GAH Thermeco Bedienungsanleitung

clean heat technology

High Efficiency Oil FirHigh Efficiency Oil Fir

High Efficiency Oil Fired Boilersed Boilers

ed Boilersed Boilers

ed Boilers

Condensing Boiler Handbook

All Models

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For owners, installers and service engineers

Internal Wall Mounted External Wall Mounted

External Floor Standing Internal Floor Standing

heating products

Band A

SEDBUCK Range 90% and above

clean heat technology

Important Health and Safety Information for Installers and Service Engineers

SEALS AND INSULATIONSEALS AND INSULATION

SEALS AND INSULATION

FIBREGLASS INSULATION, GLASS ROPE, MINERAL WOOL,

INSULATION PADS AND CERAMIC FIBRE.

1. Avoid inhalation of fibres or dust, wear face mask.

2. Avoid eye contamination by fibres or dust - wear eye

protection.

3. As far as possible avoid any skin contact with Fibreglass

Insulation, Glass Rope, Mineral Wool, Insulation Pads and

Ceramic Fibre.

OTHER MATERIALSOTHER MATERIALS

OTHER MATERIALS

SEALANTS, ADHESIVES AND PAINTS

Sealants, Adhesives and Paints are used in the construction of

Boilers. When used in the manner for which they are intended

they do not present any known hazard.

ELECTRICELECTRIC

ELECTRIC

All Boilers when in use have electrical supply of 240V (enough

to endanger life) connected to the Panel and Burner.

Always isolate the boilers during cleaning, servicing and repair.

EXTERNAL BOILERS

In wet weather conditions due consideration should be given to

the metal casing and electrical current within the Boiler casing.

Never open the front door of External Wall Mounted Boilers in

conditions such that water could come in contact with any

electrical component causing an immediate danger to life.

Health and Safety at Work Act 1974

Consumer Protection Act 1987

COSHH Regulations 1988

The following information is given as a requirement of the above

legislation.

Great care is taken by Thermeco Boilers to ensure that Boilers

are designed and manufactured to meet general safety

requirements when properly used and installed as

recommended in this manual.

It is the responsibility of Users and Engineers to ensure that

adequate protective clothing and glasses are worn when working

on the Boiler.

FUELFUEL

FUEL

KEROSINE GAS & OIL FUELS (MINERAL OILS)

1. The effect of minerals oils on the skin vary according to the

duration of exposure.

2. The lighter fractions also remove the protective grease

normally present on the surface of the skin rendering the

skin dry, liable to crack and more prone to damage caused

by cuts and abrasions.

3. Skin rashes (oil Acne). Immediately seek medical attention

for any rash, wart or sore developing on any part of the body,

particularly on the scrotum.

4. As far as possible avoid any skin contact with mineral oil or

clothing contaminated with mineral oil.

5. Never breathe any mineral oil vapours. Do not fire the

Burner in the open i.e. out of the Boiler as misfire will cause

unburnt oil vapours.

6. Barrier cream containing lanolin such as Rosalex Antisolv,

is highly recommended together with a strict routine of

personal cleansing.

7. Under no circumstances should mineral oils be taken

internally - never suck or blow a pipe!

Patents GB2373838 Application 0222400.2atents GB2373838 Application 0222400.2

atents GB2373838 Application 0222400.2atents GB2373838 Application 0222400.2

atents GB2373838 Application 0222400.2

©©

2008 GAH (Heating Products) Ltd.2008 GAH (Heating Products) Ltd.

2008 GAH (Heating Products) Ltd.

Manual by Harber Technical Services Tel/Fax 01263 515444

E-mail:[email protected] www.harbertech.co.uk

GAH (Heating Products) Ltd.GAH (Heating Products) Ltd.

GAH (Heating Products) Ltd.

Building 846

Bentwaters Parks,

Rendlesham,

Woodbridge

Suffolk

IP12 2TW

Tel:el:

el:el:

el: 01394 42116001394 421160

01394 42116001394 421160

01394 421160 - T- T

- T- T

- T

echnical Supporechnical Suppor

echnical Support & Salest & Sales

t & Salest & Sales

t & Sales

Fax:Fax:

Fax: 01394 42117001394 421170

01394 42117001394 421170

01394 421170

[email protected]

www.gah.co.uk

In pursuance of a policy of constant development, GAH (Heating Products)

Limited reserve the right to change any boiler part or design without notice,

therefore certain details included in this manual may not be correct at the time

of printing. Any modification and improvements detailed in this manual does not

commit Thermeco to update any system previously supplied.

Manual Part No. .................. 015-22362

Manual Ref ......................... BC1

Issue ...................................5

Date ....................................Jan 2011

GAH (Heating Products) Limited will not accept

responsibility for any damage or personal injury caused by

not giving due consideration to the above safety

recommendations.

HTS REF /GAHMANUAL COND1 250111

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CONTENTSCONTENTS

CONTENTS

1 USER INFORMATION

2 OPERATOR CONTROLS

3 BOILER OPERATION

4 INSTALLATION GENERAL

5 INSTALLATION

6 OIL SUPPLY

7 BALANCED FLUE

8 COMMISSIONING

9 SERVICING

1010

10 FAULT FINDING

1111

11 TECHNICAL INFORMATION

APPENDIX

CONTENTSCONTENTS

CONTENTS

Section 1 User InformationSection 1 User Information

Section 1 User Information

1-1 Installer ---------------------------------------------------------- 4

1-2 Householders Information ---------------------------------------- 4

1-3 Service History -------------------------------------------------- 4

1-4 Boilers covered by this manual ---------------------------------- 5

Section 2 Operator ControlsSection 2 Operator Controls

Section 2 Operator Controls

2-1 Control Box Internal Boilers -------------------------------------- 6

2-2 Control Panel External Boilers ----------------------------------- 6

Section 3 Boiler OperationSection 3 Boiler Operation

Section 3 Boiler Operation

3-1 Switching the Boiler ON ----------------------------------------- 8

3-2 Switching the Boiler OFF ---------------------------------------- 8

3-3 Burner ‘Lockout’ ------------------------------------------------- 8

3-4 Care of the Boiler ------------------------------------------------ 9

Section 4 Installation GeneralSection 4 Installation General

Section 4 Installation General

4-1 Compliance --------------------------------------------------- 10

4-2 Siting and Positioning the Boiler ------------------------------- 10

4-3 Condensate Drain Arrangement -------------------------------- 11

Section 5 InstallationSection 5 Installation

Section 5 Installation

5-1 Floor Standing - Internal --------------------------------------- 13

5-2 Internal Wall Mounted ----------------------------------------- 14

5-3 Select External Wall Mounted --------------------------------- 17

5-4 Floor Standing External ---------------------------------------- 19

5-5 Floor Standing System - -------------------------------------- 20

Section 6 Oil SupplySection 6 Oil Supply

Section 6 Oil Supply

6-1 Oil Storage Tanks ---------------------------------------------- 25

6-2 Oil System ---------------------------------------------------- 25

6-3 Oil Supply System -------------------------------------------- 26

Section 7 Balanced FlueSection 7 Balanced Flue

Section 7 Balanced Flue

7-1 Balanced Flue Selection --------------------------------------- 28

7-2 Suggested Flue Siting ----------------------------------------- 29

7-3 Burner Air Supply ---------------------------------------------- 30

Section 8 CommissioningSection 8 Commissioning

Section 8 Commissioning

8-1 Commissioning Checks --------------------------------------- 31

8-2 Extra Procedures for System Boilers --------------------------- 32

8-3 Extra Procedures for External Boilers --------------------------- 33

8-4 Combustion Tests --------------------------------------------- 33

8-5 Handing Over -------------------------------------------------- 33

Section 9 ServicingSection 9 Servicing

Section 9 Servicing

9-1 Routine Service ------------------------------------------------ 34

9-2 Boiler Baffles -------------------------------------------------- 35

Section 10 Fault Finding

Section 10 Fault FindingSection 10 Fault Finding

Section 10 Fault Finding

10-1 Householders Fault Finding ------------------------------------ 39

10-2 Householders Fault Finding - System Boilers ------------------ 39

Section 11 TSection 11 T

Section 11 Technical Informationechnical Information

echnical Informationechnical Information

echnical Information

11-1 Boiler Specifications ------------------------------------------ 38

11-2 Burner Setting Data -------------------------------------------- 40

11-3 Burner Settings ------------------------------------------------ 41

11-4 Panel Wiring Diagrams ---------------------------------------- 42

11-5 Parts Supplied with Boiler ------------------------------------- 45

11-6 Boiler Dimensions --------------------------------------------- 46

11-7 Conventional Flue Arrangement - All Internal Boilers ---------- 51

11-8 Balanced Flue Dimensions ------------------------------------ 54

AppendixAppendix

Appendix

AP1 Regulations ---------------------------------------------------- 63

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Boiler Installed by:-

Tel:

Fax:

email:

The type of fuel required for the Boiler is :-

Tank Capacity

Oil Suppliers

Kerosine 28 second class C

✍

To the householder.

Thank you for purchasing a Themeco Oil

Fired Boiler.

In the unlikely event of a problem arising

with the Boiler please first refer to:-

Section 10-1 ‘Householders Fault

Finding’ of this Manual.

If you cannot rectify the problem from the

information given, or if the problem

persists contact the INSTALLER who will

assess the problem and if necessary

contact our service department.

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1-1 Installer

1-2 Householders Information

1-3 Service History

Note

The price of fuel has seasonal fluctuations and

varies from supplier to supplier. You are advised

to shop around for a good deal.

USER INFORMAUSER INFORMA

USER INFORMATION 1TION 1

TION 1TION 1

TION 1

DO NOT involve a third party that may incur you costs as this will not be covered by the Boiler Guarantee.

Any work not authorised by GAH (HEATING PRODUCTS) LTD. may also invalidate the Guarantee.

Work carried out and parts fitted by unauthorised engineers cannot be guaranteed.

The Boiler must be commissioned within 10 working days of installation, failure to do so will invalidate the Guarantee.

Boiler Commissioned by:-

Tel:

Fax:

email:

Boiler Service Engineer

☎

It is a condition of the Guarantee that the Boiler is serviced every 12 months.

For Information on Bio fuel

consult installer or GAH.

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USER INFORMAUSER INFORMA

USER INFORMATION 1TION 1

TION 1TION 1

TION 1

Floor Standing Internal

Model BFIC 12/24

kW 12.0 to 24.0

Btu/hr x 1000 40 to 80

✍

Floor Standing Internal

Model BFILC 12/20

kW 12.0 to 20.0

Btu/hr x 1000 40 to 70

✍

Floor Standing Internal System

Model BFISC 12/24

kW 12.0 to 24.0

Btu/hr x 1000 40 to 80

✍

Wall Mounted Internal

Model BWIC 12/16

kW 12.0 to 16.0

Btu/hr x 1000 40 to 55

✍

Wall Mounted Internal System

Model BWISC 12/16

kW 12.0 to 16.0

Btu/hr x 1000 40 to 55

✍

Wall Mounted External

Model BWEC 12/16

kW 12.0 to 16.0

Btu/hr x 1000 40 to 55

✍

Floor Standing External

Model BFEC 12/24

kW 12.0 to 24.0

Btu/hr x 1000 40 to 80

✍

Floor Standing External System

Model BFESC 12/24

kW 12.0 to 24.0

Btu/hr x 1000 40 to 80

✍

1-4 Boilers covered by this manual

My Boiler Tick box Wiring

Diagram

QUICK PAGE REFERENCE

Dimensions

Oil

Connection

Floor Standing Internal

Model BFIC 24/30

kW 24.0 to 30.0

Btu/hr x 1000 80 to 100

✍

INTERNAL

EXPANSION

VESSEL

INTERNAL

EXPANSION

VESSEL

EXTERNAL

EXPANSION

VESSEL

INTERNAL

EXPANSION

VESSEL

EXTERNAL

EXPANSION

VESSEL

INTERNAL

EXPANSION

VESSEL

p11 p40 p43

p24 p44

p11 p40 p43

p24 p44

p14 p40 p45

p24

p14 p40 p45

p24

p24 p44 p46

p17 p41 p47

p24

p17 p41 p47

p24 p44 p46

Floor Standing Internal System

Model BFISC 24/30

kW 24.0 to 30.0

Btu/hr x 1000 80 to 100

✍

Wall Mounted Internal

Model BWIC 16/25

kW 16.0 to 25.0

Btu/hr x 1000 55 to 85

✍

Wall Mounted Internal System

Model BWISC 16/25

kW 16.0 to 25.0

Btu/hr x 1000 55 to 85

✍

Wall Mounted External

Model BWEC16/25

kW 16.0 to 25.0

Btu/hr x 1000 55 to 85

✍

p11 p40 p??

p24

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2-1 Control Box Internal Boilers

2-1.1 Boiler Thermostat Control

The Boiler Thermostat Control is used to control the temperature of the water within the

Boiler Water Chamber.

The temperature range of the control is 60°C to 90°C. The recommended settings of the

Boiler Thermostat control are:-

Winter Heater and Hot Water 80°C - Summer Hot Water only 65°C.

2-1.2 High Limit Thermostat with Manual Reset

A High Limit Thermostat with an integral Manual Reset button is fitted as standard to all

internal condensing Boilers. Boilers fitted with Manual Reset High Limit Thermostats will

not restart automatically after overheating has occurred.

The High Limit Thermostat will trip and shut the Boiler down when the water within the

Boiler is overheated.

When the water temperature falls to a satisfactory level (10°C below High Limit

Thermostat setting), the Manual Reset button (protected by a removable plastic cap)

should be pressed - this will restart the Boiler.

If overheating occurs check that the Boiler Heating Thermostat control is set at 80°C or

below. If it still occurs more than occasionally, consult your installation engineer as there

may be a fault within the system.

THERMOSTAT CONTROL

Fig. 2-1a Control Box - Internal Boilers

HIGH LIMIT

THERMOSTAT

MANUAL RESET

2-2 Control Panel External Boilers

Fig. 2-2a Control Panel - External Boilers

2-2.1 Boiler Thermostat Control

The Boiler Thermostat Control is used to control the temperature of the water within the

Boiler Water Chamber.

The Thermostat control has a ‘STOP’ position to switch the Boiler OFF.

The temperature range of the control is 55°C to 90°C. The recommended settings of the

Boiler Thermostat control are:-

Winter Heater and Hot Water 80°C - Summer Hot Water only 65°C.

HIGH LIMIT THERMOSTAT

MANUAL RESET (OPTIONAL)

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

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TO REMOVE PLUG PRESS SMALL SCREWDRIVER

THROUGH HOLE IN REAR OF PLUG

NORMAL

OVERRID

MAINS

RED

LOCKOUT

RED

LIMIT

2-2.2 Mains Indicator Lamp

The Mains Indicator Lamp will be lit when the Boiler Mains Switch is ON and the heating

system control is calling for heat.

If the Lamp does not illuminate refer to Section 10 Fault Finding.

2-2.3 Lockout Indicator Lamp

When the Lockout Indicator Lamp is illuminated, it indicates that a Burner ‘Lockout’ has

occurred and the Boiler is not operational.

Refer to 3-3 to restart Boiler.

2-2.4 Limit Indicator Lamp

The Limit Indicator Lamp is illuminated when the water within the Boiler is overheated i.e.

the High Limit Thermostat of the Boiler control is tripped.

2-2.5 Manual Limit Reset Button

A High Limit Thermostat with an integral Manual Reset button is normally fitted to all

external condensing Boilers. Boilers fitted with ‘Manual Reset’ High Limit Thermostats

will not restart automatically after overheating has occurred.

The Limit Indicator Lamp is OFF when the Boiler is operating normally.

If the Lamp is ON the water within the Boiler is or has overheated i.e. the High Limit

Thermostat of the Boiler control is tripped.

When the Limit Lamp is ON (High Limit Thermostat tripped) the Boiler shuts down. When

the water temperature falls to a satisfactory level (10°C below High Limit Thermostat

setting), the Manual Reset button should be pressed - this will restart the Boiler.

If overheating occurs check that the Boiler Heating Thermostat control is set at 80°C or

below. If it still occurs more than occasionally, consult your installation engineer as there

may be a fault within the system.

2-2.6 Mains Plug

The Mains Plug connects power to the Boiler.

The plug must be IN for the Boiler’s Frost Protection to function.

2-2.7 Normal/Override

The Normal/Override switch allows for the household heating control circuitry to be

overridden by switching to the permanent live.

The switch is intended for use by service engineers to allow operation of the Boiler without

the necessity of entering the household.

The switch should be set at NORMAL (O) at all other times.

OPERAOPERA

OPERATOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2TOR CONTROLS 2

TOR CONTROLS 2

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3-3 Burner ‘Lockout’

The burner has its own control system that synchronises the burner ignition sequences.

The safety system of the burner includes a flame detector (photoresistor) which senses

the light of the flame.

In the event of a failure of the flame, the burner control goes through a re-ignition

sequence. If the flame is not evident within 15 seconds, the burner shuts down due to its

lockout circuit being energised.

The reset lamp in the burner beset button illuminates to indicate that ‘lockout’ has

occurred.

BOILER OPERABOILER OPERA

BOILER OPERATION 3TION 3

TION 3TION 3

TION 3

3-1 Switching the Boiler ON

Internal

1. Turn fuel supply on.

2. Switch power supply to the

Boiler ON.

3. Set Boiler Thermostat Control

to the required setting.

4. Set Central Heating Control

System to ON.

External

1. Turn fuel supply on.

2. Switch power supply to the

Boiler ON.

3. Set Normal/Override switch to

Normal.

4. Set Boiler Thermostat Control

to the required setting.

5. Set Central Heating Control

System to ON.

To set Boiler for operation:-

3-1.1 Boiler Operation

The Boiler Thermostat switches power to the burner ON and OFF in response to the

temperature of the water within the Heat Exchanger.

The burner will automatically fire when the water temperature within the Boiler falls below

the thermostat control setting, and will continue to run until the water temperature rises to

the set °C.

The burner has its own Control System that gives correct ignition and shut-off sequences

to maintain safe operation.

3-1.2 Automatic Boiler Operation

A fully automatic central heating and hot water installation with its own remote timer and

control system will switch the Boiler ON and OFF as and when heat is required.

Note

The Installer should instruct the user on

operating the central heating system.

3-2 Switching the Boiler OFF

The Boiler can be switched off by any of the following means:-

1. Switch the Mains Switch on the Boiler Control Panel to OFF (external only).

2. Turn the Boiler Thermostat control to STOP.

3. Switch OFF the mains switch controlling the Boiler.

4. Set the central heating control system to OFF.

IMPORTANT In the event of abnormal operation:-

1. Switch OFF the mains switch controlling the Boiler.

2. Shut OFF fuel supply.

3. Refer to Section 10 Fault Finding.

Note

For frost protection of External Wall

Mounted and External Freestanding Boilers

the mains switch controlling the Boiler must

be ON.

Remember

Switch on the fuel before attempting to

restart the Boiler.

Note

External Boilers have a ‘Lockout’ lamp on

the control panel. This will illuminate when

‘lockout’ has occurred.

clean heat technology

BOILER OPERABOILER OPERA

BOILER OPERATION 3TION 3

TION 3TION 3

TION 3

Fig. 3-3a Burner Reset Button

In the event of a ‘lockout’, wait 45 seconds and restart the burner by pressing the reset

button.

If lockouts are more than occasional, consult your service engineer as there may be a

fault with the fuel supply or burner.

3-3.1 Restart Boiler after ‘Lockout’

Lockouts indicate a fault in the Boiler operation and can be attributed to:-

1. An interruption in the fuel supply (most common).

2. A fault in the electrical supply i.e. very low voltage.

3. Faulty operation of the burner or its safety control system.

4. A component failure.

5. A fault in heating system control external to Boiler.

Before attempting to restart the Boiler, remove the front panel of the Boiler and look for any

obvious problems i.e. oil leaks.

Restart Procedure:-

1. Check that there is sufficient oil in the tank and that the supply valves are open.

2. Check that the Boiler thermostat, time switch or programmer and any other system

controls are set to call for heat.

3. Press and release the red glowing plunger reset button on the burner control box.

The red light will extinguish and the burner will commence the start sequence.

After 15 seconds, the burner should fire normally.

If the burner does not fire, the lockout symptoms will persist and the burner control box

reset button will again glow.

4. Wait at least 45 seconds and press the lockout button on the control box again.

IMPORTANT If the Boiler fails to start on the second attempt then:-

Switch off the Electricity Supply.

Refer to Section 10 Fault Finding.

DO NOT ATTEMPT TO START MORE THAN TWICE.

3-4 Care of the Boiler

3-4.1 All Internal Boilers

Occasionally wipe the casing down with a non-abrasive cleaner and vacuum out dust and

cobwebs from within the casing.

3-4.2 External Wall Mounted Boilers

Occasionally wipe the casing down with a non-abrasive cleaner and vacuum out dust and

cobwebs from within the casing.

Regular application of car polish to the outside of the casing will help protect the paint

finish and prevent algae growth.

3-4.3 Servicing

Condensing Boilers require servicing once a year to ensure continued reliable operation

and fuel economy. Servicing at the stated intervals is a prerequisite of the Boiler

Warranty.

A competent engineer should be sought to carry out the servicing at the required intervals.

An OFTEC trained and registered engineer would be a good choice.

IMPORTANT Ensure that the

condensate drain pipe is kept clear

and able to drain away freely.

clean heat technology

4-1 Compliance

INSTINST

INSTALLAALLA

ALLAALLA

ALLATION GENERAL 4TION GENERAL 4

TION GENERAL 4TION GENERAL 4

TION GENERAL 4

The Boiler and heating system must be installed to comply with the latest Building

Regulations, British Standards and OFTEC recommendations, refer to the Appendix at the

back of this book.

4-2 Siting and Positioning the Boiler

4:2.1 Considerations for Boiler Position

The most suitable position for the Boiler is usually dictated by the flue arrangement, the

location of the flue terminal is restricted by regulations refer to Appendix.

Other consideration will be condensate drain, oil pipe and heating pipework arrangements.

Careful consideration of the most suitable Boiler position should be undertaken before

installation.

4-2.2 Noise Levels

Quiet operation is a design feature of Themeco Boilers making them ideal for kitchen and

utility room installations. However, consideration should be given to the noise levels of the

Boiler and the following:-

1. Sound levels must be discussed with the householder as some individuals are

particularly sensitive to even low levels of noise.

2. The type and position of the flu may affect noise levels.

3. Conventional flues are generally noisier than balanced flues.

4. Noise from balanced flues facing neighbouring properties should be considered.

5. Sound levels in small rooms may appear more intrusive than the same sound

pressure in a larger room.

6. Some building materials can tend to amplify the sound from Wall Mounted Boilers,

using battens to space the Boiler off the wall may reduce this effect.

4-2.3 The Hearth - Floor Standing

The hearth temperature of Select and Option Boilers is less than 85°C. A suitable level

hearth, which is impervious to kerosine, must be provided.

Where the Boiler is to stand on a floor of combustible material then protection between the

Boiler and the floor should be provided by means of non-combustible material.

The floor must give adequate support to the filled Boiler. Consult the Building Regulations

for safe floor loadings.

4-2.4 Frost Protection

The Boiler and the central heating system must be protected from frost.

External Free Standing Boilers have a frost thermostat fitted as standard, this must be

correctly wired to provide frost protection - see wiring diagrams Section 11.

All Boilers installed in outhouses or where conditions of frost could arise must be

protected by a frost protection arrangement that will fire the Burner when the temperature

falls below 4°C.

A suitable antifreeze must also be used in applications where freezing can occur and

should be considered for all systems.

4-2.5 Rodent Intrusion

Boilers installed in situations where rodent intrusion is possible, all pipe/cable entry holes

of the Boiler must be covered, after installation, to prevent rodents entering the Boiler

casing.

Note

For Boiler Weight see Section 11.

The Boiler must be commissioned

within 10 working days of installation,

failure to do so will invalidate the

Guarantee.

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