Hounsfield Boilers Tuscan 12-19 User manual

HANDBOOK AND SERVICE LOG
Tuscan Kitchen Models
DIESEL BURNER SETTINGS
Boiler Model: 12-19 20-25 26-30
Boiler Serial No. :____________________________
Hounsfield Boilers Ltd. Maitland Road, Lion Barn Industrial Estate, Needham Market, Suffolk, IP6 8NZ
www.hounsfieldboilers.co.uk Tel.: [phone]

Dear Householder
Thank you for selecting a Hounsfield boiler, the culmination of many years experience in
the design, development and manufacture of oil fired boilers.
To claim your FREE 5 year extended warranty complete and return the enclosed
registration document, alternatively register on line at www.hounsfieldboilers.co.uk.
Following registration you will receive a warranty certificate and for the duration of the
warranty, a reminder each year that a boiler service is due.
Familiarise yourself with the controls and operation of the boiler, if you have any
queries please contact us.
Our greatest sales generator has proved to be “word of mouth” if you are happy with
the product and service we provide please tell others; if you are not tell us.
Yours faithfully
Andrew Hounsfield
Managing Director
E-mail: [email protected]

CONTENTS
HOUSE HOLDER INFORMATION:
Page
-
Controls
1
-
Condensing boiler overview
2
-Switch on the boiler
2
- Holidays and extended periods of shutdown
2
-If you run out of oil
2
-
Oil delivery
2
-
Maintenance
2
-Warranty
▪FREE extended warranty
▪Report a warranty fault
BOILER INSTALLATION
-
Regulations
3
-
Refurbishing an old system
3
-
Corrosion inhibitor
4
-
System Balancing
4
-
Boiler Location
5
-
Flue terminating positions
6
-
Fuel supply
7
-
Flue options
9
-
Electrical detail
12
-
Condensate pipe work
13
-Typical heating system layout
14
TECHNICAL
-
Boiler specifications
15
-
Service schedule
16
-
Burner settings
16
-
Fault diagnosis
17
-
Boiler parts list
18
-
Burner parts list
19
-
Service log
20
CONTACT
-Tel.: [phone]
-
E-mail: [e-mail]
[e-mail]
-Web: www.hounsfieldboilers.co.uk

HOUSEHOLDER INFORMATION
Controls
Control thermostat
Limit reset
Control thermostat
Controls the temperature of water within the boiler, set to the following positions:
-Winter when central heating and domestic hot water heating is required.
-Summer for domestic hot water only.
Power neon
Is illuminated when there is mains power to the boiler and the programmer or time clock is calling for heat.
Limit neon and limit reset button
Is illuminated when the boiler has over heated; to reset wait for the boiler to cool down then press the red
reset button.
IMPORTANT: If overheating occurs regularly consult your boiler engineer; there may be a fault with the central
heating system.
Lockout neon and lockout reset button
Is illuminated when burner ignition has failed; it indicates a fault with the burner which may be caused by a
lack of fuel.
To reset the burner, wait for two minutes, this allows a bimetallic strip to cool; press the lockout reset button
to restart the burner ignition sequence. Note. The reset button also acts as an on/off switch for the burner;
press once for off, press again to switch on.
IMPORTANT: If you experience continued or frequent lockouts contact your boiler engineer.
Reset button:
1

Exhaust plume
It is normal for a condensing boiler to produce a plume of water vapour from the flue terminal; it
demonstrates the boiler is working extremely efficiently and may be more prevalent when the boiler starts up.
Dependant on the heating system about 1 litre of condensate per hour is produced; condensate will have a PH
value in the range of 3.5-5; about the same acidity as tomato juice.
Check the condensate trap periodically to ensure it contains water, top up with fresh water if necessary.
Switching on the boiler
-Turn on the oil supply.
-Switch on the electricity supply.
-Set the programmer to “on”.
-Ensure the control thermostat is set as appropriate.
-The power neon on the boiler will now be illuminated and the burner will start to operate.
Holidays and extended periods of shutdown:
-Turn off the oil supply at the tank, just in case there’s an oil leak when the property is
unattended
-Have the boiler serviced.
-Switch off the electrical supply.
If you run out of oil
Refer to the fuel supply section –priming the burner.
Oil delivery
Over time sediment will build up in the bottom of an oil tank; to prevent its ingress into the fuel line switch off
the boiler during an oil delivery and allow the fuel to settle for a period before switching on the boiler.
Maintenance
Your boiler should be serviced annually. Failure to comply with this requirement could lead to inconvenient
breakdown and will invalidate your warranty.
If you have difficulty in locating an engineer contact our service department who will be able to provide the
name of an engineer in your area.
Warranty
Your boiler is guaranteed for one year from the date of installation.
Warranty Conditions
The boiler must be installed and commissioned in accordance with this handbook and appropriate regulations.
The boiler shall not be repaired, modified or tampered without the authorisation of Hounsfield Boilers Ltd...
Charges incurred for any unauthorised “in warranty” work will not be accepted.
2

FREE extended warranty
Extend your warranty free of charge to a total of 5 years by completing and returning the enclosed registration
document; alternatively register on line via our web site www.hounsfieldboilers.co.uk.
When the registration process is completed you will receive an extended warranty certificate and a reminder
each year to have the boiler serviced for the duration of the warranty period.
Extended Warranty Conditions
The boiler must be maintained annually with evidence in the form of invoices and a completed service log to
support this.
The paper element of oil filter supplied with the boiler must be installed near the boiler.
Reporting a warranty fault
If you suspect a boiler fault in the first instance please contact your installer who will be able to verify the
cause of the problem.
If appropriate, your installer must contact Hounsfield Boilers Ltd. for authorisation to undertake remedial work
or arrange for an engineer to attend. Under no circumstances should “in warranty” work be undertaken
without the authorisation of Hounsfield Boilers Ltd.
If your installer is unavailable please contact our service department, please have your boiler model and serial
number available.
BOILER INSTALLATION
Regulations and codes of practice
NZ/AS 1691:1985 Domestic oil-fired appliances –installation
BS5410 Part 1: Code of Practice for the installation of oil fired boilers up to 45kW
BS5449: Forced circulation hot water central heating systems for domestic premises.
BS7593: Treatment of water in hot water in heating systems.
Building Regulations: Part L1 Part J 2002 England and Wales, Part F Scottish Regulations and Technical
Booklet L Northern Ireland.
BS7671: I.E.E. Wiring Regulations.
BS7074: Code of Practice for Sealed Systems.
OFTEC: Recommendations.
Refurbishing an old system
WARNING! –BEFORE INSTALLING A NEW BOILER
The system must be chemically cleaned to remove sludge that accumulates in radiators and pipe work over
time. Failure to do this will result in debris adhering to the clean surfaces of a new boiler, causing kettling
noises; similar to a domestic kettle boiling. It also prohibits efficient heat transfer. A cleanser such as Defender
Central Heating Cleaner should be added to the system at least 48 hours prior to changing the boiler.
3

Corrosion inhibitor
After installation of the new boiler the system must be flushed with a cleaner such as Defender Central
Heating Cleaner to remove traces of flux residues, grease, metal, swarf, solder pieces and oils used during
component manufacture.
After flushing
A corrosion inhibitor such as Defender Central Heating Inhibitor must be added to the system. This will
minimise the chemical action and chemical change that takes place in the system’s primary water and system
components.
System balancing
The optimum performance of your condensing boiler will be achieved if the following parameters are met:
-Under floor heating system: heating flow temperature of 50oC and a return temperature of 40oC.
-Radiator system: heating flow temperature of 70oC and a return temperature of 50oC
The boiler does not normally need a bypass but some radiators on the heating circuit equal to at least 10% of
the minimum boiler output, usually those where the room thermostat is located should not have thermostatic
radiator valves fitted.
Systems incorporating zone valves which could completely cut off the flow through the system must
also include a bypass.
Procedure
1. Set the programmer to ON. Close all thermostatic radiator valves. Valves on radiators in the same room as
the room thermostat should be fully open. Note –Radiators located in the same area as the room
thermostat should not be of the thermostatic type.
2. Turn up the room thermostat and adjust the valves on the radiators located in the same room to give a
boiler flow and return temperature of not more than 20ᵒC. These valves should now be left as set.
3. Open all manual or thermostatic radiator valves and adjust the lock shield valves on the remaining
radiators to give around 15ᵒC temperature drop at each radiator. Adjust the room thermostat and
programmer to NORMAL settings.
4

Boiler Location
This boiler is only suitable for installing internally within a property at a suitable location onto a fixed rigid
surface of the same size as the boiler and capable of supporting the boiler weight. The boiler must be installed
on a flat level surface to ensure condensate does not enter the primary heat exchanger.
The maximum surface temperature of 75ᵒC will not be exceeded if operated as intended as all surfaces are
water cooled / contain water including the underside of the boiler as well as being fully insulated.
5

Flue terminating positions
A
Directly below an opening, air brick, window etc.
600mm
B
Horizontally to an opening, air brick, window etc.
600mm
C
Below a gutter, eaves or balcony with protection
75mm
D
Below a gutter or balcony without protection
600mm
E
From vertical sanitary pipe work
300mm
F
From an internal or external corner
300mm
G
Above ground or balcony level
300mm
H
From a surface or boundary facing a terminal
600mm
J
From a terminal facing the terminal
1200mm
K
Vertically from a terminal on the same wall
1500mm
L
Horizontally from a terminal on the same wall
750mm
M
Above the highest point of an intersection with the roof
600mm
N
From a vertical structure to the side of the terminal
600mm
O
Above a vertical structure less than 750mm from the side of the terminal
600mm
P
From a ridge terminal to a vertical structure on the roof
1500mm
Q
Above or to the side of any opening on a flat or slopping roof
1500mm
R
Below any opening on a slopping roof
1000mm
Notes.
1. Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets
around the building or entering into buildings.
2. Terminating positions must be at least 1.8 metres from an oil tank.
3. Ref. C above. Where a terminal is less than 600mm from gutters, eaves or balcony a heat shield at least
750mm wide should be fitted to protect surfaces.
4. Where a flue terminates near the boundary of a property, consideration should be given to possible noise
disturbance as some people are sensitive even to low noise levels.
5. Avoid flue terminating positions where PVC windows, doors or decorative patio slabs are directly below the
terminal; over time products of combustion may cause staining.
6. Condensate pluming will occur around the terminal, positions where this could cause a nuisance should be
avoided.
6

Fuel supply
FIRE VALVE
SIGHT GAUGE
SENSOR
10mm
COPPER PIPE
MAXIMUM
ISOLATING
2.5MTR. LIFT
VALVE
NON RETURN VALVE
(SUB GRAVITY
PAPER ELEMENT FILTERS
SUPPLY SYSTEMS ONLY)
ISOLATING
VALVE
OIL TANK TO BOILER
MAXIMUM 100MTRS.
Fuel supply line
A single pipe line is required for the fuel supply to the boiler; a Tiger Loop deaerator or two pipe system is
unnecessary. The oil pump is designed to lift oil up to 4 meters; we recommend a maximum boiler installation
height of 2 metres, the overriding consideration being to provide safe access for a service engineer. The
pump’s lift capacity does provide greater flexibility than most when considering the location of the oil tank;
allowing it to be sited at the bottom of an incline or up to 100 metres from the boiler.
IMPORTANT! In a suction oil supply system particular attention is required to prevent air being sucked into the
fuel line; keep the number of joints to a minimum, in particular those that are likely to be above the minimum
oil level and subject to negative pressure.
With the above in mind install the oil filter, isolation valve, NRV and fire valve assembly, just above ground
level and before the vertical rise of the oil line to the boiler.
For installations where the oil level in the tank, may be lower than the burner a non return valve will be
required.
Soldered fittings must not be used; flux deposits will damage the fuel pump and joints may fail in the event of
fire.
Filters
A paper element filter and isolation valve is supplied with the boiler, to be installed near the boiler, an
additional filter adjacent to the oil tank is recommended. Paper element filters should be installed in
preference to gauze; they provide greater protection and longevity to the oil pump.
Fire valve
A remote sensing fire valve is required, a clamp to support the phial is provided next to the boiler thermostat
panel.
Oil tank
If a top outlet tank is to be installed, there may be a non-return valve fitted to the oil line within the tank; this
should be removed.
Ensure there is enough clearance between the tank and the concrete base to allow removal of the oil filter.
7

Priming the burner
Press the burner reset button, the firing sequence will commence. During the firing sequence slacken the vent
plug to purge air from the oil line. If ignition fails the burner will go to lockout; the reset button will be
illuminated. Press the reset button to restart the firing sequence. The reset button also acts as an on/off
switch; press once for off, press again to switch on.
Vent
Reset button
Pump pressure
Testing the fuel supply
For wall mounted boilers fitted with a clear oil line, with the burner operating it is normal for a static air
bubble to remain at the highest point of the clear flexible oil line; a continuous stream of bubbles indicates
that air is being drawn in. This must be cured check all joints above the oil level in the tank.
If a non-return valve is installed, test its function by releasing the flexible oil line connection onto the pump,
hold the oil line vertically; the oil level should be maintained.
Oil line accessories
Item
Part no.
Fire valve 1.5mtr capillary 66oC
BSF1.566
Fire valve 3mtr capillary 66oC
BSF366
Fire valve 6mtr capillary 66oC
BSF666
Fire valve 9mtr capillary 66oC
BSF966
Fire valve 15mtr capillary 66oC
BSF1566
3/8” Non return valve
BS0002
3/8” Oil filter
BS0003
3/8” Oil filter element
BS0004
8

Flue options
Conventional flue
An adaptor to fit the top of the boiler is required, see accessory table below.
A stainless steel flue liner suitable for use with oil fired boilers must be installed. Twin wall rigid or flexible
liners are readily available at merchants.
An air supply for combustion and ventilation is required as detailed in the table below. An allowance must be
made for extractor fans and tumble dryers within the room; test combustion with these appliances operating.
CLAMP PLATE
WITH FLAUNCHING
COWL
BACKFILL SINGLE WALL
LINER WITH VERMICULITE
TWIN WALL RIGID
OR FLEXIBLE LINER
BULKHEAD TO SEAL
ENTRY INTO CHIMNEY
SOOT DOOR
RIGID PIPE SECTION
INTO CHIMNEY
Hounsfie ld
550mm2/kW
OPEN FLUE IN A ROOM
550mm2/kW
1100mm2/kW
IN A COMPARTMENT
VENTED FROM OUTSIDE
550mm2/kW
1100mm2
/kW
1650mm2
/kW
IN A COMPARTMENT
VENTED FROM A ROOM
COMBUSTION AND VENTILATION AIR SUPPLY
TYPICAL CONVENTIONAL FLUE INSTALLATION
9

Balanced Flues
A boiler installed in a cupboard or confined space will require air for ventilation at high and low level, as
detailed VENTED FROM OUTSIDE VENTED FROM A ROOM
550mm2/kW
1100mm2/kW
550mm2/kW
1100mm2/kW
Low level horizontal flue
The standard low level flue kit has a telescopic range of 220-450mm; 300mm extension kits are available,
extension length should not exceed 950mm.
For side outlet flue installations the effective telescopic range of the flue is reduced by 200mm.
Where the lowest part of a terminal is below 2 metres and people are likely to have access a terminal guard
should be fitted.
High level horizontal flue
The same parameters apply as the low level horizontal flue. The vertical section of the terminal has a
telescopic range of 750-1200mm; extensions are available to increase the vertical height to a maximum of 3.5
metres.
Vertical balanced flue
The flue is telescopic, as supplied it has a range of 1000-1500mm from the top of the boiler to the flash line;
extension kits are available to increase the vertical height up to 4 metres. Pitched and flat roof flashings are
available.
Flue kits and flue accessories
Item
Part no.
Conventional flue adaptor
FK100CA
Low level horizontal kit
FK80LL
High level horizontal kit
FK80HL
Vertical kit
FK80V
150mm horizontal extension
FK80X150
300mm flue extension
FK80X300
600mm flue extension
FK80X600
900mm flue extension
FK80X900
Roof flashing
FK125FL
Flue terminal guard
FK125TG
10

1 MTR. MINIMUM
PITCHED AND FLAT ROOF
FLASHINGS AVAILABLE
125
AS SUPPLIED 2000-2600mm
140
VERTICAL FLUE
142
125
SIDE OUTLET
80 765
LOW LEVEL HORIZONTAL FLUE
142
125
1900
HIGH LEVEL HORIZONTAL FLUE
11

Electrical detail
The electrical supply to the boiler must be via a
fused double pole isolating switch located near the
boiler in order to provide easy access to the user
after installation. Fuse rating should be 5amps.
Connection to the boiler should be made using
flexible three core PVC insulated cable, not less
then 0.75mm2to BS6500 1990 table 16.
Route the flexible cable into the boiler via the
20mm grommet in the rear panel and connect to
the three pin socket. Connect the switched live
supply to the 3-pin plug, N = negative, L1 =
switched live and earth.
Thermostat panel wiring diagram
Mains power connections
L1 Positive (brown)
Earth (green/yellow)
N = Negative (blue)
12

Condensate pipe work
A 22mm condensate drain trap (code OBT1-CO) is provided with the boiler, dependant on site conditions other
options may be more appropriate, see below; these fittings are available from plumber’s merchants.
Condensate can be discharged into an independent soak away, soil waste or rain water disposal systems
within a property.
In accordance with The Building Regulations 2000 Document H a 75mm water seal is required; this will prevent
flue gases exiting. Pipe work fall must be a minimum of 18mm per metre. Where pipe runs are external,
consideration should be given to the consequence of potential freezing of the condensate, in this circumstance
lag pipe work or increase the pipe size to 32mm.
13

Typical heating system layout
FULLY PUMPED Y-PLAN HEATING SYSTEM
FEED AND EXPANSION TANK
CYLINDER
THERMOSTAT
HOT WATER FEED
AIR VENT
V E N T
FE E D
RADIATOR
ELECTRICAL
PROGRAMMER
CONNECTION BOX
ROOM
THERMOSTAT
150mm MAXIMUM
3 PORT
MOTORISED VALVE
FLOW
PUMP
BOILER
RADIATOR
RETURN
RELIEF VALVE
WIRIN G DIAGRAM FOR HONEYW ELL Y-PLAN SYSTEM
GREEN /YELLOW
MAINS SUPPLY
BLUE
EXPANSION
WHITE
L
N
E
BOILER
GREY
VESSEL
ROOM STAT.
CYL.ST AT.
2
E
1
3
C
2
1
ORANG E
MAINS WATER
PRESSURE IN
FILLING LOOP ASSEMBLY
SEALED SYSTEM LAYOUT
HW OFF
HW ON
HTG.
N
N
E
L
N
E
L
E
BOILER
PUMP
REPLACES F&E TANK
PROGRAMMER
3 PORT
MOTO RISED
VALVE
L
14