GAH S40/65 User manual

1
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
1 USER INFORMA1 USER INFORMA
1 USER INFORMA1 USER INFORMA
1 USER INFORMATIONTION
TIONTION
TION
2 OPERA2 OPERA
2 OPERA2 OPERA
2 OPERATOR CONTROLSTOR CONTROLS
TOR CONTROLSTOR CONTROLS
TOR CONTROLS
3 BOILER OPERA3 BOILER OPERA
3 BOILER OPERA3 BOILER OPERA
3 BOILER OPERATIONTION
TIONTION
TION
4 INST4 INST
4 INST4 INST
4 INSTALLAALLA
ALLAALLA
ALLATION GENERALTION GENERAL
TION GENERALTION GENERAL
TION GENERAL
5 INST5 INST
5 INST5 INST
5 INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
6 INST6 INST
6 INST6 INST
6 INSTALLAALLA
ALLAALLA
ALLATIONTION
TIONTION
TION
7 OIL SUPPL7 OIL SUPPL
7 OIL SUPPL7 OIL SUPPL
7 OIL SUPPLYY
YY
Y
8 CONVENTIONAL FL8 CONVENTIONAL FL
8 CONVENTIONAL FL8 CONVENTIONAL FL
8 CONVENTIONAL FLUEUE
UEUE
UE
9 BALANCED FL9 BALANCED FL
9 BALANCED FL9 BALANCED FL
9 BALANCED FLUEUE
UEUE
UE
10 COMMISSIONING10 COMMISSIONING
10 COMMISSIONING10 COMMISSIONING
10 COMMISSIONING
11 SERVICING11 SERVICING
11 SERVICING11 SERVICING
11 SERVICING
12 F12 F
12 F12 F
12 FAULAUL
AULAUL
AULT FINDINGT FINDING
T FINDINGT FINDING
T FINDING
13 TECHNICAL13 TECHNICAL
13 TECHNICAL13 TECHNICAL
13 TECHNICAL
INFORMAINFORMA
INFORMAINFORMA
INFORMATIONTION
TIONTION
TION
APPENDIXAPPENDIX
APPENDIXAPPENDIX
APPENDIX
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
Section 1 User InformationSection 1 User Information
Section 1 User InformationSection 1 User Information
Section 1 User Information
1-1 Installer ---------------------------------------------------------- 2
1-2 Householders Information --------------------------------------- 2
1-3 Service History -------------------------------------------------- 2
1-4 Boilers covered by this manual ---------------------------------- 3
Section 2 Operator ContrSection 2 Operator Contr
Section 2 Operator ContrSection 2 Operator Contr
Section 2 Operator Controlsols
olsols
ols
2-1 Control Panel - Select and Combistream ------------------------ 4
2-2 Control Panel - Option ------------------------------------------- 6
2-3 Combi Thermostatic Mixing valve ------------------------------- 7
2-4 Combi &Expansion Relief --------------------------------------- 7
Section 3 Boiler OperationSection 3 Boiler Operation
Section 3 Boiler OperationSection 3 Boiler Operation
Section 3 Boiler Operation
3-1 Switching the Boiler ON ----------------------------------------- 8
3-2 Switching the Boiler OFF ---------------------------------------- 8
3-3 Burner ‘Lockout’ ------------------------------------------------- 8
3-4 Care of the Boiler ------------------------------------------------ 9
Section 4 Installation GeneralSection 4 Installation General
Section 4 Installation GeneralSection 4 Installation General
Section 4 Installation General
4-1 Compliance --------------------------------------------------- 10
4-2 Siting and Positioning the Boiler ------------------------------ 10
Section 5 InstallationSection 5 Installation
Section 5 InstallationSection 5 Installation
Section 5 Installation
5-1 Select and Option Internal Floor Standing --------------------- 11
5-2 Select Internal Wall Mounted ---------------------------------- 12
5-3 Select External Wall Mounted --------------------------------- 14
5-4 Select Free Standing External ---------------------------------- 16
5-5 Option Floor Standing System Boiler - ------------------------ 18
Section 6 Installation CombistrSection 6 Installation Combistr
Section 6 Installation CombistrSection 6 Installation Combistr
Section 6 Installation Combistream and Combi 65eam and Combi 65
eam and Combi 65eam and Combi 65
eam and Combi 65
6-1 Combistream System and Combi 65 -------------------------- 21
6-2 Combistream System and Combi 65 Components ------------ 23
6-3 Combistream and Cobi 65 Connections to the Boiler ---------- 26
Section 7 Oil SupplySection 7 Oil Supply
Section 7 Oil SupplySection 7 Oil Supply
Section 7 Oil Supply
7-1 Oil Storage Tanks ---------------------------------------------- 28
7-2 Oil System----------------------------------------------------- 28
7-3 Oil Supply System --------------------------------------------- 29
Section 8 Conventional FlueSection 8 Conventional Flue
Section 8 Conventional FlueSection 8 Conventional Flue
Section 8 Conventional Flue
8-1 Conventional Flue --------------------------------------------- 31
Section 9 Balanced FlueSection 9 Balanced Flue
Section 9 Balanced FlueSection 9 Balanced Flue
Section 9 Balanced Flue
9-1 Balanced Flue Selection --------------------------------------- 32
9-2 Suggested Flue Siting ----------------------------------------- 33
9-3 Burner Air Supply---------------------------------------------- 34
Section 10 CommissioningSection 10 Commissioning
Section 10 CommissioningSection 10 Commissioning
Section 10 Commissioning
10-1 Commissioning Checks --------------------------------------- 35
10-2 Extra Procedures for System Boilers --------------------------- 36
10-3 Extra Procedures for Combi Boilers ---------------------------- 36
10-4 Combustion Tests --------------------------------------------- 37
10-5 Handing Over -------------------------------------------------- 37
Section 11 ServicingSection 11 Servicing
Section 11 ServicingSection 11 Servicing
Section 11 Servicing
11-1 Routine Service ------------------------------------------------ 38
11-2 Extra Procedure for System Boilers ---------------------------- 38
11-3 Extra Procedure for Combi Boilers ----------------------------- 39
11-4 Baffle Positions ------------------------------------------------ 39
Section 12 Fault FindingSection 12 Fault Finding
Section 12 Fault FindingSection 12 Fault Finding
Section 12 Fault Finding
12-1 Householders Fault Finding ----------------------------------- 41
12-2 Householders Fault Finding - System Boilers ----------------- 41
12-3 Householders Fault Finding - Combi Boilers ------------------ 41
12-4 Engineers Fault Finding --------------------------------------- 42
12-5 Engineers Fault Finding - System Boilers --------------------- 43
12-6 Engineers Fault Finding - Combistream Boilers --------------- 43
Section 13 TT
TT
Technical Informationechnical Information
echnical Informationechnical Information
echnical Information
13-1 Boiler Specifications ------------------------------------------ 44
13-2 Boiler Output Options ------------------------------------------ 45
13-3 Burner Setting Data -------------------------------------------- 45
13-4 Burner Settings ------------------------------------------------ 47
13-5 Panel Wiring Diagrams ---------------------------------------- 49
13-6 Parts Supplied with Boiler ------------------------------------- 52
13-7 Boiler Dimensions --------------------------------------------- 54
13-8 Balanced Flue Dimensions ------------------------------------ 59
AppendixAppendix
AppendixAppendix
Appendix
AP1 Regulations ---------------------------------------------------- BC
COMBISTREAMCOMBISTREAM
COMBISTREAMCOMBISTREAM
COMBISTREAM
COMBI 65COMBI 65
COMBI 65COMBI 65
COMBI 65

2
Boiler Installed by:-
Tel:
Fax:
email:
The type of fuel required for the Boiler is
Tank Capacity
Oil Suppliers
✍
✍
To the householder.
Thank you for purchasing a Thermecon
Oil Fired Boiler.
In the unlikely event of a problem arising
with the Boiler please first refer to:-
Page 41 section 12 ‘Householders Fault
Finding’ of this Manual.
If you cannot rectify the problem from
the information given, or if the problem
persists contact the INSTALLER who will
assess the problem and if necessary
contact our service department.
yBetaD
ecivreStxeN
ybeud
setoN
dellatsnI A/N
denoissimmoC
ecivreS
ecivreS
ecivreS
ecivreS
ecivreS
ecivreS
ecivreS
1-1 Installer
1-2 Householders Information
1-3 Service History
Note
The price of fuel has seasonal fluctuations and
varies from supplier to supplier. You are
advised to shop around for a good deal.
USER INFORMAUSER INFORMA
USER INFORMAUSER INFORMA
USER INFORMATION 1TION 1
TION 1TION 1
TION 1
DO NOT involve a third party that may incur you costs as this will not be covered by the Boiler Guarantee.
Any work not authorised by GAH (HEATING PRODUCTS) LTD. may also invalidate the Guarantee.
Work carried out and parts fitted by unauthorised engineers cannot be guaranteed.
Boiler Commissioned by:-
Tel:
Fax:
email:
Boiler Service Engineer
☎
☎
☎
☎
☎☎
11
11
1
It is a condition of the Guarantee that the Boiler is serviced every 12 months.

3
Select Floor Standing
Model S40/65 S60/80 S80/95 S90/120
Btu/hr x 1000 40 to 65 60 to 80 80 to 95 90 to 120
kW 11.7 to 19.1 17.6 to 23.5 23.5 to 27.6 26.4 to 34.9
Model S100/150 S140/190 S190/240 S240/270
Btu/hr x 1000 100 to 150 140 to 190 190 to 240 240 to 270
kW 29.3 to 44.0 41.0 to 55.7 55.7 to 70.3 70.3 to 79.1
Option Floor Standing
Model O40/65 O60/80 O80/95 O90/120
Btu/hr x 1000 40 to 65 60 to 80 80 to 95 90 to 120
kW 11.7 to 19.1 17.6 to 23.5 23.5 to 27.6 26.4 to 34.9
✍
Model O100/150 O140/190 O190/240 O240/270
Btu/hr x 1000 100 to 150 140 to 190 190 to 240 240 to 270
kW 29.3 to 44.0 41.0 to 55.7 55.7 to 70.3 70.3 to 79.1
✍
Option Floor Standing System
Model OS60/80 OS80/95 OS90/120 OS100/150
Btu/hr x 1000 60 to 80 80 to 95 90 to 120 100 to 150
kW 17.6 to 23.5 23.5 to 27.6 26.4 to 34.9 29.3 to 44.0
✍
Combistream & Combi 65I Combi 65E
Model C40/65 Model C40/65E
Btu/hr x 1000 40 to 65 Btu/hr x 1000 40 to 65
kW 11.7 to 19.1 kW 11.7 to 19.1
✍ ✍
Select Wall Mounted Internal
Model W40/50I W50/80I
Btu/hr x 1000 40 to 50 50 to 80
kW 11.7 to 14.7 14.7 to 23.4
✍
Select Wall Mounted External
Model W40/50E W50/80E
Btu/hr x 1000 40 to 50 50 to 80
kW 11.7 to 14.7 14.7 to 23.4
✍
Select Free Standing External
Model F40/50E F50/80E
Btu/hr x 1000 40 to 50 50 to 80
kW 11.7 to 14.7 14.7 to 23.4
✍
USER INFORMAUSER INFORMA
USER INFORMAUSER INFORMA
USER INFORMATION 1TION 1
TION 1TION 1
TION 1
1-4 Boilers covered by this manual
My Boiler
✔ Tick box Wiring
Diagram
QUICK REFERENCE
Dimensions Oil
Connection
Page 49 Page 54 Page 11
Page 49 Page 54 Page 11
Page 49 Page 54 Page 11
Page 49 Page 54 Page 11
Page 49 Page 54 Page 11
Page 51 Page 58 Page 11
Page 49 Page 55 Page 14
Page 50 Page 56 Page 16
Page 50 Page 57 Page 17
11
11
1
Combistream
only

4
90
70
55
HEATING LIMIT
HEATINGHOT WATER
HW LIMIT
2-1.1 Boiler Thermostat Control
The Boiler Thermostat Control is used to control the temperature of the water within the
Boiler Water Chamber.
The heat sensor phial of the Thermostat is on the end of a capillary tube and placed in
one of the tubes on top of the Boiler waterway.
The Thermostat control has a ‘STOP’ position to switch the Boiler OFF.
The temperature range of the control is 55°C to 90°C.
The recommended settings of the Boiler Thermostat control are:-
1. Winter Heating and Hot Water 80°C.
2. Summer Hot Water only 65°C.
A setting below 60°C can, on some heating systems, induce corrosion and reduce the life
of the Boiler.
2-1 Control Panel - Select, Combistream and Combi 65
Select and Internal Wall
Fig. 2-1a Control Panels
HIGH LIMIT
THERMOSTAT
MANUAL RESET
(OPTIONAL)
HINGED FLAP HELD CLOSED BY A
PUSH OPEN - PUSH SHUT MAGNET
HIGH LIMIT THERMOSTAT
MANUAL RESET (OPTIONAL)
SEAL
OPEN
DOOR KNOB
HIGH LIMIT THERMOSTAT
MANUAL RESET (OPTIONAL)
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
Wall Mounted External & Free Standing External
Combistream and Combi 65 Internal
22
22
2
HEATING
HEATING
LIMIT
HW LIMIT
HOT WATER
Combi 65 External

5
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
MAINS
RED
LOCKOUT
RED
RED
LIMIT
2-1.2 Mains Switch
O = Off I = On
The Mains Switch switches the Boiler ON and OFF. When power to the Boiler is ON and
the Mains Switch is ON the Mains Indicator Lamp will be lit.
2-1.3 Mains Indicator Lamp
The Mains Indicator Lamp will be lit when the Boiler Mains Switch is ON and the heating
system control is calling for heat.
If the Lamp does not illuminate refer to Section 12 Fault Finding.
2-1.4 Lockout Indicator Lamp
When the Lockout Indicator Lamp is illuminated, it indicates that a Burner ‘Lockout’ has
occurred and the Boiler is not operational.
Refer to 3-3 to restart Boiler.
2-1.5 Limit Indicator Lamp
The Limit Indicator Lamp is illuminated when the water within the Boiler is overheated i.e.
the High Limit Thermostat of the Boiler control is tripped.
Standard High Limit Thermostat with automatic reset
When the Limit Lamp is lit (High Limit Thermostat tripped), the Boiler shuts down until
the water temperature falls to a satisfactory level (5°C below High Limit Thermostat
setting). The High Limit Thermostat then resets automatically and normal operation
should follow.
2-1.6 Manual Limit Reset Button (Option)
A High Limit Thermostat with an integral Manual Reset button is normally fitted to System
Boilers and Combistream Boilers. Boilers fitted with ‘Manual Reset’ High Limit
Thermostats will not restart automatically after overheating has occurred.
The Limit Indicator Lamp is OFF when the Boiler is operating normally.
If the Lamp is ON the water within the Boiler is or has overheated i.e. the High Limit
Thermostat of the Boiler control is tripped.
When the Limit Lamp is ON (High Limit Thermostat tripped) the Boiler shuts down.
When the water temperature falls to a satisfactory level (5°C below High Limit Thermostat
setting), the Manual Reset button should be pressed - this will restart the Boiler.
If overheating occurs check that the Boiler Heating Thermostat control is set below 80°C
- see 2-1.1 If it still occurs more than occasionally, consult your installation engineer as
there may be a fault within the system.
The following items are for Combistream and Combi 65 only.
2-1.7 Hot Water Thermostat Control
With Manual Reset
The Hot Water Thermostat Control is used to set the temperature of the hot water from the
Combistream to the hot water taps. The heat sensor phial of the Thermostat is on the end
of a capillary tube and placed in a recess in the hot water storage cylinder.
The temperature range of the control is 30°C to 70°C. The recommended setting control
is 70°C.
The temperature of the hot water at the taps is controled by the Thermostatic Mixing Valve
see 2-3.
Installer tick if applicable
Installer tick if applicable
RED
LIMIT
Note
On Combistream Boilers It may also be
necessary to press the Hot Water manual
reset - see 2-1.8.
HOT WATER
22
22
2

6
TO REMOVE PLUG PRESS SMALL SCREWDRIVER
THROUGH HOLE IN REAR OF PLUG
2-2 Control Panel - Option
2-2.1 Boiler Thermostat Control
The Boiler Thermostat Control is used to control the temperature of the water within the
Boiler Water Chamber.
The temperature range of the control is 60°C to 90°C. The recommended settings of the
Boiler Thermostat control are:-
Winter Heater and Hot Water 80°C - Summer Hot Water only 65°C.
A setting of 60°C or below is not recommended as this can induce corrosion and reduce
the life of the Boiler.
2-2.2 High Limit Thermostat with Manual Reset
A High Limit Thermostat with an integral Manual Reset button is fitted as standard to
Option Boilers.
Boilers fitted with Manual Reset High Limit Thermostats will not restart automatically
after overheating has occurred.
The High Limit Thermostat will trip and shut the Boiler down when the water within the
Boiler is overheated.
When the water temperature falls to a satisfactory level (10°C below High Limit
Thermostat setting), the Manual Reset button (protected by a removable plastic cap)
should be pressed - this will restart the Boiler.
If overheating occurs more than occasionally, consult your installation engineer as there
may be a fault within the system.
C
90
75
60
THERMOSTAT CONTROL
Fig. 2-2a Option Control Panel with
Manual Reset
HIGH LIMIT
THERMOSTAT
MANUAL RESET
2-1.8 Hot Water High Limit Thermostat
With Manual Reset
A Hot Water High Limit Thermostat with an integral Manual Reset button is fitted to the
Boiler.
When the Hot Water High Limit Thermostat has tripped the Boiler shuts down and will not
restart automatically. The Limit lamp (2-1.6) will not be on as this is only for the Heating
High Limit.
To reset after hot water overheating has occurred, allow time for the water to cool, or run
off some hot water, then remove the plastic cap and press the HW Limit manual reset
button.
If overheating of the hot water occurs, turn down the Hot Water Control - see 2-1.7. If it
still occurs consult your installation engineer as there may be a fault within the system.
The following items are for all External Boilers only.
2-1.9 Mains Plug
The Mains Plug connects power to the Boiler.
The plug must be IN for the Boiler’s Frost Protection to function.
2-1.10 Normal/Override
The Normal/Override switch allows for the household heating control circuitry to be
overridden by switching to the permanent live.
The switch is intended for use by service engineers to allow operation of the Boiler
without the necessity of entering the household.
The switch should be set at NORMAL (O) at all other times.
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
HOT WATER
HW LIMIT
Note
It may also be necessary to press the
Heating Limit manual reset - see 2-1.6.
NORMAL
OVERRID
E
Note
Boilers fitted with Manual Reset are
suitable for Sealed Systems.
22
22
2

7
OPERAOPERA
OPERAOPERA
OPERATOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2TOR CONTROLS 2
TOR CONTROLS 2
2-4 Combistream and Combi 65 Expansion Relief
2-4.1 Tundish
The Combi boiler’s hot water system has two TPR valves, one for the hot water storage
cylinder and one for the incoming cold supply. In the event of pressure within the hot
water or incoming cold supply becoming too high, either of the TPR valves will vent.
A Tundish should be fitted and located in the same space or compartment as the hot
water storage cylinder. This device provides an air break when pressure is being vented.
When pressure is being vented water/steam will be evident at the Tundish and from the
discharge pipe of the Tundish.
Cold water will normally only discharge when there is an increase in pressure caused by
loss of air pressure in the Accumulator.
In the event of water/steam being seen at the discharge pipe or Tundish, do the
following:-
1. Turn ON a hot and cold tap to relieve the pressure.
2. Turn OFF the Heating System.
3. Investigate possible cause for high pressure e.g.:-
i Hot Water Thermostat Control is set too high.
ii Mains water is not on or fully on.
iii Restriction in hot water pipework.
iv Loss of air pressure in the Accumulator.
4. Contact the installer before restarting the system.
2-4.2 Heating TPR Valve
Combi boilers have a Heating TPR valve mounted on top of the Heat Exchanger and
discharging to the rear of the Boiler. In the event of the pressure within the heating
system becoming too high the TPR valves will vent.
In the event of water/steam being seen at the discharge pipe or Tundish, do the
following:-
1. Check that the radiators are turned on, the heating system should never be operated
with all radiators OFF.
If all radiators are fitted with thermostatic valves, these can all be in a shut condition
if the temperature in the dwelling is sufficient. In this circumstance the heating
system should have a bypass that should be open - see 6-1.3.
2. Turn OFF the Heating System.
3. Investigate possible cause for high pressure e.g.:-
i Boiler Thermostat Control is set too high.
ii Air in the system.
4. Contact the installer before restarting the system.
Fig. 2-4a Tundish
AIR BREAK
DISCHARGE PIPE
Note
Either the Tundish or discharge pipe must
remain in view, do not box in or cover up.
Note
For more information see 6-2.12.
2-3 Combistream and Combi 65 Thermostatic Mixing Valve
The Mixing Valve will be positioned outside the Boiler case and may be in a different
location than the Boiler. This valve mixes hot water from the Boiler with cold water to
provide hot water of a constant temperature at the taps.
The recommended maximum hot water temperature at the taps is 65ºC.
The recommended setting of the valve is between No.4 and 7 (49º to 63ºC).
The Mixing Valve is factory set to the following approximate mixed outlet temperatures:-
Knob Position Min 1 2 3 4567Max
Output Temp. ºC 27º 32º 38º 44º 49º 53º 58º 63º 67º
Fig. 2-3a Combistream Mixing Valve
22
22
2
0
1
2
3
4
5
6
0
20
40
60
80
bar psi

8
3-3 Burner ‘Lockout’
The Burner has its own Control System that synchronises the Burner ignition sequences.
The safety system of the Burner includes a flame detector (photoresistor) which senses
the light of the flame.
In the event of a failure of the flame, the Burner Control goes through a re-ignition
sequence. If the flame is not evident within 15 seconds, the Burner shuts down due to
its lockout circuit being energised.
The Reset Lamp in the Burner Reset button and the *Lockout Lamp on the Boiler Control
Panel illuminate to indicate that ‘lockout’ has occurred.
BOILER OPERABOILER OPERA
BOILER OPERABOILER OPERA
BOILER OPERATION 3TION 3
TION 3TION 3
TION 3
3-1 Switching the Boiler ON
Select and Combi
1. Turn fuel supply on.
2. Switch power supply to the
Boiler ON.
3. Switch Mains Switch of the
Boiler Control Panel ON.
4. Set Boiler Thermostat Control
to the required setting.
5. Set Central Heating Control
System to ON.
External
1. Turn fuel supply on.
2. Switch power supply to the
Boiler ON.
3. Set Normal/Override switch to
Normal.
4. Set Boiler Thermostat Control
to the required setting.
5. Set Central Heating Control
System to ON.
Option
1. Turn fuel supply on.
2. Switch power supply to the
Boiler ON.
3. Set Boiler Thermostat Control
to the required setting.
4. Set Central Heating Control
System to ON.
To set Boiler for operation:-
3-1.1 Boiler Operation
The Boiler Thermostat switches power to the Burner ON and OFF in response to the
temperature of the water within the Heat Exchanger.
The Burner will automatically fire when the water temperature within the Boiler falls below
the thermostat control setting, and will continue to run until the water temperature rises to
the set °C.
The Burner has its own Control System that gives correct ignition and shut-off sequences
to maintain safe operation.
3-1.2 Automatic Boiler Operation
A fully automatic central heating and hot water installation with its own remote timer and
control system will switch the Boiler ON and OFF as and when heat is required.
Note
The Installer should instruct the user on
operating the central heating system.
3-2 Switching the Boiler OFF
The Boiler can be switched off by any of the following means:-
1. Switch the Mains Switch on the Boiler Control Panel to OFF (not Option or External).
2. Turn the Boiler Thermostat control to STOP.
3. Switch OFF the Mains Switch controlling the Boiler.
4. Set the Central Heating Control System to OFF.
IMPORTANT In the event of abnormal operation:-
1. Switch OFF the Mains Switch controlling the Boiler.
2. Shut OFF fuel supply.
3. Refer to Section 12 Fault Finding.
Note
For frost protection of External Wall
Mounted and External Freestanding
Boilers the mains switch controlling the
Boiler must be ON.
Remember
Switch on the fuel before attempting to
restart the Boiler.
*NOT ON OPTION RANGE.
33
33
3

9
BOILER OPERABOILER OPERA
BOILER OPERABOILER OPERA
BOILER OPERATION 3TION 3
TION 3TION 3
TION 3
Fig. 3-3a Burner Reset Button
In the event of a ‘lockout’, wait 45 seconds and restart the Burner by pressing the Reset
button.
If lockouts are more than occasional, consult your service engineer as there may be a
fault with the fuel supply or Burner.
3-3.1 Restart Boiler after ‘Lockout’
Lockouts indicate a fault in the Boiler operation and can be attributed to:-
1. A fault in the electrical supply i.e. very low voltage.
2. An interruption in the fuel supply.
3. Faulty operation of the Burner or its safety control system.
4. A component failure.
5. A fault in heating system control external to Boiler.
Before attempting to restart the Boiler, remove the front panel of the Boiler and look for
any obvious problems i.e. oil leaks.
Restart Procedure:-
1. Check that there is sufficient oil in the tank and that the supply valves are open.
2. Check that the Boiler thermostat, time switch or programmer and any other system
controls are set to call for heat.
3. Press and release the red glowing plunger Reset button on the Burner control box.
The red light will extinguish and the Burner will commence the start sequence.
After 15 seconds, the Burner should fire normally.
If the Burner does not fire, the lockout symptoms will persist and the Burner control box
Reset button will again glow.
4. Wait at least 45 seconds and press the lockout button on the control box again.
IMPORTANT If the Boiler fails to start on the second attempt then:-
Switch off the Electricity Supply.
Refer to Section 12 Fault Finding.
DO NOT ATTEMPT TO START MORE THAN TWICE.
3-4 Care of the Boiler
3-4.1 All Internal Boilers
Occasionally wipe the casing down with a non-abrasive cleaner and vacuum out dust and
cobwebs from within the casing.
3-4.2 External Wall Mounted Boilers
Occasionally wipe the casing down with a non-abrasive cleaner and vacuum out dust and
cobwebs from within the casing.
Regular application of car polish to the outside of the casing will help protect the paint
finish and prevent algae growth.
3-4.3 Servicing
The Boiler requires regular servicing to ensure continued reliable operation and fuel
economy. Servicing at the stated intervals is a prerequisite of the Boiler Warranty.
A competent engineer should be sought to carry out the servicing at the required
intervals. An OFTEC trained and registered engineer would be a good choice.
SERVICE INTERVAL
FUEL - 28 Second Viscosity Class C Kerosene - Service required once a year.
FUEL - 35 Second Viscosity Class D Heating Oil - Service required twice a year.
33
33
3

10
4-1 Compliance
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION GENERAL 4TION GENERAL 4
TION GENERAL 4TION GENERAL 4
TION GENERAL 4
The Boiler and heating system must be installed to comply with the latest Building
Regulations, British Standards and OFTEC recommendations, refer to the Appendix at the
back of this book.
4-1.1 System Controls
IMPORTANT
It is recommended that the Boiler is installed so that the system controls
prevent the Burner firing unless there is demand for heat from a room or
cylinder thermostat.
When thermally operated or motorised valves are fitted to the system and can stop
adequate flow of water through the Boiler provision MUST be made to
simultaneoussly switch off the electricity supply to the oil burner.
4-2 Siting and Positioning the Boiler
4-2.1 Noise Levels
Quiet operation is a design feature of Thermecon Boilers making them ideal for kitchen
and utility room installations. However, consideration should be given to the noise levels
of the Boiler and the following:-
1. Sound levels must be discussed with the householder as some individuals are
particularly sensitive to even low levels of noise.
2. The type and position of the chimney may affect noise levels.
3. Noise from balanced flues facing neighbouring properties should be considered.
4. Draught stabilisers (when fitted) may affect the noise levels.
5. Sound levels in small rooms may appear more intrusive than the same sound
pressure in a larger room.
6. Some building materials can tend to amplify the sound from Wall Mounted Boilers,
using battens to space the Boiler off the wall may reduce this effect.
4-2.2 The Hearth - Floor Standing
The hearth temperature of Select and Option Boilers is less than 85°C. A suitable level
hearth, which is impervious to kerosine, must be provided.
Where the Boiler is to stand on a floor of combustible material then protection between
the Boiler and the floor should be provided by means of non-combustible material.
The floor must give adequate support to the filled Boiler. Consult the Building
Regulations for safe floor loadings.
4-2.3 Frost Protection
The Boiler and the central heating system must be protected from frost.
External Free Standing Boilers have a frost thermostat fitted as standard, this must be
correctly wired to provide frost protection - see wiring diagrams Section 13.
All Boilers installed in outhouses or where conditions of frost could arise must be
protected by a frost protection arrangement that will fire the Burner when the temperature
falls below 4°C.
A suitable antifreeze must also be used in applications where freezing can occur and
should be considered for all systems.
4-2.4 Rodent Intrusion
Boilers installed in situations where rodent intrusion is possible, all pipe/cable entry
holes of the Boiler must be covered, after installation, to prevent rodents entering the
Boiler casing.
Note
For Boiler Weight see Section 13.
44
44
4

11
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
5-1 Select and Option Internal Floor Standing
5-1.1 Service Access
Boiler Models 40/65, 60/80, 80/95 and 90/120 can have the heat exchanger serviced
from both the front or top of the Boiler. The Burner is serviced from the front.
Boiler Models 100/150, 140/190, 190/240 and 240/270 require top access for servicing
the heat exchanger. The Burner is serviced from the front.
Note
For Boiler dimensions see Section 13.
Fig. 5-1a shows recommended access.
5-1.2 Heating Connections
The flow and return connections may be diagonally opposed to give maximum flow
through the Boiler but this is not essential for satisfactory operation.
If the design of the heating system calls for flow pipes smaller than the Boiler flow
tappings, the reduction of the outlets should be made by using excentric reducing
sockets to ensure that all air can vent from the top of the Boiler waterway.
5-1.3 Connecting Control Panel (refer to wiring diagram)
Select and Option Boilers are despatched with the Control Panel fitted. The phials of the
two thermostats are inserted vertically into the pockets situated on either side on the top
of the Boiler heat exchanger, see fig. 5-1c.
The mains electricity supply, preferably from a spur switched and fused 5 amp socket
should enter the Boiler casing through one of the holes or knockouts provided.
A plug is provided for connection to the mains supply. The plug fits into the mains
connection on the underside of the Control Panel.
Select - The Burner has cable and plug that connects to underside of Control Panel.
Option - The Burner is prewired to the Control Panel.
5-1.4 Oil Connection
All Floor Standing Boilers are supplied with a pump set for single pipe oil system.
750
750
750
750
750
Fig. 5-1a Recommended Access
40/6540/65
40/6540/65
40/65
60/8060/80
60/8060/80
60/80
80/9580/95
80/9580/95
80/95
90/12090/120
90/12090/120
90/120
UNDER
WORKTOP
40/6540/65
40/6540/65
40/65
60/8060/80
60/8060/80
60/80
80/9580/95
80/9580/95
80/95
90/12090/120
90/12090/120
90/120
FRONT
AND/OR
TOP (optional)
ACCESS
100/150,100/150,
100/150,100/150,
100/150,
140/190,140/190,
140/190,140/190,
140/190,
190/240190/240
190/240190/240
190/240
240/270240/270
240/270240/270
240/270
FRONT AND
TOP ACCESS
REQUIRED
Fig. 5-1b Heating Connections
Fig. 5-1c Phial Positions
Fig. 5-1d Oil Connections
FIRE VALVE SENSOR
FIXED ABOVE BURNER
SHUT OFF VALVE
FILTER ✓FIRE VALVE
✓✓
SHUT OFF VALVE ✓
FLEXIBLE OIL PIPE ✓
✓
✓SUPPLIED WITH BOILER - SEE SECTION 13.
55
55
5

12
205 35
45
1 BSP/F
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
5-2 Select Internal Wall Mounted - W40/50I & W50/80I
5-2.1 Service Access
Boilers have a quick release front panel enabling all routine servicing to be carried out
without the necessity of removing any other panels.
A large bolted service door is provided on the front of the heat exchanger giving easy
access to the baffles and combustion chamber.
Note
Before removing side panels study the Burner position and the Boiler wall position and decide on the
best oil pipe configuration, see Section 7.
5-2.2 Heating Connection
The flow and return connections are on top of the Boiler heat exchanger - 1” female BSP.
IMPORTANT
The FLOW connection is on the RIGHT HAND side, the RETURN
connection is on the LEFT HAND side when facing the Boiler from the
front - see fig. 5-2b.
5-2.3 Fixing the Boiler - Suggested Procedure
1. Remove carton.
2. Study the Burner position and the Boiler wall position and decide on the best oil
pipe configuration, see Section 5-2.5 and Section 7.
3. Remove pull-off front panel, top panel and Control Panel.
Unscrew and remove side panels and bottom panel.
4. Remove access door and lift out all baffles from heat exchanger.
5. Remove Boiler body from wood transport blocks - 3 screws, 1 top, 2 bottom.
6. Offer back panel to the position required on the wall and use this as a template to
mark the drilling positions for the 3 mounting rawl bolts ‘R’.
Also mark the positions of any holes required through wall for oil pipes, fire check
valve and electric cable.
7. Remove panel and accurately drill required holes and fit 3 rawl bolts into holes ‘R’.
8. Remove required knockouts ‘K’ from back panel.
For top entry flues ignorFor top entry flues ignor
For top entry flues ignorFor top entry flues ignor
For top entry flues ignore steps 9 to 16 and move onto 17.e steps 9 to 16 and move onto 17.
e steps 9 to 16 and move onto 17.e steps 9 to 16 and move onto 17.
e steps 9 to 16 and move onto 17.
BALANCED FLUE (Rear) MODELS ONLY
Refer to Instruction Sheet supplied in flue kit.
9. Hang back panel onto rawl bolts and mark position for balanced flue.
10. Remove panel and, using a core drill, cut a NEAT hole through the wall for the flue.
11. Fit back panel onto the 3 rawl bolts - do not fit nuts.
12. Check that the hole drilled is in the middle of the square cut-out of the panel and
that the flue terminal passes through the hole.
13. Clear work space and carefully lift the Boiler heat exchanger onto the 3 rawl bolts, fit
nuts (the long nut is for the top bolt). Tighten nuts sufficiently to set rawl bolts in
the wall.
14. Assemble the flue as per instructions supplied with the flue kit.
15. Pass the flue through the drilled hole and connect it to the Boiler with the gasket.
16. Adjust the Boiler for level and tighten the 3 rawl bolt nuts.
TOP FLUE MODELS ONLY
17. Place Back Panel onto the 3 rawl bolts - do not fit nuts.
SERVICE DOOR
W50/80I SHOWN
Fig. 5-2a Service Access
FRONT VIEW
PLAN
Fig. 5-2b Heating Connections
Note
For back panel dimensions, see page 55.
K x 3
K x 3
K
R
RR
Fig. 5-2c Drilling Positions
R - 3 HOLES DRILL 12Ø FOR RAWL BOLTS
K - KNOCKOUT POSITIONS
RETURNRETURN
RETURNRETURN
RETURN FLFL
FLFL
FLOWOW
OWOW
OW
55
55
5

13
18. Clear work space and carefully lift the Boiler heat exchanger onto the 3 rawl bolts, fit
nuts (the long nut is for the top bolt). Tighten nuts sufficiently to set rawl bolts in
the wall.
19. Adjust for level and tighten the 3 rawl bolt nuts.
20. Fit the flue as per instructions supplied with the flue kit.
ALL MODELS
21. Make water connections.
22. Make oil pipe connections, see 5-2.5.
23. Fit side panels, bottom panel and top panel.
24. Fit Control Panel, see 5-2.4.
5-2.4 Connecting Control Panel
Internal Wall Mounted Boilers are despatched with the Control Panel fitted. The phials of
the thermostats are inserted horizontally in the pockets situated in the heat exchanger,
see fig. 5-2e.
The mains electricity supply, preferably from a spur switched and fused 5 amp, should
enter the Boiler casing through one of the holes or knockouts provided - see fig. 5-2c.
The Burner is supplied with a 4 wire cable and plug. The plug fits into the Burner supply
socket on the Control Panel.
A 3 pin plug is provided for connection to the mains supply. This plug fits into the socket
in the rear of the Control Panel.
IMPORTANT
Do not trap phial capillary tubes behind access covers.
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
Note
Use cardboard box to protect worktop.
WW
WW
WARNINGARNING
ARNINGARNING
ARNING
The weight of the Boiler Heat Exchanger
bare is 50kg (110 lbs) - it is a two person
job to lift it in place.
Fig. 5-2d Internal Casing Assembly
W50/80I SHOWN
Fig. 5-2e Phial Positions
12
LIMIT STAT PHIAL
CONTROL STAT PHIAL
FIT PHIALS IN EITHER 1 OR 2
BURNER CABLE
5050
5050
50 kgkg
kgkg
kg
55
55
5

14
5-3 Select External Wall Mounted W40/50E & W50/80E
5-3.1 Service Access
External Wall Mounted Boilers have a large hinged front door that gives access to the
Control Panel and enables all routine servicing to be carried out without the necessity of
removing main case or flue. The door can be lifted off in windy conditions.
A large bolted service door is provided on the front of the heat exchanger giving easy
access to the baffles and combustion chamber.
5-3.2 Heating Connection
The flow and return connections are on the top of the Boiler heat exchanger - 1” female
BSP. The standard arrangement is to connect through the back panel as shown in fig.
5-3b.
5-3.3 Boiler at Ground Level
The External Wall Mounted range can be wall mounted at ground level, however the
following conditions must be considered.
1. A terminal guard must be fitted (not supplied).
2. A 50mm free air space must be provided under the Boiler.
3. The Burner is supplied for two pipe operation and will probably require changing to
single pipe operation.
4. Protection against rodent intrusion is essential.
SERVICE DOOR
W40/80E SHOWN
Fig. 5-3a Service Access
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
5-2.5 Oil Connections
All Wall Mounted Boilers are supplied with a pump set for two pipe oil system.
FIRE VALVE SENSOR
FIXED ABOVE BURNER
OIL HOSES ✓
FLOW
ALTERNATIVE BOTTOM ENTRY
NO VALVES IN
RETURN LINE FIRE VALVE
RETURN
FLOW
SHUT OFF VALVE
FILTER ✓
✓SUPPLIED WITH BOILER, SEE SECTION 13.
Fig. 5-2f Recommended Two Pipe Oil Connection - Wall Mounted Internal
✓✓
205 35
45
1 BSP/F
25 min
150 ma
FR
Fig. 5-3b Heating Connections
55
55
5

15
5-3.4 Fixing the Boiler - Suggested Procedure
1. Remove carton.
2. Open Boiler door and remove flue components.
3. Remove Control Panel by unplugging Burner plug and unbolt two nuts.
4. Remove main casing - 3 screws each side.
5. Remove access door and lift out all baffles from heat exchanger.
6. Remove Boiler body from wood transport blocks - 3 screws, 1 top, 2 bottom.
7. Offer back panel to the position required on the wall and use this as a template to
mark the drilling positions for the 3 mounting rawl bolts ‘R’.
Also mark the positions of any holes required through the wall for water pipes, oil
pipes, fire check valve and electric cable.
8. Remove panel and accurately drill required holes and fit 3 rawl bolts into holes ‘R’.
9. Place back panel onto the 3 rawl bolts - do not fit nuts.
10. Clear work space and carefully lift the heat exchanger onto the 3 rawl bolts, fit nuts -
do not tighten yet.
11. Adjust for level and tighten the 3 rawl bolts.
12. Make oil pipe connections, see Section 5-3.6.
13. Make water connections.
14. Fit main casing.
15. Fit flue bend with gasket to Boiler.
16. Fit seal inside flue terminal.
17. Lubricate seal with lubricant supplied and fit terminal with 4 screws.
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
Note
Before removing main case, study the
Burner position and the Boiler wall position
and decide on the best oil pipe
configuration, see Section 5-3.6 and
Section 7.
K x 2
R
RR
K
R - 3 HOLES DRILL 12Ø FOR RAWL BOLTS
K - KNOCKOUT POSITIONS
Fig. 5-3c Drilling Positions
WW
WW
WARNINGARNING
ARNINGARNING
ARNING
The weight of the Boiler Heat Exchanger
bare is 50kg (110 lbs) - it is a two person
job to lift it in place.
Note
For back panel dimensions, see page 56.
5050
5050
50 kgkg
kgkg
kg
Fig. 5-3d External Boiler Flue Assembly
18. Re-fit Control Panel.
19. Re-fit Baffles and Access Cover - see page 39.
20. Finally, seal top and both sides externally with sealant provided - ensure GOOD
NEAT SEAL.
IMPORTANT
Do not trap phial capillary tubes behind access cover.
5-3.5 Connecting Control Panel
The three phials of the thermostats are inserted horizontally in the pockets situated in the
heat exchanger, see fig. 5-3e.
The Burner is supplied with a 4 wire cable and plug which connects into the Burner
supply socket on the Control Panel.
The mains electricity supply, preferably from a spur switched and fused 5 amp, should
enter the Boiler casing through one of the holes or knockouts provided, see Fig. 5-3c.
SEAL
FITTED INSIDE TERMINAL
SCREWS X 4 MAIN CASE
FLUE BEND
FLUE TERMINAL
GASKET
1
3
2
Fig. 5-3e Phial Positions
FROST STAT PHIAL (NO SLEEVE)
POSITION 3
LIMIT AND CONTROL STAT PHIAL
POSITIONS 1 & 2
BURNER CABLE & PLUG
MAINS SUPPLY PLUG
FIT FLUE GUARD IF
APPLICABLE.
55
55
5

16
FLOW
Fig. 5-4a Heating Connections
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
5-4 Select Free Standing External - FE40/50 & FE50/80
5-4.1 Free Standing External Boilers
The Thermecon External Free Standing range of Boilers are based on the External Wall
Mounted range, they have a special mounting frame to enable them to be positioned on a
suitable base remote from the dwelling. They are not designed to be placed against a
wall at ground level.
5-4.2 Heating Connections
The flow and return connections are on the top of the Boiler heat exchanger - 1” female
BSP.
RETURN - 1” BSP - air bleed normally required.
FLOW - 1” BSP
Incoming pipes should enter the Boiler through the cut-outs provided in the bottom panel
as shown.
5-4.3 Base Details
See fig. 5-4b.
The Base must be level, impervious to kerosene and non-combustible.
Pipes must be fully protected and insulated.
Cables must be suitable for outside and/or underground use.
Note
For:-
Service Access ..................... see p.14
Connecting Control Panel ..... see p.15
A 4 pin plug is provided for connection to the mains supply. This connects into the
socket in the side of the Control Panel - for wiring see page 50,
5-3.6 Oil Connections
All Wall Mounted Boilers are supplied with a pump set for two pipe oil system.
FIRE VALVE SENSOR
FIXED ABOVE BURNER
OIL HOSES ✓
FLOW
NO VALVES IN
RETURN LINE
FIRE VALVE
RETURN
FLOW
SHUT OFF VALVE FILTER ✓
✓SUPPLIED WITH BOILER, SEE SECTION 13.
Fig. 5-3f Recommended Two Pipe Oil Connection - Wall Mounted External
✓
✓
RETURN
55
55
5

17
5-4.4 Oil Connection
Free Standing External Boilers are supplied with a pump set for single pipe oil system.
The oil pipe and electric cable should also enter through the cut-outs provided in the
bottom panel - see fig 5-4c.
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
FIRE VALVE SENSOR
FIXED ABOVE BURNER
OIL HOSE ✓
FLOW
FIRE VALVE
SHUT OFF VALVE
FILTER ✓
✓SUPPLIED WITH BOILER, SEE SECTION 13.
✓
✓
Fig. 5-4c Recommended Two Pipe Oil Connection
12
4
3
1. OIL SUPPLY
2. ELECTRICAL SUPPLY
3. FLOW AND RETURN PIPES
FULLY INSULATED
4. RAWL BOLTS FOR BOILER FIXING
Fig. 5-4b Base Details
Fig. 5-4d External Boiler Flue Assembly
SEAL
FITTED INSIDE TERMINAL
SCREWS X 4 MAIN CASE
FLUE BEND
FLUE TERMINAL
GASKET
FIT FLUE GUARD IF
APPLICABLE.
5-4.5 Fitting the Flue
1. Fit flue bend with gasket to Boiler.
2. Fit seal inside flue terminal.
3. Lubricate seal with lubricant supplied and fit terminal with 4 screws.
4. Fit terminal guard.
55
55
5

18
5-5.3 Pump
The Pump is a standard 3 speed central heating circulating pump which pumps the hot
water through the system. The unique design of the Boiler enables the pump direction
to be the same for both left hand and right hand flow connection.
5-5.4 Pressure Gauge
The Pressure Gauge is provided to indicate the system pressure.
When the system is full with cold water and all radiators are full, on and vented, the
gauge will show the cold fill pressure. Set the red pointer to the cold fill pressure. If the
system pressure, indicated by the black pointer, falls below the cold fill pressure, it
indicates that the system requires topping up.
Fig. 5-5b Typical Sealed System
1
23, 4
AIR VENT
(NOT SUPPLIED) DOMESTIC HOT WATER
INDIRECT CYLINDER
FLOW
RETURN
OPTIONAL EXTRA PUMP
ON RETURN FOR
LARGER SYSTEMS
COLD MAINS FEED
7
5
1. PUMP
2. PRESSURE GAUGE
3. PRESSURE RELIEF VALVE
4. PRESSURE VENT
5. EXPANSION VESSEL
6. AIR VENT
7. FILLING LOOP
Note
No other pump should be fitted to the
system.
2
bar
13
40
5-5 Option Floor Standing System Boiler - OS60/80, OS80/95, OS90/120, OS100/150
5-5.1 Boiler Arrangement
4
3
1
2
5
COOLED RETURN
EITHER SIDE
HOT FLOW
EITHER SIDE
INTERNAL SEALED PIPEWORK
FOR MINIMUM HEAT LOSS AND
EASY INSTALLATION
1. PUMP
2. PRESSURE GAUGE
3. PRESSURE RELIEF VALVE
4. P.R.V. DISCHARGE (Piped by installer)
5. EXPANSION VESSEL
6. AIR VENT
Fig. 5-5a Schematic Diagram of System Boiler
OS80/95 SHOWN
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
Note
For:-
Service Access .................... see 5-1.1
Heating Connections ........... see 5-1.2
Connecting Control Panel .... see 5-1.3
Oil Connection .................... see 5-1.4
5-5.2 The Heating System
6
6
55
55
5
0
1
2
3
4
5
6
0
20
40
60
80
bar psi

19
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
5-5.5 Pressure Relief Valve
The Pressure Relief Valve is provided to vent excess pressure from the system. The valve
will open when the pressure exceeds 3 Bar ± 10%.
The pressure relief valve can be manually opened by turning the red knob clockwise, to
close the valve continue turning clockwise until it clicks.
5-5.6 Pressure Relief Valve Discharge Pipe
The outlet from the pressure relief valve must be piped using 15mm copper pipe to a
visible position outside the dwelling by the installer. The pipe must have a continuous
fall and ideally be terminated over a drain.
Local by-laws may require a Tundish to be fitted.
Knockouts are provided for the vent pipe in the back panel and in the flue blanking plates
each side of the Boiler, see fig. 5-5c.
IMPORTANT
Scalding water and steam can be blown out of the discharge pipe.
Position the discharge so that it is not a hazard to property or people
(especially children).
5-5.7 Expansion Vessel
Maximum charge pressure 1.5 Bar Maximum working temperature 90°C
Pre-charge pressure 1 Bar Maximum working pressure 3Bar
Capacity
OS60/80, OS80/95 & OS90/120 10 litres - for maximum system expansion of 9 litres.
OS100/150 20 litres - for maximum system expansion of 18 litres.
The expansion vessel supplied is suitable for systems with a static head of up to 5
metres. If the static head is greater than 5 metres the charge pressure of the expansion
vessel will need to be increased. Increase the pressure using a standard car tyre pump
and pressure gauge when the system is empty (zero pressure).
Expansion vessels are suitable for systems requiring a maximum expansion of 9 or 18
litres as detailed above. For systems requiring more expansion a second expansion
vessel will be required. BS7074 Part 1 includes information on this requirement.
5-5.8 Filling Loop
A Filling Loop comprising a flexible hose, double check valve and an isolating valve is
supplied for filling and topping up the system.
The filling loop should be fitted between the incoming mains and the heating system
return as shown in fig. 5-5e.
When not in use one of the hose unions must be disconnected as there must not be a
permanent connection to the mains supply.
OS60/80 & OS80/95 SHOWN
Fig. 5-5c Discharge Pipe
Fig. 5-5d Static Head
Fig. 5-5e Filling Loop
MAINS
SUPPLY
ISOLATING VALVE
SUPPLIED
FLEXIBLE HOSE
SUPPLIED
DOUBLE CHECK VALVE
SUPPLIED
HEATING
RETURN
HOSE MUST BE
DISCONNECTED WHEN
NOT IN USE
TYPICAL ARRANGEMENT
Note
Normally expansion requirement is 4% of
the system water content including the
Boiler.
HIGHEST POINT OF SYSTEM
EXPANSION VESSEL
STATIC HEAD
55
55
5

20
L
N
PUMP ELECTRICAL CONNECTIONS
Fig. 5-5f Wiring Connections
Note
Older systems need careful checking as
they will be operating at a higher pressure.
Note
The expansion vessel is factory set at 1.5
Bar.
5-5.9 Wiring
The wiring of the pump should be done by the installer to best suit the system timer/
programmer.
IMPORTANT
The pump MUST be wired so that it is ON at all times the Boiler is ON.
INSTINST
INSTINST
INSTALLAALLA
ALLAALLA
ALLATION 5TION 5
TION 5TION 5
TION 5
2
LIMIT STAT CONTROL STAT
C21C
L N
BL
BR
GY
BL
GY
R
TO BURNER
PREWIRED
BR
GY
MAINS SOCKET
PREWIRED
BL
LN
GY
LIVE BROWN
EARTH G/Y
NEUTRAL BLUE
5-5.10 Cold Fill Pressure
The Cold Fill Pressure of the central heating system should be:-
Recommended Pressure - 2 Bar Max. Pressure - 3 Bar Min. Pressure - 1 Bar
It is advised to use a pressure gauge when filling the system to ensure correct pressure.
5-5.11 Expansion Vessel Pressure
The pressure of the expansion vessel should be set at 0.5 Bar below the cold fill pressure.
This should be done prior to filling the system using a conventional car tyre gauge and
pump.
IMPORTANT
The pressure of the expansion vessel cannot be checked when there is
water in the system.
5-5.12 Filling the System
1. Switch OFF electrical supply to the Boiler.
2. Check all drain cocks are closed.
3. Check spare sockets on the Boiler are plugged.
4. Connect the filling loop.
5. Open the filling loop isolating valve part-way so that the system fills slowly.
6. When full and vented make a note of the cold fill pressure on the Boiler pressure
gauge.
7. Open drain cocks and vent to fully flush the system.
8. If required, set the expansion vessel pressure to 0.5 Bar below the cold fill pressure
recorded in 6 above.
9. Check all drain cocks are closed.
10. Refill and vent the system to the correct cold fill pressure see 5-5.7.
The correct amount of suitable corrosion inhibitor should be added to the system
strictly to the manufacturer’s instructions.
11. Shut filling loop isolating valve and disconnect one hose union.
12. Check for leaks.
55
55
5WIRE TO SWITCHED
PROGRAMME LIVE