
flexiblefluepipe
HighTemperature
Siliconesealant.
ApplianceConnector
Fluefixingbrackets
Jointcaulkedwith
glassfibreropeand
sealedwithhigh
temperaturesilicone
sealant.
65mm
110mm
50mm
50mm
thepushonpieceof12mmbleedtubesupplied.
Placetheotherendofthebleedtubeintoasuitable
receptacle,andflushoutthesupplylinebyturning
ontheservicevalve.Whentheoilisclean,turnoff
theservicevalve,removethebleedtube,andre-
attachtheflexibletubefromtheburner.Turnthe
servicevalvebackon,checkforleaks,andcleanup
anyspiltoil.
PREPARATIONOFFIREPLACE
CENTRALHEATINGSYSTEM
Whenreplacinganexistingboiler,removeanyfireback
andinfillmaterialtoexposethebuildersopening.
Theopeningmustbeatleast400mmdeep(when
measuredfromthefrontfaceofthesurround,)600
mmwide(togiveaccesstotheboilerconnections,)and
650mmhigh(togiveaccesstotheflueconnection.
Ensurethatthebaseofthefireplaceislevelwiththe
hearthandthatthefaceofthesurroundisvertical.
Itisnecessarytohaveasmallcutoutinthefireplace
surroundatthebottomleftoftheopeninginorderto
bringtheoilandelectricalsupplytothefire.Itisalso
necessarytohaveasmallcutoutatthebottomrightof
theopeningtocleartheairinletduct.Seefig.7.
ThecentralheatingsystemmustcomplywithBS5449,
andshouldbeinstalledinaccordancewiththecurrent
goodpractiseguidelinesasadvisedbytheHVCA.
Centralheatingdesignisalargesubjectwhichitisnot
possibletodealwithadequatelyinthismanual.The
pointsthatareparticularlyrelevanttothisboilerare
dealtwithbelow.
Theheatingandhotwatersystemshouldnormallybe
fullypumped,althoughagravityhotwatersystemmay
beusedifitalreadyexists.
Therearenointernaldivisionsinthe boiler,andany
combinationofflowandreturntappingsmaybeused.
Ifitispossiblethendiagonalpairsoftappingsshouldbe
used,butpairsonthesamesidemaybeusedif
required.
Themaximumworkingpressureoftheboilermustnot
exceed3Bar(44psiorastaticheadof30m)
Inordertopreventabuildupofscaleandcorrosiona
suitableinhibitorshouldbeaddedtothesystem.
Whenreplacinganexistingboilerthesystemshould
bethoroughlycleanedbeforeconnectingthenew
boiler.
Fullyautomaticcentralheatingcontrolsmaybeusedto
givefullcontroloftheheatingandhotwater.When
designingthecontrolsystemitisimportanttonotethat
ifthesituationcanarisewheretheflowofwater
throughtheboilerisstopped,orsubstantiallyreduced,
whilsttheburnerisstillfiring,thenthiscanresultinthe
waterintheboilerreachingveryhightemperatures,or
evenboiling,beforetheboilerthermostatcansenseit
andswitchtheburneroff.Ifthisisapossibilitythen
Page9
OLXV5.205.04

BleedScrew
BleedHose
ConnectionPoint
OilPressureAdjustmentscrew.
ClockwisetoIncrease,
Anti-ClockwisetoDecrease.
Fig.9.OilPumpDetails
wirethecontrolstotheburnersothatitisswitchedoff
atthesametimeasthepumpormotorisedvalves.
Thisusuallymeanswiringthesupplytotheburnerinto
theoutputfromthecentralheatingprogrammer.
Unpackthestoveandremoveitfromitswooden
pallet..Ifafluelineristobeusedthenthisshouldbe
fittedinthechimneybeforefittingthefire.Theliner
willnormallycomedowntoafixingplateandashort
lengthof316Stainlesssteelfluepipeisthenusedto
connecttheboilertotheliner.Alternativelytheliner
maybefitteddirectlytotheboiler,inthiscaseensure
thattheliner isadequatelysupportedandthatitwill
notvibratewhentheapplianceisinuse.UsetheFlue
Fixingbracketsandselftappingscrewssuppliedtofix
thefluesecurelytotheboiler(seeFig.12.)Mineral
fibreorfibreglassshouldbeusedtoreducevibrations
andinsulatetheboilerandflue.Thespacebetweenthe
flexiblelinerandthechimneyshouldbefilledwith
loosevermiculiteinfillretainedbyasuitableplateinthe
chimneyabovetheboilertoallowfutureaccesstothe
boilerwithoutremovingtheinfill(seeFig.6).A
suitableraincapshouldbefittedtothetopofthe
chimney.
Positionthefiresothattherearfaceofthesideflanges
comesflushorveryslightlyinfrontofthefaceofthe
firesurround.
Maketheflueconnectiontotheappliance,ensuring
thatthefluepipeiswellsealedtotheboiler,andfixed
securelyusingthefixingscrewsandbrackets,seeFig.
10.
Connecttheheatingsystemtotheboilerensuringthat
thesystemventscorrectly.Fillthesystemwithwater
andcheckforleaks.
Theboilercomespre-wiredwithtwolengthsof3-core
cable.Theblackcableisfortheoilburner,thewhiteis
fortheflameeffectandoptionalfanheater.Connect
theblackcabletotheoutputfromthecentralheating
programmer,ensuringthatthesupplyisviaa3amp
fusedswitchedspur.Connectthewhitecabletoa
separate3ampfusedswitchedspur.Ifafanheateris
fitted,thisfusemustbe10amp.Ensurethattheearth
connectionsaremade.
Theboilercomeswiththeinternalinsulationbricksand
FITTINGTHEFIRE
ELECTRICALCONNECTION
COMBUSTIONCHAMBERASSEMBLY
bafflesfitted,anditisrecommendedthatthesebe
checkedforpositionbeforeinitialfiring.Ifitbecomes
necessarytore-fitthebafflesandbricks,followthis
procedure:-
Isolatefromthemainssupply,openthedoorsandlift
upandremovethebottomplate.SeeFig2.Liftoffthe
fenceandthecoaleffect.Loosenthefixingscrewat
eachsideoftheinnerplate,slideoutwardsintothe
slot,andliftofftheinnerbottomplate.LiftthePerspex
paneloutofthefireandundothetwowingnutsonthe
backpanel.Unplugthemainscablefromthebottomof
theflameeffect.Theflameeffectmaythenbelifted
clear.Theboileraccessdoorisnowvisible,andis
removedbyundoingthe4brassnutswitha10mm
socket.
Taketheitems1-5inorderandlowertheminto
positioninthebottomofthecombustionchamber.
Assemblethemtogetherinthispositionsothatboth
sideboardsaretightinagainstthetop&backboards,
andthefrontfaceofthetopboardishardupagainst
Page10
OLXV5.205.04
Fig.8.OilBurnerAssembly
ShownRemovedfromBoiler.
OilPump
IgnitionUnit
(BehindControlUnit)
AirInlet
Manifold
OilPressure
GaugePort
Burner
Control
Unit
ResetButton
NozzleCoverPlate
AirPressureSwitch
AirControl1-10
FuelSolenoidvalve
AirControl1-10
Photocell

Locatethisfacehard
againstinnerfront
boilerface,giving25mm
gapatrear,&40mmat
frontsides.
23
4
5
CombustionChamberInsulationBoard
OrderofAssembly
1
AssemblyOrder:
1.Base(FibreWool)
2.Back
3.RHSide
4.LHSide
5.Top
Fig11.CombustionChamberComponents
Fig10.BaffleArrangement
TopBaffle
Nibsatfront
45°Chamfer
45°Chamfer
45°Chamfer
Note!Numbersetchedontobafflesmustbe
incorrectorientationwhenassembled.
theinnerfrontoftheboiler.Thereshouldbeagapat
thebackofapprox.25mm,andequalgapsatthe
sides.Thebottombaffle(No.1)isnowcarefully
loweredintoposition,sothattheguidesonits
undersideholdtheinsulationpanelsinplace.When
assembledtheNo1shouldbeclearlyvisible,theright
wayup.Theremainingbaffles(Nos.2-4)are
assembledinorder,withthenumbersfacingthefront
ofthestoveasshowninFig10.Theaccessdoorisnow
re-fitted.Ensurethattherubbersealispushedfully
hometotheframe,andthatthe4brassnutsare
tightenedevenly.
Onceallwater,oilandelectricalconnectionshavebeen
madeandtestedtheinstallationcanbefinished.Fit
glassfibreinsulationmaterialaroundtheboilerandflue
inthebuildersopening.Thiswillbothhelppreventheat
lossandreducenoisetransmission.Fitthefire
surround.
FINISHINGTHEINSTALLATION
WARNING
Oncetheinstallationiscompleteensurethattheair
controlissetatmaximum(No.10)beforethe
burnerisfired(seeFig.8.)Otherwisesootingmay
occur.Thiswillbere-adjustedduringcommissioning.
Page11
OLXV5.205.04

FlueFixingBrackets
AirInlet
Connection
Fig.12.AirInletand
FlueFixings
COMMISSIONING
Theburnersarepre-setatthefactory,butmustbe
fine-tunedoncompletionoftheinstallation.Thisisa
conditionoftheguarantee.
Beforefiringtheboilercheckthatthebafflesandblast
chambercomponentsarefittedinthecorrectpositions
asdescribedaboveandshowninFigs.10&11.
Ensurethattheheatingsystemisconnectedandfilled
withwaterbeforeattemptingtofiretheboiler.
Tosettheoilpressureandtheairsettingitisnecessary
toremovetheinnerbottomplate.Isolatefromthe
mainssupply,openthedoorsandliftupandremove
thebottomplate.SeeFig2.Liftoffthecoals,thefence
andthecoaleffect.Loosenthefixingscrewateachside
oftheinnerplate,slideoutwardsintotheslot,andlift
offtheinnerbottomplate.Accesstotheboiler
samplingpointisbehindtheflameeffect.Togainaccess
liftthePerspexpaneloutoftheflameeffectandundo
thetwowingnutsonthebackpanel.Unplugthemains
cablefromthebottomoftheflameeffect,whichmay
thenbeliftedclear.Theboilersamplingpointisatthe
topoftheaccessdoor,usea5mmallenkeytoremove
theblankingscrew.Settheaircontrolfullyopen(No.
10)beforetheinitialfiring.Theelectricalpowermaybe
turnedbackontotesttheburner.
TheburnercomponentsareshowninFig.8.
Turnonthesupplytotheprogrammer,setthe
programmertogiveheatingandhotwaterandturnthe
thermostattoMed.Afterafewsecondsyoushould
heartheburnerignite.Ifnecessarybleedthepump.
RefertoFig.9.Fitthepieceof4mmplastichose
providedontothebleedport,placetheendofthehose
intoasuitablereceptacleandopenthebleedscrew
takingcarenottospillanyoil.Whenbleedingthe
pumpwillbequitenoisy.Oncealloftheairisoutof
thesystemclosethebleedscrewandremovethehose.
Takecaretomopupanydropsofoilspilt.
365 170 548
261
250
520
547 255
654
(693with
optional
fanheater)
394 62
ø130
CharnwoodOLXOverallDimensions
(alldimensionsareinmm)
Boilertappingsare1”BSPFemale,
2eachside
Page12
OLXV5.205.04

Writethedateontheflexibleoillinelabel.The
flexibleoillineMUSTbereplacedevery2years.
Allowthefiretorunfor20-30minutesbeforechecking
thesootandCO2readings.Thesamplingpointison
theboileraccessdoor.Theaircontrolissituatedonthe
frontoftheblackrubberairmanifoldwhichistowards
therightoftheburner,asshowninFig.8.Initiallysetto
No.10,theburnerwillbeburningwithexcessairand
withtheoilpressuresetatamid-rangesetting.Fita
pressuregaugetothepressuregaugeportshownin
Fig.8andadjusttotherequiredsetting(100-140psi.)
Afteradjustingthepumppressureallowthefiretorun
forapproximately10minutesbeforecheckingthe
smokereading.Reducetheairinletbyslackeningthe
nutinthecentreofthemanifold,movingthepointer
clockwisetoalowernotchandre-tighteningthenut.
Whensootoccurs,graduallyincreaseittogive
combustionfreeofsoot.(10=maxair,1=minair).
Thisshouldgive11–12%CO2and0-1Smokewitha
fluetemperatureofapproximately180°Cabove
ambient.Measurementstakenattheboileraccessdoor
willgiveaslightlyhighertemperature(approx.220°C
aboveambient)thanreadingstakenactuallyintheflue.
Amodernburnerworkswith lessexcessairandoften
alsowithsmallernozzlesthanoldermodels.This
increasestheefficiencybutalsotheriskof
condensationinthechimney.Theriskincreasesifthe
areaofthechimneyflueistoolarge.Thetemperature
ofthefluegasesshouldexceed60°Cmeasured0.5
metresfromthechimneytop.Ifnecessarysomeofthe
followingmeasuresmaybetakentoraisethechimney
temperature:
Insulatethechimneyincoldattics.
Installachimneyliner.
Installadraughtregulator(dilutesthefluegasesduring
operationanddriesthemupduringstandstill).
Increasetheoilquantity.
Raisethefluegastemperaturebyremovingsomeof
thebaffleplatesintheboiler.
Re-fittheElectricFlameeffectandcheckitsoperation.
Theflamepatternmaytakeafewminutestobecome
established,particularlywhenthefireisswitchedonfor
thefirsttime.Arrangethecoalssuppliedwiththe
applianceontopofthefibreglasscoaleffecttoproduce
abeautifulfire.
Advisethecustomerontheuseoftheboiler,andthe
systemcontrols.Alsoadviseoftheneedforannual
servicingoftheboilerbyanOFTECtrained&
registeredtechnician.LeavetheseOperatingand
InstallationInstructionswiththecustomer.
Page13
OLXV5.205.04

Page14
OLXV5.205.04
Max.AllowableOperatingTemperature95°C
Max.AllowableOperatingPressure3bar(PressureClass2)
TestPressure4.5bar
HeatOutputRange11-13kW
HeatInputatRatedOutput15kW
OilPumpPressure110-140psi
RequiredFlueDraught0.07inHO(0.17mbar)
ExitFlueGasTemp205°C
ExitFlueGasMassFlow……kg/s
ExitFlueConnectionDiameter130mmsockettotake125mm(5in)or
100mm(4in)pipe
AirInletDiameter55mmsockettotake50mm(2in)pipe
Max.RecommendedAirPipeLength10M+4x90°SweptBends
Water-sideResistance
RangeofTemperatureControl40-90°C
SafetyThermostatTemperature 110°C
FuelTypeUsedKerosene28second
BoilerTypeOn/OffType
BoilerTappingsize1inBSPFemale
ElectricalProtectionIP20
EarthingTerminalCopperFlashedSteel
ElectricalSupply240v50Hz
ElectricalPowerInput@240vac(standard)200Watts
(withfanheater)2200watts
FuseinFlameEffect250v2Ax20mm
FusesRequiredinPowerSupply
FlameEffectonly3A240V
FlameEffect+FanHeater10A240V
Burner3A240V
FireValveOperatingTemperature90°C
BoilerWaterVolume23.4Litres
TotalWeightofStove140Kg
2
4.1mbar@DT=10°C
@flowrate2.9litres/min1.5mbar@DT=20°C
OLXBoiler-Specifications

Page15
OLXV5.205.04
E
L
N
MainsInput
fromTimer
SwitchedLive.
MainsInput
FusedSpur.
E
L
NFlameEffect
E
L
N
FlameEffect
IECFused
ChassisPlugin
Skt2
E
N
L
IECLead
Burner
Skt4
ThermostatMountingBox
E
L
N
Skt1
E
N
L
IECChassis
Skt3
OutletSocket Plugto
Fusedat3Amp.
DualActing
Thermostat
TS1
IECLeadSocketto
from13Amp
N
E
FanHeater
Optional
FlameEffect
RotarySwitchSW1
L1
L2
TypeRPSBC20M90
SocketTo
Plug
FanHeater
BurnerControl
P
SatronicControlTerminals
Fan
1ampantisurgefuse
Ballast
FluorescentLight
11 12
21
31 32
22
TR TB
P1 3
2
1
Brown
Black
Blue
Green/
Yellow
WireColours
fromFanHeater
2+
(2+)
(1+) 1+
(1-) 1-
(2-) 2-
Diode
IgnitionUnit
SolenoidValve
(Oil)
Oil
Pump
AirPressure
Switch
123456789
Photocell
ABCN N N S2
10
Fan
CharnwoodOLX
WiringDiagram
AboveSerialNo.1562

CharnwoodOLX
ElectrodeSettings
Alldimensionsareinmm
9.0±1.0
3.0±0.20.5±0.5
Page16
OLXV5.205.04

Page17
OLXV5.205.04
ItemPartNo.DescriptionItemPartNo.Description
3*008/KV35SDoorSealSetInc.Adhesive38004/TV03AccessDoor
4006/KV18GlassInc.GlassChannel39004/TV25ThermostatMountingBox
5*008/TV95GlassSeal(Neoprene)40004/TV33ThermostatPhialClampingPlate
6004/KV23GlassRetainer41008/TV17InnerFrontInsulation
7002/TV07FrontFirebar42010/TV14InnerFrontPlate
8008/KV16R.H.DoorHandle43010/TV43InnerFrontPlateFixingBracket
9002/KV14DoorCatchCam44008/TV86AirInletGasket
10008/KV13L.H.DoorKnob45008/TV49AirInletManifold
11008/TV19ThermostatKnob46010/TV84/1AirInletSideCover
12008/TV20FlameEffectKnob47a010/TV108AirControl-LocationDisk
13008/BW39/SHingePinSet(4perset)47b010/TV109AirControl-Pointer
14008/TV80FluorescentLamp47c010/TV110AirControl-Adjuster
15008/TV78AmberLampSleeve48010/TV42SFlueFixingBracket(setof3)
16040/TV69ResetButtonExtension49011/PV27BackCeramicGasket
17008/TV09AccessDoorInsulation50040/TV77ServiceValve&Elbow
18008/TV22Thermostat51040/TV94BurnerMountingFlange
19008/TV24FlameEffectRotarySwitch52M12HalfNuts
20008/TV27HingePost53005/TV06/##LowerTopPanel-forFanHeater
21a011/TV106BlastChamberInsulationBoardSet54008/TV111FanHeater
23a010/TV31Baffle-No.1
24a010/TV47ABaffle-No.2.
24b010/TV47BBaffleNo.3
25a010/TV48ABaffle-No.4
26008/TV13FibreglassCoalEffect
27003/TV01/##L.H.Door
28003/TV02/##R.H.Door
29005/TV04/##L.H.SidePanel
30005/TV05/##R.H.SidePanel
31005/KV06/##LowerHoodPanel
32005/KV09/##TopHoodPanel
33005/TV16/##BottomPanel
34008/TV11FlameEffectCartridge
35008/TV15OilBurner
36001/TV10BFirebox/Boiler(OLX)
37004/KV50PanelFixingBracket
*Theseitemsarenotshownonthedrawing
##Pleasespecifycolourwhenordering
55010/TV137ControlBoxOffsetBracket
Toobtainsparepartspleasecontactyourlocalstockist
givingModel,PartnumberandDescription.Incaseof
difficultycontactthemanufacturerattheaddressshown.
ThisdrawingisforIdentificationpurposesonly.
CHARNWOOD BishopsWay,Newport,IsleofWightPO305WS,UnitedKingdom
T:[phone]F:[phone][email protected]kwww.charnwood.com
IssueC CharnwoodOLXMk.2
PartsList
8289
102713204
6
33
42
41
7
43
50
55
35
51
16
45 44
46
37
30
40
32
31
48
36
391819
29
12
11
38 49
34 14
26
15
52
21a
21a
21a
21a
23a
24a
24b
25a
47a47b 47c
53
54
17
Mk.3ReplacementBurnersfor
appliancesbeforeSerialNo.
45****1562requirebracket
toaligncontrolboxwithre-set
hole.
NOTE!

Page18
OLXV5.205.04
CHARNWOOD BishopsWay,Newport,IsleofWightPO305WS,UnitedKingdom
T:[phone]F:[phone][email protected]kwww.charnwood.com
IssueA
Toobtainsparepartspleasecontactyourlocal
stockistgivingModel,PartnumberandDescription.
Incaseofdifficultycontactthemanufactureratthe
addressshown.
Thisdrawingisforidentificationpurposesonly.
ItemPartNo.DescriptionItemPartNo.Description
1 040/TV61 Nozzle-0.4 80°EH38 040/TV124 SolenoidValve
2 040/TV154 ElectrodeMountingBlock39 040/TV123 SolenoidPlug&Lead
3 040/TV153 Electrode40 040/TV161 BurnerMountingFlange
4 040/TV140 NozzleHolder41 040/TV162 MountingFlangeGasket
5 040/TV155 NozzleHolderCoverPlate42 Electrodefixingscrew
6 040/TV141 Al.Washer
7 040/TV143 BanjoUnion
8 040/TV142 FibreWasher
9 040/TV144 BanjoBolt
10 040/TV160 FlexibleOil Line
11 040/TV63 BlastTube Seal
12 040/TV112 Photocell Plug-inType
13 040/TV113 SolenoidCoil Plug-inType
14 040/TV164 BlastTube
15 040/TV151 AirGuideinBlastTube
16 040/TV28 BurnerChassisPlate
17 040/TV74 FanMotor&Impeller
18 040/TV92 PumpMountingBracket
19 040/TV72 Oil Pump
20 040/TV71 IgnitionUnit
21 040/TV75 ControlBox
22 040/TV54/AFanMountingRing
23 040/TV158 Photocell Plug&Cable
24 040/TV159 Photocell Holder
25 040/TV68 AirPressure Switch
26 040/TV148 GaugePortElbow
27 040/TV149 GaugePortPlug
28 040/TV150 Oil TConnector
29 040/TV69 ResetButton Extension
30 040/TV152 BlastTubeMountingFlange
31 040/TV146 Oil Pipe(PumptoSol.Valve)
33 040/TV145 Oil Pipe(Sol.ValvetoNozzle)
34 040/TV15~1BurnerCasting
35 040/TV163 FanWasher
37 040/TV147 Oil Elbow8/10mm male/male
TheseItemsshownRotated
315
30
4
2
1
14
11
41
40
42
17 23 12 24 534 6735 8
22
9
25
29
21
40
33
13
38
37
10
19
31
18
28
26
27
16
20
CharnwoodOLXBurnerMk.3
PartsList