Trianco Contractor Series Operating instructions

1
H.E. 50/90 EXTERNAL
HE. 100/125 EXTERNAL
OIL-FIRED CENTRAL HEATING BOILER

2

3
CONTENTS
1. USER INSTRUCTIONS
Introd ction
How to se the boiler
After-sales service information
2. INTRODUCTION TO INSTALLATION
3. TECHNICAL INFORMATION
Technical specifications
4. INSTALLATION
Reg lations / Health & Safety
Siting
System design
Heating & hot water systems
Electrical s pply
Wiring diagram
Condensate drain connections
5. OIL SUPPLY
Oil
Storage tank
Single pipe oil s pply
Two pipe oil s pply
Oil de-aerators
6. FLUE SSTEM
Installation/Clearances
Assembly
7. COMMISSIONING
8. SERVICING
9. BURNER FAULT FINDING
10. SPARES LIST
PAGE NUMBER
4
4/5
5
6
7
8
8/9
10
10
10
10
10
11
11
12
13
13
13
14/15
14/15
14
16
16
17
18
18/19
20/21
22

4
1. USER INSTRUCTIONS
Please note, to assist Trianco in improving customer service,
it is important that the guarantee/registration card is
returned.
INTRODUCTION
The Trianco Contractor H.E. External boiler has been
designed and constructed to give years of trouble-free
service and these instructions are provided to assist you in
obtaining the best performance ith the least trouble and
cost.
The boiler ill provide both domestic hot ater and central
heating ith the simplest of controls. It is supplied ith an
adjustable boiler control thermostat, and a manual-reset high
limit thermostat, requiring little attention, other than the
setting of any system controls (such as a room thermostat or
programmer).
TO FIRE THE BOILER
Before firing the boiler, ensure that the system is full of
ater, that there is a sufficient level of oil in the storage tank,
and that all isolation valves are fully open.
Check that the time-s itch/programmer (if fitted) is on and
that the room thermostat is calling for heat.
Set the boiler thermostat (fig.1) to the desired temperature.
S itch on the electrical supply to the boiler. The burner
should fire after a fe seconds.
Set the time-s itch/programmer (if fitted) to the times and
programme required.
The boiler should no operate automatically, cutting in and
out according to the heat demand.
TO STOP THE BOILER
The boiler may be s itched off by turning off the boiler
control thermostat (fig.1) fully anti-clock ise to the off
position, ‘O’.
If the boiler is to be off for a long period of time, it is
recommended that the mains supply to the appliance is
s itched off, or the time-s itch/programmer (if fitted) is set
to the OFF position.
BOILER CONTROL THERMOSTAT
The boiler control thermostat allo s you to select the
temperature of the ater leaving the boiler. It is calibrated
bet een High and Lo , in five intermediate settings,
corresponding to a temperature range bet een 82°C (High)
and 55°C (Lo ). The thermostat is s itched off hen the knob
is turned fully anti-clock ise to position ‘O’.
Note: Where a cylinder thermostat or room thermostat is fitted,
ensure that the boiler thermostat is set above or equal to the
highest setting. satiatied
HIGH-LIMIT THERMOSTAT
The high-limit thermostat is factory-set and requires no
adjustment. Should the boiler thermostat malfunction and the
ater temperature rise to 110°C, the limit thermostat ill take
over and shut do n the appliance.
The limit thermostat is located on the rear of the control box and
can be reset by pushing in the button. If the thermostat operates
frequently, consult your service engineer, as there may be a fault
in the system.
Note: the high-limit thermostat can only be reset hen the ater
temperature has dropped by at least 20°C.
BURNER LOCK-OUT
If the burner fails to light for any reason, the boiler ill go into
lock-out mode, indicated by the illumination of the reset button on
the burner control box (fig. 2). To reset the burner, press this
button. If the burner returns to lock-out, ait for one minute
before pressing the button again.
If the burner still fails to light, follo the simple fault-finding guide
(page 5), before s itching off the electrical supply to the boiler
and contacting your service engineer if the failure persists.
Important: do not attempt to reset the b rner more than
twice – constant attempts to do so may ca se permanent
damage to components within the b rner.
FIG. 2
FIG. 1
BOILER LOCK-OUT
LIGHT &
RESET BUTTON

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SYSTEM CONTROLS
ROOM THERMOSTAT
The room thermostat should not be positioned near a source
of heat, such as a radiator, or be exposed to direct sunlight,
as this ill cause the heating to s itch off before the room is
up to the correct required temperature. Al ays follo the
manufacturer’s instructions for the best siting position of the
room thermostat.
TIME-SWITCH/PROGRAMMER
When choosing the operating times for your boiler, it is
useful to remember that central heating systems usually take
bet een half an hour and an hour before becoming effective
and usually remain arm for up to half an hour after boiler
shut-do n. The timer can therefore be s itched off earlier as
an economy measure.
FROST PROTECTION
As the boiler ill be sited externally to the property being
heated, the ater may be in danger of freezing and, as such,
the appliance is protected by a factory-fitted frost thermostat,
hich ill cause the boiler to fire should the temperature
ithin the casings drop to belo 7°C).
If the system is shut do n for a long period during very cold
eather, it is also advisable to completely drain the system.
Ho ever, too frequent draining of the system should be
avoided, especially in hard ater areas, as this could lead to
scaling of the boiler ater ays.
See page 7 for flushing and ater treatment.
SHUTTING DOWN FOR THE SUMMER
If the boiler is shut do n for the summer months, it is
advisable to have it serviced and thoroughly cleaned as
soon as possible to minimise corrosion of the heating
surfaces.
OIL
The oil for your boiler is 28 sec. Kerosene class C2 to BS
2869.
Al ays ensure that the oil storage tank is topped up
regularly; do not ait until the tank is nearly empty before
refilling, as sludge and ater could be sucked into the oil
pipe, affecting the operation of the burner and potentially
reducing the life of the pump.
After a delivery of oil, it is recommended that it be allo ed to
settle in the tank for about half an hour before restarting the
boiler.
Sludge and ater caused by condensation should be dra n
off at the drain-cock on the oil tank annually.
SIMPLE FAULT-FINDING
If the boiler fails to start for no apparent reason, carry out the
follo ing checks before calling your service engineer:
1. Check for failure in the electrical supply.
2. Check for a blo n fuse. If the fuse has blo n and the
replacement subsequently blo s again, s itch off the mains
electrical supply to the boiler and contact your service
engineer.
3. Check that there is adequate oil in the tank and that all
isolation valves are fully open.
4. Check for burner lock-out (see page 4).
5. Check for excess ater temperature (see high-limit
thermostat details, page 4, for further details).
Note: If the boiler has been shut do n due to a failure of the
po er supply, it may be necessary to reset the time-
s itch or programmer to the correct time, unless the
device has an in-built po er reserve.
SERVICING
To ensure the efficient and reliable operation of the boiler it is
essential that the burner be commissioned immediately after
installation, and prior to first use. The boiler requires an annual
service thereafter.
IMPORTANT NOTES
1. Only an OFTEC-trained and registered engineer can carry
out commissioning and service ork.
2. Electrical safety checks should be carried out by a qualified
electrical engineer.
3. It is the responsibility of the installer to ensure proper
commissioning is carried out.
4. It is a requirement of the guarantee and any extended
arranty that an annual service is carried out.
5. The system ater must al ays be protected by a corrosion
inhibitor.

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7
INSTALLATION INSTRUCTIONS
2. INTRODUCTION
The Contractor H.E. Extenal boiler has been designed to
conform to European Directive/Standards BED 92/42 EEC
LVD 73/23/EEC EMC 89/336/EEC.
The boiler design incorporates a secondary stainless steel
heat exchanger, hich recovers heat from the flue gases
hich ould normally be lost hen using conventional oil-
fired boilers.
The matched pressure-jet burner is exceptionally quiet in
operation and ensures clean and efficient combustion, ith
lo NOx emissions.
The boiler is suitable for all normal open-vented central
heating and indirect hot ater systems. The boiler can also
be used ith sealed systems up to a orking pressure of 3
bar, ith the appropriate sealed system safety equipment.
One return and t o flo sockets are provided to facilitate
connection to the heating and hot ater systems.
To ensure that the boiler is operating at maximum efficiency,
the central heating return temperature should be 50°C or
above. Maximum performance ill be achieved by
maintaining a differential of 20°-30°C bet een the flo and
return ater temperatures.
Due to the high efficiency of this range of boilers, and to
comply ith Building Regulations, Part L, it is essential that
the appliance be fitted on fully-pumped systems only.
All servicing can be carried out from the front of the boiler.
The front-mounted flue-cover permits easy access for
removal of the baffles and cleaning of heating surfaces.
The boiler is fully automatic in operation and incorporates all
necessary safety controls to ensure safe and reliable
running.
The Contractor H.E. External boiler is supplied ith the burner
set for 28 sec. Kerosene Class C2 to BS 2869 fuel to meet the
Building Regulation requirements for lo -level flue discharge.
FLUSHING AND WATER TREATMENT
The performance of the appliance could be impaired by system
debris or the effects of corrosion. Ne systems must be
thoroughly flushed to remove metal filings, solder, machining oils
and any other fluxes or greases before connecting the boiler.
When fitting the appliance to an existing system, it is advisable to
clean the system by using an appropriate flushing and descaling
agent. Refer to BS 7593 [1992] for guidance.
System additives - corrosion inhibitors and all flushing
agents/descalers should be suitable for steel boilers and comply
ith BS 7593 requirements.
Al ays refer to manufacturers' instructions.
Fail re to fl sh and add inhibitors to the system will
invalidate the appliance warranty.
The appliance is designed to be fitted to f lly-p mped
systems only. Fail re to do so will invalidate the
warranty.
The boiler m st not be r n witho t water in the
system.
IMPORTANT NOTICE:
To comply with reg lations in force, the boiler m st be installed and commissioned by an
OFTEC-registered engineer. The installation m st comply with all req irements of c rrent
Building Regulations, Part L.
Fail re to meet the terms of these req irements may invalidate the g arantee.
THE PERSON(S) WHO INSTALLS THIS APPLIANCE, SERVICES OF CARRIES OUT ANY
REMEDIAL WORK, i.e. ELECTRICAL FAULT-FINDING, MUST HAVE THE SUITABLE
ENGINEERING QUALIFICATIONS.

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3. TECHNICAL INFORMATION
FIG. 3 OUTLINE DIMENSIONS
FIG. 4
View of rear of boiler showing boiler
connections. Connections can be
made on left or right side of boiler.

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TECHNICAL SPECIFICATION
50/90 100/125
WEIGHT 140kg 170kg
WATER CONTENT 25 litres 32 litres
FLOW CONNECTIONS 1” BSP 1¼” BSP
RETURN CONNECTION 22mm Compression
MAX OPERATING PRESSURE 3 bar (43.5 psi)
TEST PRESSURE 4.5 bar (65.3 psi)
STARTING CURRENT 3.5 amp
RUNNING CURRENT 0.77 amp
CONTROL THERMOSTAT Adjustable up to 82°C
LIMIT THERMOSTAT Factory-set at 110°C
FROST THERMOSTAT Factory-set at 7°C
CASING FINISH Galvanised Steel, Painted Green
THERMAL INSULATION Boiler shell insulated ith glass fibre
ELECTRICITY SUPPLY 230/280V – 50Hz fused at 5 amp
BURNER INFORMATION
Model O tp t
(non-condensing)
O tp t
(condensing
)
Inp t Nozzle P mp
Press re CO
2
(%)
50,000 BTUs 51,272 53,022 0.45 x 80ºEH 120 psi 11.5
60,000 BTUs 61,526 63,626 0.5 x 80ºEH 140 psi 11.5
70,000 BTUs 71,781 74,231 0.65 x 80ºS 140 psi 11.0
80,000 BTUs 82,649 85,470 0.75 x 80ºEH 130 psi 11.5
Contractor
H.E. 50/90
90,000 BTUs 92,980 96,154 0.85 x 80ºS 105 psi 11.5
100,000 BTUs 102,360 109,866 1.0 x 80ºEH 96 psi 11.8
112,500 BTUs 115,326 120,102 1.1 x 80ºEH 104 psi 12.6
Contractor
H.E. 100/125
125,000 BTUs 129,656 132,726 1.1 x 80ºEH 120 psi 12.3

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4. INSTALLATION
REGULATIONS
Installation of the boiler must comply ith the follo ing
British Standards and Regulations:
BS 5410: Part 1 – Code of Practise for Oil-Firing.
BS 5449 – Forced Circulation Hot Water Central Heating
Systems.
Building Regulations - Part J (England and Wales)
- Part F sect. 111 (Scotland)
- Part L
The Control of Pollution (Oil) Regulations
Current I.E.E. Regulations
Local Water Undertakings Byla s
OFTEC Installation Requirements for Oil-Fired Boilers and
Oil Storage Tanks, OFST 100 & OFST 200.
HEALTH AND SAFETY AT WORK ACT
The installer should be a are of his responsibilities under
the Act and provide, here necessary, appropriate
protection for all persons carrying out the installation.
In the interests of safety, it is required that the appliance is
installed, commissioned and serviced by and OFTEC
registered technician.
A guide to safe orking practices for oil-firing technicians is
available from OFTEC.
Electrical work sho ld be carried o t in accordance with
BS 7671:2001 by a q alified electrical engineer.
SITING THE BOILER
So nd Levels
Whilst the lo sound level of the boiler makes it suitable for
utility room installation, the follo ing factors should be taken
into consideration before installation:
(a) Some people are particularly sensitive to lo noise
levels – discuss ith the householder.
(b) Lo -level flue terminals produce some exhaust noise,
so care should be taken hen siting adjacent to
neighbouring property, patios and play areas.
(c) Due to the condensing nature of the boiler, a plume of
ater vapour ill be discharged from the flue. This
should be taken into account hen siting the flue
terminal. Refer to section on flue systems.
Clearance and Service Access
When siting the boiler, ensure adequate clearance is allo ed for
making ater and flue connections. As the boiler can be fully
serviced from the front, there is no need for headroom allo ance.
Ho ever, a clearance of at least 750mm is required at the front
of the boiler for future service access.
Hearth
The boiler must be fitted on a non-combustible base, hich is
level and capable of supporting the installed eight of the boiler,
including its full ater content. The base should be above ground
level to prevent ater damage.
SYSTEM DESIGN
To achieve the maximum system efficiencies, the heating system
should be designed to the follo ing parameters:
Boiler Flo Temperature - 50°C to 80°C
Flo Differential Temperature - 10°C to 30°C
COMBUSTION AND VENTILATION AIR
The provision of an adequate supply of combustion air is
essential for the efficient and safe operation of the boiler. The
combustion air inlet is located at the top of the front door of the
appliance. Under no circumstances should this be covered or
blocked.
HEATING AND DOMESTIC HOT WATER SYSTEMS
The heating system should be installed in accordance ith
current HVCA Codes of Practice and BS 5449 Part 1 – Forced
Circulation Hot Water Central Heating Systems.
The flo ater connections can be made to the boiler by using
the tappings on the left or right hand side of the boiler. The return
is made via the connection on the secondary heat exchanger.
All exposed pipe ork connecting the boiler to the heating system
m st be lagged.
A drain-off cock should be fitted in the lo est part of the system.
Where the boiler is also used for providing domestic hot ater, a
double-feed indirect cylinder to BS 1566 Part 1 must be used.
Flush out the system to remove any residue before fitting the
circulating pump.
Make s re all n sed boiler tappings are pl gged before
filling the system.

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ELECTRICAL SUPPLY
230V single-phase 50Hz (f sed 5 amp)
Note: this appliance must be earthed and the electrical
supply cable must be of a greater length than the
current-carrying conductor cables (i.e. live and
neutral supply cables).
All electrical iring must be carried out by a qualified
electrician, in accordance ith current I.E.E. Regulations and
any local regulations hich may apply.
The 230V – 50Hz electrical supply must be fused by a
double-pole s itch, ith a contact separation of at least
3mm in both poles, and by a shuttered socket adjacent to
the boiler (both devices must meet the requirements of BS
1363).
The minimum requirement for the po er supply cable is PVC
sheathed flexible cord, 0.75mm² (24x0.2mm, code
designation H05 VV-F or H05 VVH2-F), as specified in table
16 of BD 6500.
All external cables entering the control box must be secured
in position by the use of strain-relief bushes (supplied, see
fig. 7 for fitting instructions).
Terminal connections are also provided in the control box for the
ancillary controls.
It is strongly recommended that an RCD is fitted in the boiler
supply circuit.
See iring diagram, Fig. 8 for further details.
High and Low Voltage Warning
In certain areas of the country, here there is a kno n risk of
high or lo voltage fluctuations, the burner should be prevented
from starting by the use of a voltage-sensitive device if the
voltage drops or increases sufficiently to endanger the
installation.
FIG. 8 – WIRING DIAGRAM
FIG. 7
FIXING OF STRAIN
RELIEF BUSHES
NOTE:
MAINS SUPPLY FOR EXTERNAL CONTROLS MUST
COME FROM THE BOILER AS SHOWN, VIA AN RCD

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CONDENSATE DRAIN CONNECTIONS
The condensate pipe can be run to either the left or the right
side of the boiler and for ease of installation should be fitted
before the boiler is positioned. Remove the boiler back
casing before installing the condensate pipe ork.
To install the condensate pipe, after deciding the direction in
hich it should run, feed the long end through the side
casing from the inside. Attach the short end ( ith the
connecting nut) to the drain connector on the back of the
condensing unit, ensuring a atertight seal is made.
Where possible, connect the condensate pipe ork to an
external aste drain.
The drain pipe must be installed to allo the condensate to
drain naturally from the boiler, on a minimum fall of 1:20.
The drain from the boiler must be 22mm diameter pipe ork.
The pipework from the condensate trap to the external
drain is not s pplied with the boiler.
Upon successful installation of the condensate pipe ork,
remove the inspection cover from the top of the condensing
unit and pour a small amount of ater inside. Examine the
condensate pipe ork for any resultant leaks and rectify
accordingly.
Failure to fill the trap ith ater before firing the boiler may
result in damage to the drainage pipe ork and potentially
allo the escape of flue gases. Any damage caused as a
result of not filling the trap ill not be covered by the
appliance guarantee.
This process ill also leave ater inside the ‘U’ section of the
condensate pipe ork, creating a seal to stop the escape of flue
gases.
Fail re to carry o t this proced re will res lt in damage to
the boiler and invalidate the appliance warranty.
IMPORTANT NOTES:
When running any external pipe ork from the trap to the drain, it
is essential that the pipe ork is kept to a minimum and is
insulated to prevent the condense from freezing.
MAINTENANCE:
The trap should be inspected at regular intervals to ensure
correct operation, and should be checked as part of the annual
service schedule.
FIG. 10
DRAIN FROM BOILER
NOT SUPPLIED
FIG. 9 – CONDENSATE PIPEWORK
DRAIN FROM BOILER NOT SUPPLIED

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5. OIL SUPPLY
OIL
The burner is factory-set to burn 28 sec. Kerosene Class C2
to BS 2869.
Trianco makes no guarantee as to the satisfactory operation
of the boiler using fuels other than that hich is stated
above.
STORAGE TANK
The tank should be fitted ith eather-protected fill and vent
connections, a drain-off cock, and an oil level indicator.
Size and Location of Tank
The tank should be large enough to allo for economic
deliveries and be located in an unobtrusive position, having
regard to the need for safety, filling, maintenance, and head
of oil required (see Fig. 11).
Steel Tanks
Steel tanks must comply ith the requirements of BS 799
Part 5: 1987 and should be mounted on brick or block piers,
ith a aterproof membrane fitted bet een the piers and
tank.
Plastic Tanks
Polyethylene tanks may be used, having several advantages
over traditional steel tanks:
(a) Pier supports are not required; the tank may be fitted
directly onto a flat surface.
(b) They do not corrode; therefore never require repainting.
(c) They are easier to handle because of lo er eight.
(d) They are supplied ith a 10-year manufacturer’s
guarantee.
Fire Protection
Whilst it is highly unlikely that a fire could start from a
domestic oil tank, protection is required from a fire hich
may originate else here. The tank should be at least 1.8
metres from a building and 750mm from a site boundary.
Where it is not feasible to adhere to these limits, the building
all must not have any openings other than those for
ventilation, the all must have at least a half-hour resistance
to fire, and must extend 1.8 metres from any part of the tank.
Alternatively, a non-combustible radiation barrier can be
employed, hich meets all the requirements of BS 5410 Part
1. This standard applies to tanks up to a capacity of 3,500
litres.
See current OFTEC regulations for further details.
To comply ith Building Regulations, section J5:
1. Where the tank is close to a d elling, fire protection must be
provided to the eaves, if less than 1.8 metres from the top of
the tank.
2. Cladding must extend at least 300mm beyond the tank.
3. The tank must be fitted on a non-combustible base.
Poll tion Protection
To comply ith Building Regulations, section J6, the tank must
be bunded (double- alled) if:
1. The tank is less than 10m from a stream
2. The tank is less than 50m from a ell, spring, or other
source of drinking ater.
3. The tank cannot be vie ed from the point of delivery.
4. There is risk of oil reaching a manhole cover or drain in the
event of a leak.
5. The tank capacity exceeds 2,500 litres.
SUPPLY
A long-life flexible oil hose is supplied ith the boiler. A filter and
shut-off valve are also required. These should be fitted as sho n
on Figs. 11, 12, & 13.
All oil line joints must be completely sealed and the total pipe run
should be flushed thoroughly before connection is made to the
burner. No soldered joints are permitted in the oil line.
Fire Valve
A remote-operated fire valve must be fitted in the oil supply line,
externally to the premises, ith the sensing phial located at a
point above the burner.
To comply with OFTEC reg lations, a CD/10 form m st
be completed and left with the appliance pon
installation.

14
OIL SUPPLY (cont.)
Single-Pipe Oil S pply (Fig. 12)
Where the lo ermost part of the tank is above the level of
the burner, a single-pipe gravity system can be used. The oil
supply pipe should be connected to the suction port on the
burner pump via the flexible hose supplied.
Two-Pipe Oil S pply (Fig. 13)
Where the lo ermost part of the tank is belo the level of
the burner, a t o-pipe suction lift is necessary.
When using the t o-pipe system, it is important to convert
the suction pump on the burner to operate as such: remove
the end cover and filter, then remove the bottom scre and
the ‘U’ asher. Replace the scre , making sure it is fully
inserted. See the burner details leaflet for further information.
A spring-loaded non-return valve must be fitted in the suction
line to prevent the oil running back to the tank. No valves are
permitted in the return line.
An additional flexible oil line is also required.
Notes:
1. The pump suction should not exceed 0.4bar, as dissolved
gas may be released from the oil, affecting combustion.
2. The return pipe must end at the same level as the suction
outlet to prevent loss of prime.
3. The outlet from the tank should be approximately 75mm (3”)
above the bottom to prevent sediment and ater being
dra n into the supply line.
Single-Pipe Oil S pply with De-aerator (Fig. 11)
Where a t o-pipe suction lift is required, but the return pipe
requirement is too long, or impractical to run, an oil de-aerator
can be used. The burner should be piped as for a t o-pipe
system, up until the de-aerator, hen a single pipe can be taken
the remaining distance to the storage tank. The de-aerator
should be fitted at the closest point to the boiler, externally to the
premises.
A non-return valve is not required ith this system, but the ‘U’
asher must be removed in the same manner as a standard t o-
pipe system.
FIG. 11
REFER TO MANUFACTURER’S
INSTRUCTIONS FOR OIL DE-AERATOR
INSTALLATION DETAILS

15
FIG. 12 – SINGLE-PIPE OIL SUPPLY
BOILER
FIG. 13 – TWO-PIPE OIL SUPPLY
BOILER

16
6. FLUE DISCHARGE
To evacuate the products of combustion safely and
thoroughly, the boiler has a highly efficient integral flue
system and there is no need to fit the boiler to a separate
flue. See page 17 for flue fitting instructions.
INSTALLATION NOTES
a) Trianco H.E. boilers operate at high efficiencies
ith lo flue gas temperatures. The flue system
used on this boiler is suitable for lo flue gas
temperatures and condensation.
b) Ensure that all the joints on the flue system are
adequately sealed, and that no condensation can
escape. It may be necessary to apply a thin bead of
silicone sealant or other lubricating substance
around the flue joints and ‘o’-ring seals before
assembling the flue.
c) Only 28 sec. Kerosene class C2 to BS 2869 is
permitted for boilers using lo -level flue discharge.
d) Positioning of flues under balconies and carports is
to be avoided
e) Modern lo -level flue boilers are designed to operate at
lo noise levels. Ho ever, hen positioning you boiler,
it is not recommended to have the terminal facing a
neighbour’s property or patio, etc.
f) The boiler should also be positions to avoid the products
of combustion entering the building. A distance of at
least 600mm must be allo ed bet een the terminal and
any indo , door or other opening into the building (see
fig. 14) for recommended terminal positions.
g) At certain times during operation, a plume of
condensation ill be produced from the terminal. When
positioning the boiler, this should be taken into
consideration to ensure that it does not cause a
nuisance to neighbouring properties.
h) Keep the terminal clear of infra-red sensing devices,
such as those used to control security lighting.
i) The terminal must be protected by the guard supplied.
DIM ‘A’
Directly belo an opening, air brick, indo , etc. 600mm
Horizontally to an opening, air brick, indo , etc. 600mm
Belo a gutter, eaves or balcony ith protection 75mm
Belo a gutter, eaves or balcony ithout protection 600mm
From vertical sanitary pipe ork 300mm*
From an internal or external corner 300mm*
Above ground or balcony level
300mm*
From a surface or boundary facing the terminal 600mm
From another terminal facing the terminal 1200mm
Vertically from another terminal 1500mm
Horizontally from another terminal 750mm
* Scotland 1990
FIG 14
TERMINAL POSITIONS
All distances in millimetres, as measured to the
termination point or rim of lo -level discharge
terminal.

17
FLUE ASSEMBLY
The flue terminal pack (supplied) should contain the
follo ing items. Check all components are present before
fitting:
1 x Flue Terminal Assembly
1 x Elbo & Sealing Plate Assembly
1 x ‘O’-Ring Seal
1 x Tube of Silicone Sealant
The flue may exit from the rear, right or left side of the boiler.
The termination point is angled, and can be rotated to enable
the combustion fumes to be directed a ay from areas here
they could cause a nuisance.
FITTING INSTRUCTIONS
1) Decide hich direction the flue is to be pointed. Remove
the top panel and using the nuts provided, fit the
elbo /sealing plate assembly (item 1) onto the rubber
gasket on top of the boiler via the 4 x studs, ensuring
that the open end is pointed in the direction required.
2) Fit the ‘o’-ring seal (item 2) into the groove on the flue
terminal (item 3), ensuring that the flat, ribbed face is to
the inside.
3) Smear a thin bead of silicone sealant (supplied) around the
‘o’-ring seal and slide the terminal into the elbo from the
outside of the boiler casing, being careful to ensure that the
‘o’-ring remains in place. The rotation of the terminal should
be decided before applying the silicone sealant.
4) Place the terminal in the desired position and angle of
rotation. Ensure that a minimum distance of 50mm is kept
from the termination point to the face of the boiler casing.
5) Slide one of the sealing rubbers (item 4) over the terminal to
meet the boiler casing, ensuring the holes line up ith those
in the casing.
6) Fit the collar plate (item 6) over the flue terminal and secure
to the boiler casing ith the scre s provided, clamping the
sealing rubber firmly in place.
7) Blank off the 2 x unused flue openings on the boiler casings
ith the remaining sealing rubbers and blanking plates (item
5).
8) Replace the top casing and fit the terminal guard (item 7)
over the flue, securing in position ith the scre s provided.
FIG 15
FLUE ASSEMBLY

18
To maintain the boiler’s high thermal efficiency and
ensure reliable operation, it should be serviced
annually by a qualified and registered OFTEC
engineer. Electrical ork should be carried out by a
qualified engineer. A CD/11 servicing and
commissioning form should be completed and left
ith the appliance on-site.
If the boiler is used to provide central heating and hot
ater all year round, the best time for the annual
service is just before the start of the heating season.
Condensate Unit & Trap
The condensate unit and trap should be inspected as
part of the annual service schedule. Remove the
access cover from the top of the condensate unit and
clean all deposits from ithin. Ensure there are no
blockages ithin the condensate pipe ork and the ‘U’
trap itself. When complete, recheck the integrity of the
pipe ork joints by pouring a small amount of ater
into the condensate unit and looking for leaks. Some
ater should be retained ithin the ‘U’ trap.
Casing
Clean ith a damp cloth. Check for signs of corrosion,
apply a suitable protective material if necessary.

19
Condensate Unit & Trap
The condensate unit and trap should be inspected
as part of the annual service schedule. Remove the
access cover from the top of the condensate unit
and clean all deposits from ithin. Ensure there are
no blockages ithin the condensate pipe ork and
the ‘U’ trap itself.
When complete, recheck the integrity of the
pipe ork joints by pouring a small amount of ater
into the condensate unit and looking for leaks.
Some ater should be retained ithin the ‘U’ trap.
FIG. 16 – BAFFLE ARRANGEMENTS
IMPORTANT:
FAILURE TO ENSURE THE CORRECT PLACEMENT OF BAFFLES WILL
RESULT IN THE INCORRECT OPERATION OF THE BOILER,
INVALIDATING THE APPLIANCE WARRANTY.
50/90 100/125

20
9. FAULT-FINDING
BURNER FAULT-FINDING
ELECTRICAL SAFETY - before making any electrical checks, switch off the mains s pply to the boiler
FAULT
BURNER WILL NOT START
BURNER STARTS BUT
FLAME NOT ESTABLISHED
FLAME ESTABLISHED BUT
BURNER LOCKS OUT AFTER
A FEW SECONDS
POSSIBLE CAUSE
Control box locked out
High limit stat tripped
System controls satisfied
Fuse blo n
Motor or pump seized
No oil supply
Photocell not seeing flame
Air trapped in pump
Solenoid valve faulty
Nozzle blocked
Electrodes incorrectly set
Electrode insulator cracked
Ignition transformer or leads faulty
Lo oil pressure
Oil contaminated ith ater
Oil filter partially blocked
Photocell faulty
Lo oil pressure
ACTION
Press orange reset button on front of
burner. NB: ONLY TRY TWICE
Press red reset button (under control
panel) and check function of boiler stat
Ensure all controls are calling for heat
Fit ne fuse (5A). If problem persists,
check for short circuit in iring
Check for rotation, replace as necessary
Check oil level in tank, check oil supply for
adequate flo
Clean photocell, ensure it is fully inserted
Bleed excess air via tapping on oil pump
Check coil for continuity, replace as
necessary
Replace nozzle ith one of same
specification (see burner leaflet)
Reset gap and position to settings sho n
in burner leaflet
Replace as necessary
Check for spark, check condition of HT
leads, replace as necessary
Check pump pressure and adjust to
settings sho n in burner leaflet
Run off oil at burner until free of ater and
drain condensation from tank
Wash filter clean ith kerosene
Clean photocell, ensure it is fully inserted,
check for damage. Replace as necessary
Check pump pressure and adjust to
settings sho n in burner leaflet