Ormandy Commodore Plus Guide

INSTALLATION COMMISSIONING AND OPERATING MANUAL
CAST IRON OIL-FIRED BOILER
Commodore Plus (uk) - 1007-01
Commodore Plus
Hartley and Sugden

1. Technical data ............................................................................................4
2. Layout of the heating installation of the boiler ...........................................5
3. Assembly of the boiler ...............................................................................7
4. Hydraulic installation of the boiler ........................................................... 23
5. Protection of chimneys against internal condensations ...........................26
6. Electrical connections ..............................................................................27
7. Spare parts list .........................................................................................31
8. Maintenance .............................................................................................36
9. Guarantee conditions on the products..................................................... 36
-Theboiler must be installed and commissioned bya registered installer in accordance with instructions herewith.
- It is important for the safe operation of boilers that there is sufficient fresh air inlet and ventilation provided.
-Maintenance of the boiler should be done once or twice a year, depending on the conditions of use.
- It is inadvisable to regularly drain down the boiler as frequent additions of fresh water may bring about the
premature deterioration of the boiler fabric through the deposit of mineral substances present in the water.
- Precautions must be taken to avoid any damage that might be caused by frost .
User's advices
CONTENTS
Page
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General rules
The flues of the products of combustion must be
calculated and carried out according to the standards
in force, the local obligations and the regulations of the
manufacturer.
The hydraulic installations, fuel or gases will be
established according to standards of installation and
safety in force in the country of use.

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111
719
63
399
321
321
830
1. Technical data
Maximum water temperature: 90°C; maximum installation pressure: 4 bar
REMARK:
The temperature adjusted on the second step
thermostat H/L (switch nr. 8) should be lower
than the one on the first step thermostat
(switch nr. 7).
1. Main switch with on/off light
2. Boiler thermometer
3. Safety limit with manual reset (110°C )
4. Burner opening: diam. 170 mm standard.
5. Opening drain cock: 3/4"
6. Eyepiece to view flame
7. First step thermostat (e.g. of adjustment : 80°C)
8. Second step thermostat
9. Place foreseen for the control system
10. Place foreseen for hour meters
Height Width Depth Ø Depth
122 5 200,0 1165 900 1300 400 790
132 6 237,5 1165 900 1300 400 920
241 7 275,0 1165 900 1560 400 1050
242 8 312,5 1165 900 1560 400 1180
234 9 350,0 1165 900 1820 400 1310
244 10 387,5 1165 900 1820 400 1440
335 11 425,0 1165 900 2080 400 1570
345 12 462,5 1165 900 2080 400 1700
355 13 500,0 1165 900 2340 400 1830
455 14 537,5 1165 900 2340 400 1960
Type
ABC
Total
numb.
section
Boiler dimension (mm) Dim. chambre de combustion
Net heat
output (kW)
A = number of front inter sections
B = number of middle inter sections
C = number of rear inter sections
Commodore Plus N° 122 132 241 242 234 244 335 345 355 455
Max. heat input (kW) 178 225 246 278 312 340 375 407 430 474
Net heat output (kW) 162 204 224 253 283 310 339 371 394 432
Net heat output (kW) to 1*CE 92/42 (*) 200 237,5 275 312,5 350 387,5 425 462,5 500 537,5
Number of sections 7 8 9 10 11 12 13 14 15 16
Furnace pressure (mbar) 2,9 3,50 2,20 2,60 3,70 3,50 3,60 4,40 4,60 4,60
ǻT° flue - T° ambiance 156 160 156 161 160 152 162 153 141 150
Load losses wat er side (mbar) ǻT 15°C 4,5 7,1 8,5 14 16,7 19,5 22,6 26,7 29,6 35
Exit flue gas mass flow (g/s) 75 97 103 116 132 147 163 176 185 205
Combustion circuit (dm³) 195 226 258 290 322 354 386 418 450 482
Relative standby loss (%) 0,6 0,51 0,48 0,44 0,4 0,38 0,35 0,32 0,3 0,29
Water capacity of the boiler (l) 115 130 145 160 175 190 205 220 235 250
Heating body weight (kg) 705 800 895 980 1060 1150 1240 1330 1420 1510
Outlet (3")
3
Flue
Inlet (3")
9
7
4
8
1
2
6
5
* : n° 7-8 inter (+260 mm)
: n° 9-10 inter (+520 mm)
: n° 11-12 inter (+780 mm)
: n° 13-14 inter (+1040 mm)
910
900
388
1253*
1295
838
450
1165
155
1007
450
558
88
Ø 180
Maximum water temperature: 90°C; maximum installation pressure: 4 bar
(*):forindication

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2. Layout of the heating installation of the boiler
The boiler must be installed and commissioned by a registered installer.
The installer must make the necessary arrangements on site to ensure that the positioning and the fitting of the boiler, the
supply of combustion air, ventilation of the boiler house, connection of the gas supply and the removal of the combustion
gases via the flue systemare all in conformitywith the prevailing regulations and standards. In the following paragraphs, Saint
We remind you of some rules concerning the above aspects. If the conditions summarised above are not strictly adhered to
and resulting damage occurs then our guarantee would be invalidated.
2.1. Positioning
The boiler must not be installed inareas where there is a significant riskof frost damage or where there is arisk of the combustion
air being contaminated with halogenated substances (e.g. chlorine, detergents, aerosols, etc.), printing establishments, dry
cleaning establishments, laboratories, etc..., unless sufficient measures have been taken to ensure the supply of unpolluted
combustion air.
2.2. Aeration and ventilation of the boiler room
It is important for the safe operation that there are sufficient areas of fresh air inlet and ventilation provided to the room in
which the boiler is installed.
2.3. Installation of the boiler
The boiler must be positioned in accordance withprevailing standards, as far as possible fromany wall surface that may be
damaged by heat (wood, etc...); if necessary cover the wall with an insulated panel.
The boiler must be placed in such a way that it can easily be maintained and regularly checked.
2.4. Warning of the extractors and burners
When using combustion gas extractors, it is necessary to control to the extractors the functioning of the burners, so that those
ones cannot start if the extractors have not been brought into service beforehand and that they stop immediately in the event
of stop of the extractors.
2.5. Non-specific burners compatibility
When using a non-specified burner - i.e. a burner which has not been supplied with the boiler, the installer must satisfy himself
that he has chosen technical compatible equipment and verify the operation of the equipment after start up.
2.6. Thermal shocks and corrosion on combustion produce side
For burners it is necessary to limit the fuel flow rate, taking the efficiency into account so that the instantaneous output of
the burner cannot exceed the normal or maximum boiler output or peak boiler output as determined by the manufacturer.

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2.7. Discharge of combustion products
The chimney will be determined (height and section) in function of the boiler used, it will be capable of discharging the
combustion gases, maintaining a vacuum in the furnace (see "draught losses" in the table page 3).
If it is impossible to provide sufficient vacuum, it is possible to use a flue gas extractor, the characteristics of this one will
be given in function of the boiler to connect.
TEMPERATURE OF SMOKE : 160° C
OUTPUT (mm)
HEIGHT (m)

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- A base must be built according to good engineering practice, considering the dimensions and the weight of the
heating boiler
- Start the installation with the rear boiler section (A1)
3. Assembly of the boiler
3.1. Cast iron body installation
A
1. Position the rear boiler section vertically at the chosen place, also determined
by the overall dimensions of the boiler (jacket included).
2. Coat the section ribs with adhesive (supplied with the installation accessories)
and attach the lengths of sealing cord ( code n° 1-30-240-60410 / Ø 10mm ) in the
section ribs. Carefully degrease the double-taper nipples and bores. Coat the
nipples with compound ( supplied with the installation accessories ). Drive the
double-taper nipples into the bores using a mallet or a hammer. It is extremely
important that the nipples should be driven in smoothly and exactly in the centre
line of the bore.

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3. Insert the rear intermediate section ( attention with the visual code on the
section ).
4. Coat the section ribs with adhesive (supplied with the installation accessories)
and attach the lengths of sealing cord ( code n° 1-30-240-60410 / Ø 10mm ) in the
section ribs. Carefully degrease the double-taper nipples and bores. Coat the
nipples with compound ( supplied with the installation accessories ). Drive the
double-taper nipples into the bores using a mallet or a hammer. It is extremely
important that the nipples should be driven in smoothly and exactly in the centre
line of the bore.
5. Repeat the operation according to the number of rear inter, see table
page 3 in our exampleof illustration : 2 x.

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6. Follow the same procedure as for the points 3 to 5 for the inter middle sections
and front inter by taking care to check well the visual code on the cast-iron section:
- front inter section
-middleintersection
7. 8.
9. 10.

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11. 12.
13. 14. Insert the front section. Install the assemblyequipment according
to the drawing hereafter and tighten the nuts of both mounting
bars at the same time.

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15. Installation of the tie rods for assembly of the cast iron body. Insert the
4 tie rods in the lugs of the front and rear sections.
On the front face : 4 plain washers M16.
4 nuts DIN934 M16.
On the rear face : 4 plain washers M16.
4 nuts DIN934 M16.
Once the tie rods have been installed, unscrew the nut of the mounting
bar and remove the front plate. Remove the mounting bars.
16. Flue gas box installation.
Screw the2 studsDIN 939 12x90 ( code n° 1-80-300-12090 ) into the
tapped holes in the rear section, the end with the shortest thread
in the section.
17. Place the siliconed rope Ø14mm(code 1-30-240-60114) in the throat of
the flue gas box and fix this one with help of 2 washers M12 and 2 nuts
DIN 934 M12.

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18. Place the tube of 3swith its flange on the boiler outlet. According
to the configurations, there might be an inlet water injector, this
one is always placed on the boiler inlet. If no inlet water injector
in the configuration, place the second tube of 3swith its flange on
the boiler inlet.
19. Place the plunger in the foreseen opening on the rear section, place a
plug with hexagon head of 2son the front section in upper part and a
fitting reduction from 2sto 3/4sas well asa draincock 3/4sin lower part.
20. Screw the 2 hinges into the tapped holes in the front section ( left
or right side according to the direction opening selected). Respect
the distance of 60mm as showed on fig 21b. then place the washer
M16 and the nut M16 to block la rotation of the hinge.
20b.
60
Type Pipe injectors
L=70mm
Pipe injectors
L=140mm
Pipe inje ctors
L=190mm
122
132
241
242 X
234 X
244 X
335 X
345 X
355 X
455 X

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21. Place 2 insulations in the burner fixing flange then come to place
the door insulation by sticking it on the door, see fig. 21A. Place
the rope Ø 20mm(code 1-30-240-60120) in the groove of the door
insulation. Position the door on the hinges.
22. Tighten the door against the front section with help of screws
M16x120 and washers M16. Then place the sightflame according
to fig. 22A.
3.2. Hydraulic test
- After having assembled the cast iron block, the boiler must be subjected to an hydraulic pressure test higher than 30%of
the maximum installation pressure i.e. 1,3 x 4 = 5,2 bar , this before assembly of the insulation and the mantle. During this
operation, no defect of leaks must appear.
ZONE TO AFFIX THE
GLUE IN ORDER TO
AVOID THE COMBUSTION
GAS LEAKAGES
21A.
22A.

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3.3. Jacket installation
DO NOT TIGHTEN TOO MUCH TO OBTAIN OPTIMAL INSULATION
3.3.1. Insulation installation (mantle)
1. Place the insulation around the heating body while taking care to engage this one below the heating body.
2. Bind it with 3 (6) tapes (see schema here under).
Caution the first(s) tape(s) A, must be at +/- 5 cm of the edge of the insulation.
3. Place the rear insulation on the rear section
4. Place the 2 rear tapes (see schema here under : example for a 132 (6) model).
Pull Pull
Assembly hooping and buckles reinforced: tightening
Basic parcel = casing (122-132) Extension Lg: 260mm Extension Lg: 520mm
Commodore Plus 4-15-000-10006 4-15-000-10026 4-15-000-10052
Number of
in termed iate s e ct ions
n° 5 (122) 1 - -
n° 6 (132) 1 - -
n° 7 (241) 1 1 -
n° 8 (242) 1 1 -
n° 9 (234) 1 - 1
n° 10 (244) 1 - 1
n° 11 (335) 1 1 1
n° 12 (345) 1 1 1
n° 13 (355) 1 - 2
n° 14 (455) 1 - 2
Casing composition Commodore Plus

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3.3.2. Sectional drawing for the Commodore Plus 5 & 6 (122 - 132)
Nb: The right and left lower and upper guides are locatable thanks to the square
cutting of 10 x 10 in the middle of the guide and on the upper edge of the panels.
A
DÉTAIL F
ECHELLE 1 : 4

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3.3.3. Assembled view
Commodore n° 5 & 6 (122 - 132)
Commodore n° 7 & 8 (241 - 242)

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Commodore n° 9 & 10 (234 - 244)
Commodore n° 11 & 12 (335 - 345)

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Commodore n° 13 & 14 (355 - 455)

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3.3.4. Assembly of the panels and plates
1. Fixing of the front right lower guide support on the front cast-
iron section (fold backwards).
- 1 Tensilock screw M8X12
21
2. Fixing of the front left lower guide support on the front
cast-iron section (fold backwards).
- 1 Tensilock screw M8X12 1
3. Fixing of the rear left lower guide support on the rear cast-
iron section (fold inside).
-1TensilockscrewM8X12
43
4. Fixing of the rear right lower guide support on the rear
cast-iron section (fold inside).
- 1 Tensilock screw M8X12
5
5. Fixing of the upper guide support on the front cast-iron
section (fold backwards).
- 2 nuts M16
-2washersM16
6. Fixing of the upper guide support on the rear cast-iron
section (fold backwards).
- 2 nuts M16
-2washersM16
6
7. Fixing of the left lower guide.
- 2 Parker screws 4.2X10
8. Fixing of the right lower guide.
- 2 Parker screws 4.2X10
NB : the front right lower guide supports are the same as the rear left.
the front left lower guide supports are the same as the rear right.
7
7
8
8
rear part
front part
rear part
front part

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9. Fixing of the left upper guide.
- 2 Parker screws 4.2X10
10. Fixing of the right upper guide.
- 2 Parker screws 4.2X10
10 10
10
11. Placing of the set screw at the bottom of the
2 upper guides.
Screw only 2 times
- 2 Parker screws 4.2X10
12. Placing of the centering studs on the panels.
12.1.Screw the M4 screw on the centering stud
(drawing A)(donotblock).
12.2. Insert the unit (stud external side) in the
oblong hole (drawing B),
Slip the unit in the back of the oblong and
tighten the thrust screw M4 (drawing C).
- from 4 to 12 centering studs Ø8X16 (M4)
according to model. 4 centering studs for the
Commodore Plus 5 & 6, 8 centering studs for the
Commodore Plus 7, 8, 9 & 10, 12 centering studs
for the Commodore Plus 11, 12, 13 & 14.
- from 4 to 12 thrust screws M4X6 according to
model. 4 thrust screws for the Commodore Plus 5
& 6, 8 thrust screws for the Commodore Plus 7, 8,
9 & 10, 12 thrust screws for the Commodore Plus
11, 12, 13 & 14.
AB C
13. Encase the upper and lower slide from the right rear panel
on the right lower and upper guides and make slip this
one against the Parker screw 4.2x10 fixed at the end of the
right guide.
(rear panel locatable thanks to the oblong hole on upper
edge detail A).
A
13
13
9
9
rear part
front part
front part rear part
11