Worcester danesmoor 50/70 User guide

WORCESTER BOSCH
50/70, 70/90, 90/110
FLOOR STANDING OIL-FIRED PRESSURE JET APPLIANCES
INSTALLATION AND
SERVICING INSTRUCTIONS
THESE INSTRUCTIONS ARE TO BE LEFT WITH THE APPLIANCE
This appliance must be installe an service by a competent person

1.1 General installation information and advi e may be obtained
from the Oil Firing Te hni al Asso iation for the Petroleum
Industry (OFTEC). Training ourses are also offered by OFTEC,
leading to in lusion on their list of registered engineers.
1.2 The applian e should be installed by a ompetent person.
The person installing the applian e should be aware of the
Health and Safety at Work A t and take appropriate a tion to
ensure that the regulations are adhered to.
1.3 A qualified engineer must ommission the applian e before
handing over to the user. OFTEC re ommends the use of
registered engineers for the ommissioning of oil-fired burners.
1.4 The manufa turers notes must not be taken, in any way, as
overriding statutory obligations.
1.5 The omplian e with a British Standard does not, of itself,
onfer immunity from legal obligations. In parti ular the
installation of this applian e must be in a ordan e with the
relevant requirements of the following British Standards and
regulations in respe t of the safe installation of equipment.
BS 5410: part 1: 1997 Code of pra ti e for Oil Fired Boilers.
BS 799: part 5: 1987 Spe ifi ation for Oil Storage Tanks.
BS 7593: 1992 Code of Pra ti e for treatment of water in
domesti hot water entral heating systems.
BS 5449: part 1: 1990 Code of pra ti e for Central Heating for
Domesti Premises.
BS 7074: part 1: 1989 Appli ation, sele tion and installation of
expansion vessels and an illary equipment for sealed water
systems.
BS 7671: IEE Wiring Regulations, urrent edition.
The Building Regulations Part J England and Wales; Part F
Se tion III S otland; Part L Northern Ireland.
Lo al water ompany bye-laws.
The Control of Pollution (Oil) Regulations.
1.6 To ensure that the installation will perform to the highest
standards, the system and omponents should onform to those
mentioned in the instru tions.
2.1 The Wor ester Bos h range of applian es overed in these
instru tions have been designed to serve domesti entral
heating and hot water requirements ranging from 15 kW to
32 kW ( 51,000 Btu/h to 109,000 Btu/h ) and may be used
on sealed or open vent primary systems.
2.2 The applian es are fa tory set to burn 28 se ond Kerosene
heating oil and the output an be altered to suit the appli ation
by adjusting the burner as spe ified in tables 2 to 4.
2.3 The applian es may be onverted to burn 35 se ond Gas Oil
by hanging the nozzle and burner settings as spe ified in tables
2 to 4.
2.4 A flueless kit is available whi h allows the user to dispense
with the need for a onventional himney. The kit in orporates a
silen er whi h eliminates ex essive ombustion noise.
Note: It is a man atory requirement of the buil ing
regulations that only 28 secon kerosene is use on low
level ischarge flues.
3. Technical Data
2. General Information1. Installation Regulations
2
1. Installation Regulations...........................................Page 2
2. General Information .................................................Page 2
3. Technical Data...........................................................Page 2
4. Siting the Appliance.................................................Page 5
5. Removal of the Cabinet............................................Page 5
6. Air Supply..................................................................Page 5
7. Flue System...............................................................Page 5
8. Oil Supply..................................................................Page 7
9. Heating an Hot Water System...............................Page 8
10. Electrical....................................................................Page 10
11. Installation ................................................................Page 12
12. Commissioning the Appliance ................................Page 13
13. Instructions to the User...........................................Page 15
14. Routine Cleaning an Inspection............................Page 16
15. Short Parts List..........................................................Page 17
16. Fault Fin ing.............................................................Page 18
Contents
Fig. 1. Principal Dimensions
Model A B C D E F G
50/70 370 600 855 780 110 92 57
70/90 370 600 855 780 110 92 57
90/110 520 600 855 775 110 92 57
A
CD
G
F
Flue centre
E
B

28 Se . Kerosene 0.50 60°ES 110 1.40 1.77 215 10.5 8.5 17 58,000 15 51,000
28 Se . Kerosene 0.55 80°EH 100 1.59 2.01 225 10.5 8.75 19 65,000 17 58,000
28 Se . Kerosene 0.60 60°ES 105 1.78 2.25 235 11.5 9.0 21.5 73,000 19 65,000
35 Se . Gas Oil* 0.50 80°S 155 1.80 2.12 235 11.5 9.0 21.5 73,000 19 65,000
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
50/70 Table 2. Electro Oil Inter B9B Burner (See Fig. 13)
Fuel Nozzle
Pump
Pressure
(p.s.i.)
Fuel Flow
Rate Flue Gas
Temp.
(°C)** %CO2
Approx.
Air
Setting
Appliance
Input
kW Btu/hr kW Btu/hr
Output
Kg/h l/h
3
SPECIFICATIONS
Mo el 50/70 70/90 90/110
POWER SUPPLY 230/240V 50 Hz 230/240V 50 Hz 230/240V 50 Hz
HEATING FLOW 1 in. BSP 1in. BSP 11/4in. BSP
HEATING RETURN 1 in. BSP 1in. BSP 11/4in. BSP
FUEL LINE 1/4in. BSP 1/4in. BSP 1/4in. BSP
CONVENTIONAL FLUE DIAMETER 125 mm (5 in.) 125 mm (5 in.) 125 mm (5 in.)
MINIMUM FLUE REQUIREMENT Class 2 Class 2 Class 2
Below 260° C Below 260° C Below 260° C
HEARTH TEMPERATURE Below 100°C Below 100°C Below 100°C
MAXIMUM STATIC HEAD 30 m (98 ft.) 30 m (98 ft.) 30 m (98 ft.)
PRIMARY WATER CAPACITY 20 litres (4.4 gal.) 23.5 litres (5.2 gal.) 29.1 litres (6.4 gal.)
WEIGHT 97Kg (214 lbs.) 107 Kg (236 lbs.) 138 Kg (306 lbs.)
BURNER Ele tro Oil Ele tro Oil Ele tro Oil
Inter B9 B Inter B11C Sterling 40
WATER SIDE RESISTANCE 10°C Differen e 8 mbar 18 mbar 35 mbar
WATER SIDE RESISTANCE 20°C Differen e 6 mbar 12 mbar 19 mbar
EXIT FLUE GAS MASS FLOW 35 kg/hr 46 kg/hr 57 kg/hr
CONTROL THERMOSTAT RANGE 55°C minimum Cut In to 82°C maximum Cut Out
CONTROL THERMOSTAT DIFFERENTIAL 5°C
HIGH LIMIT THERMOSTAT SET POINT 100°C +0/-6°C
MANUAL RESET OVERHEAT THERMOSTAT 110°C +0/-6°C
Table 1
* NOTE: For use on onventional flue only.
** NOTE: The flue gas temperature is measured in the gas sampling hole on the flue outlet plate. The probe should be inserted to a depth of 50mm and angled towards the flue outlet. The temper-
ature measured is not an absolute flue gas temperature and is for general guidan e purposes only!
NOTE: The pump pressure given is for general guidan e only as variations in nozzle output an be up to ± 15%. It is, therefore, essential that the air is adjusted to give the orre t CO2value.
NOTE: The nozzle type used on 28 Se . Kerosene outputs are nozzles alibrated spe ifi ally for use with 28 Se . Kerosene whi h gives less variation in nozzle output than the standard 35 Se .
Gas Oil nozzles. However, if a 28 Se . Kerosene nozzle is not available at servi ing or ommissioning it is appropriate to install a 35 Se . Gas Oil nozzle providing the output, spray angle and
pattern of the nozzle is the same as the 28 Se . Kerosene nozzle (e.g. 0.75 80°EH may be repla ed with a 0.75 80°H).
28 Se . Kerosene 0.60 80°EH 110 1.87 2.37 215 10.5 6.0 22.5 77,000 20 68,000
28 Se . Kerosene 0.75 80°EH 115 2.10 2.66 225 10.5 7.0 25 86,000 22.5 77,000
28 Se . Kerosene 0.75 80°EH 135 2.34 2.96 240 11.5 7.5 28 96,000 25 85,000
35 Se . Gas Oil* 0.60 80°S 130 2.13 2.51 225 11.0 7.25 25 86,000 22.5 77,000
35 Se . Gas Oil* 0.60 80°S 160 2.37 2.79 240 11.5 8.0 28 96,000 25 85,000
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
70/90 Table 3. Electro Oil Inter B11C Burner (See Fig. 14)
Fuel Nozzle
Pump
Pressure
(p.s.i.)
Fuel Flow
Rate Flue Gas
Temp.
(°C)** %CO2
Approx.
Air
Setting
Appliance
Input
kW Btu/hr kW Btu/hr
Output
Kg/h l/h
28 Se . Kerosene 0.85 80°EH 110 2.36 2.99 225 11.0-11.5 11 28.5 97,000 26 89,000
28 Se . Kerosene 0.85 80°EH 130 2.66 3.37 240 11.0-11.5 12 32 109,000 29 99,000
28 Se . Kerosene 1.00 80°EH 130 2.95 3.74 245 11.5-12.0 16 35.5 121,000 32 109,000
35 Se . Gas Oil* 0.50 80°H 260 2.44 2.87 220 11.5-12.0 9 28.5 97,000 26 89,000
35 Se . Gas Oil* 0.55 80°H 265 2.76 3.25 235 11.5-12.0 14 32 109,000 29 99,000
35 Se . Gas Oil* 0.55 80°H 330 3.06 3.60 240 12.0-12.5 16 35.5 121,000 32 109,000
NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE
90/110Table 4. Electro Oil Sterling 40 Burner (See Fig. 15)
Fuel Nozzle
Pump
Pressure
(p.s.i.)
Fuel Flow
Rate Flue Gas
Temp.
(°C)** %CO2
Approx.
Air
Setting
Appliance
Input
kW Btu/hr kW Btu/hr
Output
Kg/h l/h

4
Fig. 2. General Assembl .
Control Box Assembl
Manual reset over-
heat thermostat
phial
Automatic reset high
limit thermostat phial
Burner locking
screw
Burner seal
gasket
Side panel
locking screw (A)
Burner
Optional pump
location
Manual reset
overheat
thermostat
Strain relief
bush
Burner plug-in
connector
High limit thermostat
Fire valve clip
Side panel
Top panel
Front panel
Thermostat
knob
Control thermostat
phial
Phial retaining
plug
Split pin

4.1 The applian e is not suitable for external installation unless
a suitable en losure is provided.
4.2 The applian e should be positioned on a non- ombustible
solid base as near to the flue lo ation as possible. Care should be
taken to ensure that the applian e is level; use pa king at the
orners where ne essary.
4.3 When using a low level dis harge flue system the rear of the
applian e must be positioned against an external wall su h that
the flue terminal an safely dis harge the flue gases as des ribed
in Se tion 7.
4.4 The following learan es must be left to allow a ess for
installation and servi ing:
(a) Above 300mm
(b) In front - 600mm
( ) Right and left hand side – suffi ient for panel removal and
a ess to pipe onne tions where required.
See Fig. 2.
For installation and servi ing of the applian e the abinet should
be removed as follows:
5.1 Remove the abinet top panel by lifting squarely upwards to
release the four ball stud onne tions.
5.2 Remove the front panel by pulling the bottom of the panel
forwards to release the lower ball studs and then repeat the
pro edure at the top end to release the upper ones. Take are
not to pull the bottom end too far forwards as this may ause
damage to the spring lips.
5.3 The side panels are removed by firstly following pro edures
5.1 to 5.2 as des ribed above, then remove s rew (A) from the
side panel base and the three s rews lo ated in the upper flange
of ea h side panel. Ease the side panel lear of the ele tri al
ontrol box and slide forwards to release from the lo ating lugs
on the base plate.
5.4 The ontrol box an be removed by undoing the four s rews
in the front fa ia over and then removing the wing nut on the
underside of the ontrol box. The thermostat phials should be
arefully removed from the phial po kets and the ontrol box
pla ed in a safe pla e taking are not to kink the thermostat
apillary tubes.
6.1 In order to ensure lean and effi ient ombustion an
adequate supply of air must be delivered to the ombustion
hamber. To provide suffi ient air a suitable inlet should be
provided into the room or spa e in whi h the boiler is situated,
the sizes of whi h are shown in table 5. An air bri k or other
form of ontinuous air supply may have to be built into the
installation in order to ensure an adequate supply of air.
6.2 If the applian e is to be installed in a onfined spa e or
ompartment two air vents are required, one at high level and
one at low level. The minimum free area of ea h vent is given in
Table 6 and depends whether the air is taken from another room
or from outside the building. Where the air is taken from another
room that room must ontain an air inlet as des ribed in 6.1.
6.3 There must be suffi ient learan e around the applian e to
allow proper ir ulation of ventilation air. The learan es
required for Installation and Servi ing will normally be adequate
for ventilation. See Se tion 4.
A flue system must be provided in a ordan e with BS5410:Part
1 and the Building Regulations, Part J, Se tion J2.
The flue terminal must be lo ated in a suitable position as shown
in Fig. 5, su h that the produ ts of ombustion an be fully
dispersed without the possibility of the gases entering the
dwelling or that of a neighbouring dwelling.
7.1 Conventional Flue (See Fig. 3)
Conventional Flue Diameters:
50/70 125mm (5 in.) or 100mm (4 in.)
70/90 125mm (5 in.) or 100mm (4 in.)
90/110 125mm (5 in.)
The boiler is fitted with a onventional flue lo ating spigot. The
flue pipe fits into the spigot and should be orre tly sealed with
fire ement.
Note: The size of the flue must never be redu ed from that
spe ified above. An in rease in flue size is permissible provided
that the joint is sealed orre tly.
When installed the flue should be verti al and ontain as few
bends as possible. Where bends are ne essary, a maximum of
two are permitted and 135 degree bends should be used.
All bri k and masonry himneys should be lined with a suitable
non- ombustible material, properly jointed and able to
withstand the effe ts of the working temperature of the
applian e and any ondensate whi h may form.
7. Flue S stem
6. Air Suppl
5. Removal Of The Cabinet
4. Siting The Appliance
5
AREA OF AIR INLET
MODEL cm2in.2
50/70 105 16.5
70/90 138 21.5
90/110 176 27.5
Table 5. Minimum Combustion Air Inlet Free Area for
open flue appliances.
Fig. 3. Flue Installation.
Where possible take the
flue above the apex – if not
above the apex an anti
down-draught terminal is
advisable.
Brick Chimney.
Use of a flue liner
is recommended.
Use as few bends as
possible.
Use 135° Bends.
Flues must not be reduced from
the boiler take off diameter.
ALWAYS TAKE THE FLUE ABOVE THE EAVES
Table 6. Minimum Air Vent Free Area for Open Flue
appliances installe in a compartment.
Applian e Ventilation to room or Ventilation to outside
model internal spa e
High Level Low Level High Level Low Level
50/70 209 m2314 m2105 m2209 m2
70/90 275 m2413 m2138 m2275 m2
90/110 352 m2528 m2176 m2352 m2

Down draught onditions will adversely effe t the operation of
the boiler and must be avoided. Where possible the flue should
be extended beyond the apex of the roof and should always be
taken beyond the eaves of the building. Where down-draught is
experien ed a suitable anti down-draught terminal should be
fitted to the flue termination.
The natural flue draught must be he ked in the flue pipe
immediately above the applian e or in the hole provided in the
flue outlet plate. The flue draught should be no less than
0.75mm W.g. and no greater than 5.1mm W.g. If a flue draught
greater than 5.1mm W.g. is experien ed a draught stabiliser
should be introdu ed into the flue and adjusted to a hieve a flue
draught within the spe ified range.
7.2 Low Level Discharge (See Fig. 4)
The applian e may be onverted to dis harge the produ ts of
ombustion at low level. For this purpose a spe ial flueless
kit and asso iated du ting is available, allowing the
onventional flue to be dis arded. Detailed instru tions for
onverting the applian e to low level dis harge are supplied
with the onversion kit. The 5 in h flue spigot should be
removed from the flue outlet plate, by undoing the three
retaining s rews, and the hole blanked off with the plate
provided in the kit.
Note: Un er no circumstances may 35 Secon Gas Oil be
burne with this type of flue terminal arrangement.
6
Fig. 4. Flue Installation (Rear Discharge).
See Fig. 5 for
flue terminating
positions.
80
min.
Flue guard
766
L
F
F
K
G
A
E
B
C.D.
H.J.
N
O
M
Minimum Distance (mm)
Terminal Position Open Low-Level
Flue Discharge
A Dire tly below an opening, air bri k, window, et . ............... Not allowed 600
B Horizontally to an opening, air bri k, window, et . .............. Not allowed 600
C Below a gutter or sanitary pipe................................................ Not allowed 75
D Below eaves or a bal ony.......................................................... Not allowed 600
E From verti al sanitary pipework.............................................. Not allowed 75
F From an internal or external orner......................................... Not allowed 300
G Above ground or bal ony level ................................................ Not allowed 300
H From a surfa e fa ing the terminal.......................................... Not allowed 600
J From a terminal fa ing the terminal........................................ Not allowed 1200
K Verti ally from a terminal on the same wall .......................... Not allowed 1500
L Horizontally from a terminal on the same wall..................... Not allowed 300
M Above an interse tion with the roof ........................................ 600 Not appli able
N From a verti al stru ture on the side of the terminal ........... 600 Not appli able
O Above a verti al stru ture less than 750 mm from the
side of the terminal..................................................................... 600 Not appli able
NOTE: The dimensions given are for general guidan e only. Other surrounding buildings or obje ts may affe t the learan e of
ombustion produ ts. An alternative flue terminal position should be sought when there is any possibility of a nuisan e being
aused by inadequate dispersal of flue produ ts.
The flue terminal must be lo ated in a suitable position as shown, su h that the produ ts of ombustion an be freely dispersed
without the possibility of the gases entering the dwelling or that of a neighbouring dwelling.
Fig. 5. Flue terminating positions for oil-fire appliances
Open
Flue
Win ow
Flue
Terminal

See Figs. 6 and 7.
8.1 The oil storage tank must be installed in a ordan e with
BS 799 Part 5. The tank should be arranged with a slope of 1 in
24 away from the outlet valve with a sludge o k at its lower
end .
8.2 Do not use galvanised steel tanks or pipework for the oil
supply system.
8.3 Do not use soldered joints on the oil supply pipework as this
ould ause a hazard in the ase of a fire.
8.4 The burners on all applian es are supplied so as to be
onne ted to a single pipe gravity feed system. Details of how to
onvert the burners to a double-pipe sub-gravity feed system are
shown in Fig. 6.
8.5 If a single pipe system is employed then the tank must be
positioned su h that the oil level does not ex eed 4 metres
above the level of the burner oil pump and in addition the oil
level must be at least 0.3 metres above the level of the oil pump.
Should it prove impossible to site the tank below the 4 metres
maximum oil level a head breaking devi e must be installed
between the tank and the burner.
8.6 If a double pipe system is used then the maximum su tion
height allowable is 3.5 metres.
8.7 The oil supply pipe diameter an be determined using Tables
7 and 8 depending on whether a single or double pipe system is
being installed. Sele tion of the orre t pipe diameter will
depend on the position of the oil storage tank relative to the
burner and the length of the pipe run.
8.8 The oil supply pipe should be laid as level as possible to
avoid air po kets and unne essary fri tion losses.
8.9 The following omponents should be fitted in the fuel line
between the storage tank and burner.
1. A manual isolating valve installed as lose to the tank as
possible.
2. A fire valve in a ordan e with BS799: Part 2 as shown in Fig.
7. The fire valve should be fitted externally with a fire
dete tion element lo ated within the applian e ase. Use of a
apillary type valve will allow a neat and simple installation.
A suitable valve is the KBB manufa tured by Teddington
Controls Limited. A spring lip has been provided behind the
ele tri al panel shown in Fig. 2 to allow a fire valve element
to be mounted. Alternatively a fusible link or ele tri al
system may be used. Under no ir umstan es should a
ombination isolating/fire valve be used as the sole fire
prote tion devi e.
3. A paper element filter omplying with the requirements of
BS799, Parts 2, 3 and 4 should be fitted in the fuel line between
the isolating valve and the burner and as near to the latter as
possible.
8. Oil Suppl
7
Fig. 6. Oil Pump.
(b) Danfoss BFP 11 Oil Pump.
(a) Danfoss BFP 41.
(c) Suntec AS47C Oil Pump.
Cartridge filter
12
3
4
4a
5
6
1
2
3
4
5
6
1 INLET
2 RETURN
3 BLEED AND PRESSURE
GAUGE PORT
4 VACUUM GAUGE PORT
5 PRESSURE ADJUSTMENT
6 NOZZLE OUTLET
To onvert to a double pipe system, remove plug 4a and insert the
grub s rew provided into the threaded hole. Conne t flow and
return pipes to (1) and (2).
To onvert to a double pipe system: Remove the pump front
over, remove the hangeover s rew (A) nearest to ports 1 and 2,
and the horseshoe washer underneath. Repla e the hangeover
s rew ba k into the threaded hole. Conne t the flow and return
pipes to 1 and 2.
Note: When removing the pump front over ensure that a suitable
re epta le is pla ed below the pump to at h the oil residue.
To onvert to a double pipe system, remove the return port plug (2)
and insert the grub s rew (A) provided into the threaded hole (B).
Conne t flow and return pipes to (1) and (2).
1
2
3
3
6
4
5
B
A
TABLE 7 Single Pipe Gravity Fee System
MAXIMUM ALLOWABLE PIPE RUN
HEAD (metres) (metres)
8 mm inside dia. pipe 10 mm inside dia. pipe
(10 mm O.D. opper) (12 mm O.D. opper)
0.5 10 20
1.0 20 40
1.5 40 80
2.0 60 100
TABLE 8 Double Pipe Sub-Gravity Fee System
MAXIMUM ALLOWABLE PIPE RUN
HEAD (metres) (metres)
8 mm inside dia. pipe 10 mm inside dia. pipe
(10 mm O.D. opper) (12 mm O.D. opper)
0 35 100
0.5 30 100
1.0 25 100
1.5 20 85
2.0 15 70
2.5 11 50
3.0 8 30
3.5 6 20
A

9.1 The applian e is suitable for onne tion to open vent or
sealed primary systems.
9.2 The applian e is suitable for onne tion to all onventional
indire t hot water systems utilising an indire t double feed ylinder.
9.3 The flow and return so kets are lo ated at the rear of the
applian e, two at high level (flow) and two at low level (return).
Conne tion of the flow and return so kets an either be made on
diagonally opposite so kets or on the same side of the boiler.
9.4 The applian e is supplied with an extra flow tapping to allow
a ir ulating pump to be mounted on the front fa e of the boiler.
This will allow the pump to be en losed within the abinet ase.
Where this option is hosen the flow pipe an run either side of
the boiler. (See Fig. 2).
9.5 There is no requirement for a system bypass.
9.6 The pressure jet burner fitted to the applian e has full
automati ontrol and hen e there is no requirement for heat
leak radiators.
9.7 Any unused boiler tappings should be plugged prior to
filling. It should be noted that the flow tapping on the front of the
boiler requires plugging when not used.
9.8 The primary system should be flushed and treated in
a ordan e with the re ommendations of BS 7593:1992 before
the system is handed over to the user.
9.9 The pump should be set in a ordan e with the heating load
requirements to give a flow and return differential temperature
of 11°C under full load onditions.
Open Vent Primary System (See Figs. 8 and 9).
The following points are for guidan e only. The system installation
should be arried out in a ordan e with BS 5449: Part 1.
1. Feed and Expansion System
The feed and expansion pipes must rise ontinuously from the
applian e and must be of the minimum diameter shown in Figs
8 and 9.
The istern must be arranged to provide a minimum stati head
of 1 metre above the top of the highest point in the heating
ir uit.
2. Filling and Venting
Air in the applian e is expelled through the vent pipe or
dissipated into the system. Manual air vents should be fitted at
any high points in the system.
Seale Primary System
The applian e is supplied with a manual reset high limit thermostat
and may therefore be fitted to a sealed heating system.
General
The system should be installed in omplian e with the
requirements of BS5449: Part 1. The boiler must be fitted with a
spring loaded safety valve set to operate at 3 bar (45 psi) and the
pipe onne tions made throughout the system must be apable
of sustaining a pressure of up to 3 bar.
The following is a list of major items whi h must be fitted to the
system:
1. Safety valve – 3 bar
2. Pressure gauge – 0 to 4 bar.
3. Expansion vessel
4. Automati air vent.
9. Heating And Hot Water S stem
8
Fig. 7. Oil Suppl .
(a) Single pipe s stem
Oil tank
Oil tank
Sludge cock
Maximum oil level
H = 4 m (13 ft) maximum
H = 3.5 m (11.5 ft) maximum
Tank raised 1 in 24
(40 mm per metre)
Fire valve to
BS 799 Part 2
Fire valve to
BS 799 Part 2
Isolating
valve
Shut off
valve
Paper
element
oil filter
Fire detection
element
Filter
Filter
Burner
Burner
Wall
Wall
(b) Double pipe s stem.
H = 0.3 m (1 ft) minimum
Sludge cock
Paper
element
oil filter
Tank raised 1 in 24
(40 mm per metre)
Isolating
valve
Non return
valve
Non return
valve
Fire detection
element
Shut off
valve

9
Fig. 8. T pical Open Vent Gravit Primar S stem.
Feed and
Vent Cistern
Primary cold
feed (15mm min.)
Primary cold
feed (15mm min.)
Heating vent
(22mm min.)
Heating vent
(22mm min.)
Boiler Pump Radiator
S.H. – Minimum static head 1m (3ft)
measured from the top surface of the
appliance or highest point in the
heating system to the water level in
the feed and expansion tank
N.B. A drain cock should be
installed at the lowest point
of the heating circuit
Domestic
hot water
cylinder
S.H.
S.H.
Fig. 9. T pical Open Vent Full Pumped S stem (Hone well ‘Y’ plan).
Feed and
Vent Cistern
Diverting
valve
Boiler Pump Radiator
S.H. – Minimum static head 1m (3ft)
measured from the top surface of the
appliance or highest point in the
heating system to the water level in
the feed and expansion tank
N.B. A drain cock should be
installed at the lowest point
of the heating circuit
Domestic hot
water cylinder
S.H.
S.H.

(See Figs. 10 to 12).
10.1 The wiring between the applian e and the ele tri al supply
shall omply with urrent IEE Wiring Regulations and any lo al
regulations whi h apply.
10.2 To gain a ess to the ele tri al terminal strip.
1. Isolate the mains ele tri al supply.
2. Remove the abinet front panel by pulling forwards to
release the ball studs.
3. Pull the thermostat ontrol knob forwards to remove from
its spindle.
4. Undo the fa ia retaining s rews and remove the plate.
10.3 Mains Wiring
Mains supply - 230 / 240 V AC ~ 50 Hz 5A External Fuse.
LIVE - Brown, NEUTRAL - Blue, EARTH - Green/Yellow
Mains Cable: 0.75mm2(24 x 0.20mm) to BS 6500 Table 16.
The method of onne tion to the applian e must allow omplete
isolation of the applian e, preferably via a double pole isolator
with a onta t separation of 3 mm in all poles supplying the
boiler and ontrols only.
The mains supply able should be onne ted into the terminals
marked L (Live), N(Neutral) and E (Earth) on the applian e
terminal strip and se urely held in the able lamp lo ated in the
right-hand side of the ele tri al tray base. To se ure the able,
remove the lamp retaining s rew and pull its inner body out to
allow the able to be fed through. With the able in position refit
the s rew and fully tighten to grip the able. Feed the able
between the side panel and the boiler insulation ja ket and route
to the onne tion point avoiding any hot surfa es.
The applian e must be earthed.
10.4 Programmer (See Fig. 11 and 12).
A time lo k or programmer may be added to the ontrol
system. A two hannel programmer will allow independent
ontrol of the entral heating and hot water. However, it must be
noted that the programmer used must be suitable for gravity
feed appli ations when used as shown in Figs. 11 and 12, su h
that the hot water hannel is always on when the entral
heating hannel is on, otherwise the boiler will not fire when
there is a entral heating demand.
10.5 Safety Check
In the event of an ele tri al fault after the installation of the
applian e, the ele tri al system shall be he ked for short
ir uits, fuse failure or in orre t polarity of onne tions.
10.6 Basic Control (Room Thermostat) (See Fig. 11).
As supplied the hot water and entral heating ir uits are
ontrolled by the boiler thermostat. Additional ontrol may
be obtained by the use of a room thermostat. The boiler will
remain hot when there is no demand via the room
thermostat.
10.7 Off On No Deman (Room an Cylin er Thermostat)
(See Fig. 12).
This ontrol system allows the boiler to ool when both the
ylinder and room thermostats are de-energised. The boiler
ontrol thermostat must be set to a temperature above that of
the ylinder thermostat for the ontrol system to fun tion
orre tly.
10.8 Frost Protection (See Fig. 11 and 12).
For full frost prote tion a single pole double swit h
thermostat should be fitted so that both the boiler and the
ir ulating pump ir uits are energised under frost
onditions. A suitable frost thermostat is manufa tured by
SOPAC Ltd.
10. Electrical
10
Fig. 10. Wiring Diagram (Standard).
High limit
thermostat
Brown
Green/Yellow
Blue
Brown
Green/Yellow
Blue
Brown
Blue
Green/Yellow
L
E
E
3
123 45 678
E
9
Brown
5 Amp
Brown
Brown
(C)
(1)
Brown
Green/Yellow Green/Yellow
Control
thermostat
Mains
supply
230/240V
50Hz
Satronic
control box
Burner
control
Manual reset
overheat
thermostat
Plug-in
connector
1
2
N

11
Fig. 12. Off On No Demand.
Fig. 11. Basic control.
Control box
connector block Double outlet
frost thermostat
Mains
supply
230/
240V
50Hz
Time clock/
programmer
Central
heating
Room
thermostat
Circulating pump
N
N
L
E
3
Hot water
5 Amp
Control box
connector block
Double outlet
frost thermostat
Mains
supply
230/
240V
50Hz
Time clock/
programmer
Central
heating
Room
thermostat
Cylinder
thermostat
Circulating pump
N
N
L
C
NONC
E
3
Hot water
5 Amp

11.1 After unpa kaging the applian e it is re ommended that all
abinet panels are removed, as des ribed in Se tion 5, and
stored in a safe pla e to avoid damage during installation and
allow easy inspe tion for any leaks after the system has been
filled. Where the applian e is installed lose to a wall the rear
panel may be dis arded as this is supplied for osmeti reasons
only. This will then allow the panels to be easily removed if
a ess is required in the future.
11.2 Remove the burner as des ribed below and store in a safe
pla e until the applian e is ready for ommissioning.
1. Remove the ele tri al lead plug by removing the ele tri al
fa ia and pulling the three pin onne tor free. Slide the lo ating
bush from the ele tri al box.
2. Remove the burner from the boiler by sla kening the two M6
retaining s rews lo ated in the burner housing ring and pulling
the burner lear. This will require the use of a 5mm allen key.
11.3 Flue system installation.
Install the applian e flue system as des ribed in Se tion 7.
11.4 Heating system installation.
1. Plumb the boiler into the entral heating system.
2. Che k that all unused so kets have been plugged.
3. Fill the system and vent all radiators and high points to
remove air from the system.
4. Che k the boiler and all pipework onne tions for leaks.
5. The primary system should be flushed and treated in
a ordan e with the re ommendations of BS 7593: 1992.
11.5 Oil supply installation (See Fig. 7).
Note: Never route the oil supply pipe/hose dire tly below the
ombustion hamber base.
1. Fit the oil supply pipe as des ribed in Se tion 8. The pipe an
be routed down either side of the boiler in the gap between the
base tray and the boiler shell.
Note: Never use soldered joints on oil supply pipes as this ould
ause a hazard in the ase of a fire.
2. Fit an isolating valve at the end of the oil line lose to the
burner and ensure that the valve is losed.
3. Open the main oil supply valve at the tank and he k for any
leaks.
4. Pla e a suitable ontainer below the isolating valve and open
the valve.
5. Draw off at least 2.5 litres of oil until a steady flow of lear
un ontaminated oil an be seen and turn off the isolating valve.
Note: This method may not be possible on some installations
where a sub-gravity system is used. Where this problem arises
bleed the system using the oil pump as des ribed in Se tion 12.6
and remove and lean the oil pump filter to remove any debris
olle ted as a result of installation.
11.6 Repla e the ele tri al ontrol panel and side panels in
reverse order to the removal pro edure of Se tion 5 and onne t
the ele tri al supply as des ribed in Se tion 10.
11. Installation
12

13
A qualified engineer must ommission the applian e before
handing over to the user.
Ensure that no foreign matter is left in the system as this ould
ause damage to the applian e.
12.1 Che k that the ele tri al supply to the applian e is
swit hed off.
12.2 When ommissioning the applian e after initial installation
follow the pro edure from 12.3, otherwise remove the burner
first as des ribed in se tion 14.3.
12.3 Prepare the heating system
1. After initial installation and he king for leaks, as previously
des ribed, drain down the system suffi iently to add a flushing
agent. Flush the system in a ordan e with BS 7593:1992.
2. Refill the system
12.4 Check the Burner
1. Che k that the nozzle and ele trode settings are orre t for
the relevant burner. (See Figs. 13, 14 and 15).
2. Che k that the nozzle lies entral with the ombustion head hole.
3. Che k for any visible defe ts.
12.5 Replace the burner
1. Conne t the flexible oil supply hose to the isolating valve and
tighten suffi iently to form a good seal. Where a double pipe
system is being used fit the bypass plug, as des ribed in Fig. 6,
and onne t the oil return flexible hose to the return pipe fitting.
2. With the sponge O-ring gasket around the burner blast tube
insert the burner into the housing tube. Push the burner firmly
forward to ompress the gasket and tighten the two lo king
s rews using a 5mm Allen key.
Note: It is important that a good seal is made between the
burner and the boiler to prevent re- ir ulation of the flue gases
from the ombustion hamber to the room.
3. Re- onne t the ele tri al lead plug into the ontrol box.
12.6 Check the installation
1. Che k that the applian e is orre tly wired as des ribed in
Se tion 10.
2. Che k that all baffles are orre tly lo ated and the heat shield
is orre tly mounted (70/90 and 90/110 models only) as
shown in Fig. 16.
3. Che k that the baffle retainer is orre tly mounted (70/90
and 90/110 models only) as shown in Fig. 16.
6. Che k that the ontrol thermostat and auto reset high limit
thermostat phials are orre tly lo ated in the boiler thermostat
po ket positioned in the top front of the boiler.
7. Che k that the manual reset limit thermostat is lo ated in the
steel po ket above the ele tri al box mounting bra ket on the
front fa e of the boiler.
8. Che k that all of the air-ways to the burner are lear of any
obstru tion.
12.7 Fit a pressure gauge and manifold to the burner pump at
the point indi ated in Fig. 6 or the pressure gauge port shown in
Fig. 14 on the 70/90.
12.8 Turn on the ele tri ity to the applian e.
12.9 Blee the burner.
Single Pipe System
Release the fuel bleed port on the manifold and pla e a suitable
re epta le beneath. Turn on the boiler thermostat and allow the
burner to run through to lo kout. Wait two minutes and reset
the burner ontrol box. Repeat the pro edure at least three
times or until a steady stream of oil, without air, is exhausted
from the bleed port. Re-lo k the bleed port.
Two Pipe System
A two pipe system will automati ally vent the air ba k to the oil
tank. Turn on the boiler thermostat and allow the burner to run
through to lo kout. Wait two minutes and reset the burner
ontrol box. Repeat the pro edure until the burner fires and
runs in a steady state. This may take several attempts
depending on the oil pipe length and height.
12.10 Adjust the air shutter and pump pressure to the settings
re ommended in Tables 2 to 4. After a pre-ignition period of
approximately 15 se onds the burner should ignite. Flame
sensing is arried out by means of a photo ell mounted in the
burner body. Should the boiler fail to establish a normal firing
pattern (or should flame failure o ur during running), the
absen e of a flame is sensed and the ontrol box is monitored to
a safe lo kout ondition and the boiler is shut down. The
lo kout indi ator light/reset button in the burner ontrol box
will illuminate indi ating that the burner has gone to lo kout. In
this instan e wait two minutes and press the lo kout reset
button to initiate another start sequen e. Repeat the pro edure
until a flame is established.
Note: Persistent lo kout when running indi ates a fault and a
Servi e Engineer should be onsulted.
12.11 Run the boiler for approximately 3 minutes and swit h
off he king that there is no after-spurting from the nozzle. This
an be dete ted by oil saturation on the blast tube. If after-
spurting o urs remove the burner from the boiler, uns rew the
nozzle, and while holding the burner in a verti al position, fill
the nozzle holder with oil and refit the nozzle. Repla e the
burner and ontinue to run the boiler for three minute periods
until after-spurting stops.
Note: In order that after-spurting is redu ed to a minimum
during the ommissioning period it is re ommended that a
pressure gauge only is fitted on the external pressure gauge
port on the Ele tro Oil B11 (See Fig. 14). Use of a “T” pie e
pressure gauge manifold will in rease the oil line volume and
hen e in rease the degree of after-spurting.
12.12 Run the boiler for a further 15 minute period and then
finally fine tune the air shutter setting to give the CO2level
spe ified in Tables 2 to 4 less 0.5%CO . During this period some
smoke will be emitted due to the burning of the organi binder
in the base insulation board. Smoke readings will therefore be
ina urate at this point.
Note: A flue gas sampling point is lo ated on the boiler top
plate.
12.13 Che k that the smoke reading is in the range 0-1. If this
annot be a hieved then he k that the burner head is set
orre tly and the nozzle is in good ondition.
12.14 Che k that the flue temperature does not ex eed the
value spe ified in Tables 2 to 4. If this is the ase then he k that
the baffles are orre tly lo ated. If the baffles are orre tly
lo ated then redu e the pump pressure sin e nozzle variations
of up to + or – 15% may o ur.
12.15 Remove the oil pressure gauge and manifold and he k
all oil system joints for any signs of leakage.
12.16 Refit the abinet front panel.
12.17 Allow the burner to run for a further five minutes and
then re he k the CO2level and adjust the air setting if
required. With the abinet front panel fitted as 12.16, repeat
the previous test pro edure and Che k that the smoke
number is in the range 0-1. Repeat the fine tuning pro edure
if found ne essary.
12.18 Refit the abinet top and front panels in the reverse
order to that des ribed in Se tion 5.
12.19 When the heating ir uit has rea hed full operating
temperature he k the whole system for any leaks.
12. Commissioning the Appliance

14
Fig. 13. Electro Oil Inter B9 Burner.
(50/70 Model).
Combustion Head
Draught tube Nozzle Nozzle block
Spark gap
2.0 - 2.5 mm
2 mm
10 mm
A
Combustion head
Locking screw
Transformer
Photocell
Control box
Lockout reset button
Air adjustment screw
(4mm hexagonal head)
Air control indicator
Oil pump
Pressure
adjustment
screw
Adjusting
disc
Output Combustion Dimension
kW Head A
15 PL 6/7/21.5/10 x 78 mm 3 mm
17 PL 6/7/21.5/10 x 78 mm 5 mm
19 PL 6/7/21.5/10 x 78 mm 5 mm
To adjust the nozzle position,
undo the lo king s rew lo ated
at the rear of the nozzle line and
rotate the adjusting dis one
turn anti- lo kwise to move
forward by 1 mm.
Fig. 14. Electro Oil Inter B11 Burner.
(70/90 Model).
Combustion Head
Air control indicator
Photocell
Air adjustment screw
(4 mm hexagonal head)
Transformer
Control box
Oil pump
Pressure
adjustment
screw
Draught tube Nozzle Nozzle block
Spark gap
3-3.5 mm
2 mm
10 mm
A
Lockout
reset button
Pressure
gauge port
Output Combustion Head Dimension
kW A
20-25 PL 10/4/24/10 x 78 mm 5 mm

13.1 Hand the users instru tions to the user or pur haser for
retention and instru t them in the effi ient and safe operation of
the applian e and the heating/hot water system.
13.2 Advise the user or pur haser of the pre autions ne essary
to prevent damage to the heating/hot water system and to the
building in the event of the heating system remaining
inoperative during frost onditions.
13.3 Finally advise the user or pur haser that for ontinued
effi ient and safe operation of the applian e it is important that
adequate servi ing is arried out by a qualified engineer at least
on e per year.
Wor ester Heat Systems Limited will be pleased to dis uss and
offer a omprehensive maintenan e ontra t.
13.4 Set the system ontrols to the users requirements.
13. Instructions To The User
15
Fig. 16. Location of Boiler Fluewa Baffles.
(a) 50/70
ENSURE THAT ALL BAFFLES ARE FIRMLY SEATED IN POSITION
BAFFLE
RETAINER
BAFFLE
HEATSHIELD
(b) 70/90 and 90/110
Fig. 15. Electro Oil Sterling 40 Burner.
(90/110 model).
Ignition
transformer
Connecting
pipe
Solenoid
valve
Air control
indicator
Air adjustment
screw
(4mm hexagonal head)
Pressure
adjustment
screw
Photocell
Motor
Combustion head
Control
box
Pump
Lockout
reset button
Output Combustion Head Dimension
kW A
26-32 PL 6/7/21.5/10 x 78 mm 3.5 mm
Combustion Head
Draught tube Nozzle Nozzle block
Spark gap
2.5 - 3.0mm
0mm
7.5mm
A

14.1 The following should be arried out at least on e per year
for 28 se ond Kerosene and twi e per year for 35 se ond Gas Oil,
to ensure effi ient, trouble free operation.
1. Carry out a pre-servi e he k noting any operational faults.
2. Che k and lean the burner.
3. Che k and lean the air intake grille lo ated in the boiler
room.
4. Che k and lean the baffle retainer (70/90 and 90/110
models only).
5. Che k and lean the baffles.
6. Che k and lean the heat ex hanger surfa e.
7. Che k the heat shield (on 70/90 and 90/110 models only).
8. Che k the ombustion hamber base insulation board.
9. Che k that the flue system is unobstru ted and lean as
ne essary.
11. If the applian e has been installed in a ompartment he k
that the ventilation areas are lear.
12. Clean all oil filters.
Some of the servi ing points are overed more fully in the
following instru tions:-
14.2 Pre-Service Check
1. Remove the abinet front and top panels as des ribed in
se tion 5 .
2. Operate the applian e and system, noting any faults whi h
may need to be orre ted during the servi e.
14.3 Cleaning the Burner
IMPORTANT: Dis onne t the ele tri al supply at the mains
before ommen ing any servi ing. Turn off the oil at the servi e
o k.
1. Remove the burner.
(a) Isolate the oil supply at the valve lo ated lose to the
burner.
(b) Sla ken the two burner lo king s rews, remove the burner,
and arefully pla e on the floor.
2. Clean the fan impeller using the following pro edure:
Electro-oil Inter B9 Burner
(a) Remove the two s rews holding the ombustion head in
position and withdraw the ombustion head and air guide
ollar.
(b) Remove the three remaining s rews holding the front
over plate in position and withdraw the over to expose
the fan impeller.
( ) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(d) Che k that the impeller rotates freely.
(e) Clean the air inlet passage and he k that the adjustment
me hanism operates freely.
(f) Re-assemble the omponents.
Electro Oil Inter B11
(a) Remove the a ousti fan inlet over.
(b) Remove the three s rews holding the fan owl in position
and remove the owl noting how the fan ontrol flap is
positioned.
( ) Che k that the air ontrol flap pivots freely and ensure the
air path to the burner head is lear.
(d) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(e) Che k that the impeller rotates freely.
(f) Re-assemble the omponents.
Electro Oil Sterling 40
(a) Remove the air adjustment over.
(b) Separate the main body of the burner from the burner
front by removing the M6 allen s rew (lo ated beneath the
air adjustment s rew), using a 5mm allen key.
(c) Note the position of the air damper adjustment and he k
the air damper moves freely.
( ) Che k the air path to the burner head is lear.
(e) Clean both sides of the fan impeller and remove any debris
from the burner housing.
(f) Che k the impeller rotates freely.
(g) Re-assemble the omponents.
3. Remove the ombustion head and thoroughly lean all
deposits.
4. Inspection of Mechanical Shut-off Valve.
a) Remove the nozzle.
b) Fasten an M5 s rew, with a minimum length of 30mm, into
the threaded hole (A) and pull the s rew to withdraw the he k
valve.
) Che k that the nozzle holder is lear of any debris and lean if
ne essary.
d) Che k that the 3 holes in the he k valve are lear of any
debris. Dis ard the he k valve if the holes annot be leared or
if the unit is defe tive and repla e with a new one.
e) Repla e in the reverse order.
5. It is strongly re ommended that the oil atomising nozzle is
repla ed at ea h servi e. If this is not possible then remove and
lean the integral filter, but under no ir umstan es should the
nozzle be stripped into its omponent parts and never attempt
to lean the nozzle tip.
6. Che k and reset the ele trodes, where ne essary, as shown in
Figs. 13, 14 and 15.
7. Repla e the ombustion head and he k that the nozzle lies
entral to the ombustion head and the head settings are as
shown in Figs. 13, 14 and 15.
8. Withdraw the photo ell from its housing and lean.
9. Remove and lean the oil pump internal filter using kerosene
or white spirit. The internal filter is a essed by removing the oil
pump over on the Danfoss BFP 11 and Sunte AS47C and by
uns rewing and withdrawing the artridge on the Danfoss BFP
41 as indi ated in Fig 6.
10. It is re ommended that the standard flexible oil line is
repla ed at ea h yearly servi e to prevent the possibility of a
leak due to ageing.
11. Re-assemble the burner omponents.
12. Che k the sponge O-ring seal lo ated around the ombustion
head and repla e if ne essary. It is imperative that this seal is in
good ondition sin e failure will ause the flue gases to leak into
the room.
14.4 Remove the paper element from the external oil filter and
repla e. If the filter ontains a washable element then
thoroughly lean in Kerosene or white spirit and re-assemble
into the filter.
14.5 Clean the Boiler
1. Remove the boiler top a ess door by releasing the two M10
nuts and he k the fibreglass rope seal. Repla e the seal if
ne essary.
14. Routine Cleaning And Inspection
16
Fig. 17. Mechanical Shut-off Valve.
Check ValveCheck Valve
Nozzle Assembly
A

17
15. Short Parts List
Part Manufacturers Reference Qty WHS Part No.
Burner Control 1. Box Satroni TF832.3 1 8 716 156 648 0
Photo ell Satroni MZ770 1 8 716 142 735 0
2. Remove and lean the baffle retainer (70/90 and 90/110
models only). See Fig. 16b.
3. Remove the baffles and lean and he k their ondition.
Repla e any baffles onsidered to be badly orroded.
4. Thoroughly lean all of the heat ex hanger surfa es using a
stiff wire brush and va uum lean all loose debris from the
ombustion hamber. Take are not to damage the base
insulation !
5. Remove and he k the heat shield where fitted (70/90 and
90/110 models only). See Fig. 16b.
6. Che k the ondition of the ombustion hamber base
insulation and repla e if there is any sign of signifi ant damage.
7. Che k and lean the flue.
8. Repla e the items in reverse order noting the baffle positions
shown in Fig. 16.
14.6 Che k that a fire valve is fitted to the in oming oil line with
the body lo ated outside the premises and the dete tion
element lo ated within the applian e ase. A fire valve lip is
provided for this purpose as shown in Fig. 2. test the operation
of the fire valve to ensure that the me hanism operates and that
the oil supply is ompletely isolated.
14.7 Recommission the Burner.
1. Conne t the flexible oil supply hose to the isolating valve and
tighten suffi ently to form a good seal. Where a double pipe
system is being used onne t the oil return hose to return pipe
fitting.
2. With the sponge O-ring gasket around the burner blast tube
insert the burner into the housing tube. Push the burner firmly
forward to ompress the gasket and tighten the two lo king
s rews.
Note: It is important that a good seal is made between the
burner and the boiler to prevent emission of the flue gases from
the ombustion hamber.
2. Turn on the oil supply at the servi e o k.
3. Re ommission the burner as des ribed in Se tion 12.

18
LOCKOUT
INDICATED BY RED LAMP ON CONTROL BOX
To Re-set wait 2 minutes and press re-set button
Ignition failure No oil delivery
from nozzle.
Check oil supply
at oil pump.
Air adjustment fault.
CO
2
should be
as specified in
tables 2 to 4.
Flame detection fault.
Oil at
oil pump. No oil at oil pump.
No oil in tank.
Check tank and
replenish if
necessary.
Filters or oil line
blocked. Check
filters from tank
to boiler and clean
if necessary.
Photocell
filmed over.
Clean.
Photocell
faulty.
Replace.
Faulty control box.
Replace if
necessary.
Nozzle blocked.
Replace nozzle. Faulty pump or faulty pump drive.
Replace if necessary.
Air in pump.
Bleed pump.
IGNITION FAILURE BURNER FAILS TO START PULSATION ON START
Control box fault.
Replace if necessary.
Burner motor fails
to operate.
Check motor across
mains supply.
Intermittent
lockout.
Bad electrical
connection. Downdraught. Intermittent flame detection fault.
See flame detection
fault.
Pulsation
on start.
Extend flue above
eaves, or if possible
above roof apex or
adjacent obstructions.
Fit a downdraught
cowl if flue cannot
be extended.
Check control box
connections.
Electrode
settings
incorrect.
See installation
instructions.
Faulty ignition
transformer.
Replace
if necessary.
Open circuit
ignition. Electrical connections not properly
made in
control box.
Faulty control box.
Replace control box.
Electrodes
broken. High tension leads faulty.
Boiler does not respond to a call for heat.
Boiler thermostat
faulty. Check by
linking out high
limit and control
thermostats.
Programmer
open circuit. Faulty control box. Replace
if necessary.
Flue draught
incorrect.
Check flue
draught.
Combustion
settings
incorrect.
Set up as in
installation
instructions.
Faulty nozzle.
Replace nozzle.
HIGH SMOKE NUMBER
Faulty nozzle.
Replace nozzle. Incorrect combustion settings. Readjust as in
installation instructions.
Oil pressure incorrect.
Adjust to recommended
pressure settings.
Target wall incorrectly
positioned or faulty
(where fitted).
Air intake blocked.
Check air intake is clear. Incorrect components used on combustion
head. Check with installation
instructions.
OIL SMELLS
Fumes on start-up.
Blocked flue.
Check flue with gauge.
Oil soaked hearth. Odour in boiler room.
Faulty burner
operation.
Numerous lockouts.
Cure the lockout
condition.
Oil leaks pipe fittings.
Take apart and
remake if necessary.
Leaks at tubing connectors.
Ensure end of
tubing is secure.
FAULTY BOILER OPERATION
Worn motor bearings.
Replace motor.
Noisy operation.
Fan out of balance.
Replace fan.
Pump noise.
Air in pump. Worn pump.
Replace.
Boiling. Short cycling.
Faulty boiler thermostat.
Replace if necessary. Short circuit boiler thermostat. Take out of circuit to check. Thermostat bulb not fully home in pocket.
Ensure bulb is
pushed fully home.
External controls not
operating correctly. Boiler thermostat differential incorrect.
Should be 5°C ±2°C.
Boiler rating incorrect.
If overrated heat load
satisfied very quickly.
16. Fault Finding

19
NOTES:

This booklet is a urate at the date of printing but will be superseded and should be disregarded if spe ifi ations and/or appearan es are hanged in the interests
of ontinued improvement.
All goods sold are subje t to our offi ial Conditions of Sale, a opy of whi h may be obtained on appli ation.
8 716 145 074f 05/01
Worcester Heat Systems Limited, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: [phone]. Fax: [phone].
www.worcester-bosch.co.uk