Heatese 80 Installation and operation manual

Installation, Commissioning and Instruction manual
HEATESE
80
Unique heating system
“Lavish on heat, miserly on fuel” TM
Always On, Always Warm
HEATESE issue (1) 08/2016

Insulated and Baffled 80L Copper
Cylinder with Heat-Sync on base
3 off Small Cleaning Ports
1 off Large Cleaning Port
to facilitate
Flue Cleaning
Oil Fired Burner with Fuel
Safety Valve located
externally at rear of
enclosure (sensor located
internally above burner)
Page 1

Page 2

Thermostats
Electrical Panel
Trip switch,
Timer, Relay
Removable
Cleaning Port
Covers
Automatic Air Vents at
high points in circuits
1107
Pressurised
Closed Loop
(Blue, Orange &
Green)
Return From
Dwelling
Hot Feed to
Mains Cold
Water Feed
(1.5 Bar G Max)
Pressure Relief
set at 3.0 bar
G max.
Condensate
Out
Automatic filling valve Lever valves
Page 3

Weather Cowl
Flue Gas Exhaust
Flue Gas Condenser
Return Feed
from Dwelling
Mains Feed
(1.5barG Max)
Pressure Safety Valve
opens to relieve
pressure at 3.0barG
Condensate Out
Heat Exchanger
Hot Feed
to Dwelling
18 LPressure
Vessel
Page 4

Condenser preheats return
Dwelling water before C
Shaped Baffled Boiler
Motorized Valve is open until
the Cylinder Thermostat (B)
reaches 50°C, the valve then
closes and feeds to dwelling,
which thermostat (A) would be
set at 600C.
C Shaped Baffled Boiler
transfers Heat to preheat
cylinder contents in addition
to Cylinder Coil
Page 5

Jacketed Flue Pipe
transfers Heat into Loop
which is circulated
through Cylinder Coil
Mains Cold Water Feed
for Initial Fill and Top-
Ups
L-Shaped Baffled Boiler
Wall transfers Heat into
Loop which is circulated
through Cylinder Coil
Closed Loop System
Flow Diagram
Page 6

Page 7

CONVECTOR RADIATORS
Page 8

CONTENT
LAYOUT AND COMPONENTS………………….1-7
INTRODUCTION /WARRANTY...........................11
SAFETY INSTRUCTIONS....................................13
MAINTENANCE TIPS ...........................................14
REGULAR SERVICING........................................15
GENERAL INFORMATION………………………..16
PRE-INSTALLATION.............................................18
INSTALATION GUIDE...........................................20
HEATESE USER GUIDE......................................27
ELECTRICAL CONNECTIONS...........................29
WIRING DIAGRAM................................................30
POSITIONING GUIDE...........................................31
TECHNICAL DATA TABLE –HEATESE 80......33
CONVECTOR RADIATORS.................................37
CONVECTOR RADIATOR WARRANTY...........39
CONVECTOR RADIATOR DATA………………...40
HEATESE 80 HEATING SYSTEM FAULT
FINDING GUIDE ....................................................52
HEATESE COMMISIONING CHECKLIST.........54
SERVICE RECORD...............................................57
HEATESE CONTACT NUMBERS ......................60
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This symbol indicates Caution and it is placed next to all safety warnings.
Strictly follow these instructions to avoid danger and damage to persons,
animals and things.
This symbol calls attention to a note or important notice.
Declaration of conformity
Manufacturer: Low Flame Boilers Ltd.
Address: Carnisle, Ballivor, Co. Meath, Ireland
Declares that the unit complies with the following EU directives:
Efficiency Directive 09/2015
Low Voltage Directive 07/2015
Electromagnetic Compatibility Directive
07/2015 Sound testing Directive 09/2015
Director and Legal Representative
Patrick Kiely
Cormack Lohan
Page 10

INTRODUCTION /WARRANTY
Thank you for choosing a HEATESE Heating System. We are sure that you will be
satisfied with the performance of your new heating system and with the ongoing
service that you will receive.
Reliability
Every new HEATESE Heating System leaving our factory and installed by a HEATESE
approved engineer carries a five years guarantee on parts (certain consumable parts
are excluded –for full details see below). This also includes all labour charges for the
first 12 months.
Distribution and Service Network
HEATESE have set up a distributor and service network with fully trained service
engineers available to support your HEATESE Heating System within the period of the
guarantee and after. The approved engineer installing your HEATESE Heating System
is responsible for providing this warranty.
Ensure that the service engineer completes the Service Record, at the
rear of the Installation, Commissioning and Servicing Instruction manual,
after each service.
Ensure that the service engineer completes the Commissioning part of
the manual.
Have any work carried out only by a competent HEATESE registered engineer.
Always use original spare parts, to help maintain the efficiency, safety and
reliability of the appliance.
No charge will be made for replacement parts providing:
An appliance fault is found.
The relevant part of the HEATESE Heating System is still covered by
guarantee.
Regular servicing has been carried out in accordance with the
manufacturer’s instructions by authorised HEATESE engineers, using
approved parts. Please note: The service booklet will need to be completed
accordingly.
There will be no charges during the first 12 months of the warranty.
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A call out charge may be applicable if:
The authorised HEATESE service engineer who calls to your home finds no
fault with the HEATESE Heating System.
Other parts of your plumbing system are either faulty or do not comply
with the appropriate installation instructions.
The unit is more than 12 months old.
Please note: Invoices for callout repair work carried out during the guarantee period
by any third party cannot be accepted.
In the event of an appliance fault during the guarantee period, please contact your
service provider. They will arrange for an engineer to call out as soon as possible.
Warranty
What is under guarantee:
5 Year warranty on circulating
pumps 5 Year warranty on fire valve
5 Year warranty on main structure of the heating
system 5 Year warranty on all pipes and fittings
1 Year warranty on thermostats
1 Year warranty on the Reillo burner 1
Year warranty on motorised valve
1 Year warranty on all electrical components 1
Year warranty on all pipe insulation
1 Year warranty on 3 bar pressure release
valve 1 Year warranty on automatic filling valve
1 Year warranty on pressure vessel 1
Year warranty on air vents
1 Year warranty on oil filter
What is not under guarantee:
Labour charges not directly connected with the repair or replacement of a
faulty component.
Any consequential loss.
Accidental or cosmetic damage.
Routine preventative service and maintenance.
Page 12

SAFETY INSTRUCTIONS
General information:
These operating instructions are intended for the user of the heating system.
Read any operating instructions (heating system, heating controls,
ect.) carefully before operation and keep them.
Observe the safety instructions and warnings.
Oil fumes or leaks from the appliance
If you smell oil fumes, observe the following rules:
Extinguish any naked flames
Isolate the electricity supply
Isolate the fuel supply to the heating
system Open windows and doors
Rectify the fault
Health and safety
The appliance contains no asbestos and no substances have been used in the
construction process that contravene the COSHH Regulations (Control of
Substances Hazardous to Health Regulations 1988). Where applicable, the CE mark
indicates compliance with relative EU Directives.
Combustible substances
The area, where the installation of the heating system, must be free of
combustible or chemically aggressive substances.
Do not use or store combustible or explosive materials (paper,
propellants, thinners, paints, ect.) within the vicinity of the appliance.
Do not use or store corrosive substances (solvents, adhesives,
chlorinated cleaning agents, ect.) within the vicinity of the appliance.
Appliance operation
This appliance can be used by children aged from 8 years and above and persons
with reduced physical, sensory or mental capabilities or lack of experience and
knowledge, if they have been given supervision or instruction concerning the use
of the appliance, in a safe way, and understand the hazards involved.
Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by children without supervision.
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Intended use
This appliance must only be used as a heat appliance in an open vented hot
water heating system for domestic purposes.
Any misuse or unauthorised modifications to the appliance, flue or
associated accessories and heating system will invalidate the guarantee.
Do not modify the appliance or flue system in any way.
Low Flame Boilers Ltd accepts no liability arising from any such actions. This
does not affect your statutory rights.
Handling Instructions and Guidelines
It is advised that more than one person is involved in the transfers of the
packaged appliance from the van to the point of installation.
It is advised that no attempt should be made to move the packaged
appliance without the use of a suitable truck.
At all times the correct method for handling heavy objects should be
strictly observed.
Lift only a manageable weight, or ask for help
When lifting, bend knees, and keep the back straight and feet apart. Do
not lift and twist at the same time.
Lift and carry items close to the body.
Wear protective clothing and gloves to protect from any sharp edges.
MAINTENANCE TIPS
Regularly check the oil level in the tank.
Do not obstruct the flue outlet or the air inlet.
Regularly check the system pressure gauge, to make sure that it is between ½
and 1½ bar pressure.
Check power to the heating system.
Check all control settings.
Use in hard water areas
In exceptionally hard water areas a device to prevent scale formation may be
fitted. Installation of scale inhibitor assembly should be in accordance with the
requirements of the local water company.
As isolation valve should be fitted to allow for servicing.
Page 14

REGULAR SERVICING
Regular maintenance is an essential part of keeping your HEATESE Heating System
running safely and efficiently.
Since your HEATESE Heating System operates for long intervals it is important to
ensure regular servicing is undertaken by your Authorized HEATESE engineer. Only
genuine HEATESE spare parts should be used.
Please note: Routine servicing in accordance with the manufacturer’s instructions is
also a condition of the warranty agreement.
To ensure your HEATESE Heating System receives this essential maintenance, please
contact your Distributor or service provider who will be pleased to help.
Service Intervals:
Every 12 months.
Exclusions
The warranty does not cover products which have been altered by the customer or
by third parties. All materials and spare parts must be recommended by HEATESE.
The warranty does not cover misuse, abuse or impact damage.
The warranty strictly excludes commercial use. Appliances are covered for domestic
use only.
Flues, Ventilations and External Services
External oil lines, tanks and filters are not covered under this warranty. Nor does the
warranty cover incorrectly operated or a poorly maintained HEATESE Heating System.
Product fuel conversions are not covered.
This warranty policy does not affect the owners’ statutory rights
Page 15

GENERAL INFORMATION
Your HEATESE Installation, Commissioning and Service Record Log Book
are located on the last pages of this manual. All service records must be
logged and kept up to date by end user.
HEATESE can only be installed and serviced by a HEATESE engineer.
According to the current regulation and the manufacturer’s instructions,
all incorrect installations or poor maintenance can cause damage or
physical injury. The manufacturer will decline any responsibility for
damage by errors in the installation and use, or by not following the
manufacturer’s instructions.
HEATESE declares that no harmful materials are used in the
manufacturing of this product.
This instruction book should be carefully read as it provides all information on
all aspects of the heating system. This manual must accompany the heating
system at all times and all other component manuals, especially in the event of
the heating system changing ownership.
Before cleaning or maintenance is carried out DISCONNECT AND ISOLATE
the heating system from the electrical supply.
If the system stops working or it is not operating as normal contact your
HEATESE engineer. Only HEATESE parts from the manufacture can be
used. Failure to comply with these guidelines could affect the safety and
operations of the unit.
Yearly maintenance has to be carried out by a qualified HEATESE engineer
to guarantee good operation of the unit.
This unit must only be used for the purpose for which it was designed for
i.e., for domestic use only. Any other use is considered to be improper and
therefore hazardous.
After removing the packaging, check the integrity of the contents. In case
of any doubt do not use the unit, and contact the supplier.
The images shown in this manual are a simplified representation of the
product. In this representation there may be slight, unimportant
differences with the supplied product.
Every effort is taken to ensure the accuracy of the information contained in
these instructions. The details are offered in good faith and the
manufacturer accepts no liability for matters arising as a result of errors
and / or omissions.
Due to manufacturer’s continuous product research and development, the
details contained in this manual may not truly reflect the actual product.
Page 16

Packing materials must be kept out of reach from children as they are
potentially hazardous.
General notes
To get the best from your heating system, read these instructions carefully.
Central heating system
During the first few hours of operation of the central heating system, check that all
radiators are being heated at even rate. If the top of the radiator is at lower
temperature that the bottom then it should be vented by releasing air through the
venting screw at the top of the radiator. Ask your installer to show you how this is
done. Repeated venting will reduce the quantity of water in the system and this must
be replenished for safe and satisfactory operation of the heating system.
When excessive venting or water leaks are found in the system you must contact a
HEATESE service engineer to inspect the installation and rectify any fault.
Only use additives compactible with the heating system. Use of incompatible
additives can cause damage and will invalidate the guarantee.
Condensate drain
This is a condensing heating system and the terminal will, at times give out a plume
of water vapour. This is quite normal.
The heating system also produces quantities of condensate which is discharged
regularly via a pipe to drain.
This pipe must not be blocked or altered in any way.
Clearances
Your installer will have provided adequate space around the heating system for
safety and servicing access.
Do not restrict this space next to the heating system.
FROST PROTECTION
Class VII temperature control stat can be wired into the heating system.
Frost protection should be fitted to the system where the system is most
exposed and at risk of freezing.
Page 17

PRE-INSTALLATION
Cleaning primary systems
Danger to life through electrical shock!
Before carrying out any work on electrical components,
isolate them from the power supply (230V AC) (fuse, circuit
breaker) and secure against unintentional re-connection.
Risk of damage to appliance or accessories!
All the following pre-installation sections must be read and
requirements met before starting the appliance or flue installations.
Risk of damage to system or appliance!
Debris from the system can damage the appliance and reduce
efficiency. Failure to comply with guidelines for the use of
water treatment with the appliance will invalidate the
guarantee and contravene the Building Regulations.
It is a requirement of the Building Services Compliance Guide
which is a second tier document to the Building Regulations to flush
and inhibit the primary water system in accordance with BS 7593.
HEATESE states you must fit a filter that will help
remove both magnetite and non-magnetite debris.
Before cleaning the system
Ensure that the system and pipe work is in good working order.
Where possible keep the existing appliance/ circulating pump in
place when flushing the system.
Follow the guidance of BS7593:
Treatment of water in domestic hot water central heating and also the
flushing guidelines below:
Fill the system with cold water and check for leaks.
Turn off the water to the system header tank.
Open all drain cocks and drain the system.
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Close drain cocks and add suitable flushing agent at the correct
strength for the system conditions in accordance with the
manufacturer’s instructions.
Run the heating system at normal operating temperature as directed
by the manufacturer for the flushing agent.
Drain and thoroughly flush the system to remove the flushing agent
and debris.
It may be necessary to use a power flushing machine to aid the
cleansing procedure in some circumstances.
Close the drain cocks and manual air vents.
Add a suitable inhibitor to the system in accordance with
the manufacturer’s instructions.
Turn on the water to the system header tank and allow system to fill.
Never run the appliance when the appliance/system
is unpressurised (sealed system) or empty.
Starting the appliance
Check the oil supply is correctly fitted and in good working order before turning
on the oil supply valves to the heating system.
Turn on the main on supply valve at the tank and draw off at least 2.5 litres of
oil until a steady flow of clear uncontaminated oil can be seen as follows:
The oil supply to the heating system should be primed before the burner is
operated to avoid unnecessary pump wear.
The use of an oil suction pump will prime and flush trough any oil supply set
up simply and easily, alternatively the following procedures can be used.
Priming the single pipe gravity system
Disconnect the flexible oil hose and open an isolating valve to discharge the oil
into the suitable container.
Replace flexible hose at annual service to prevent possible oil leakage.
Page 19