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APPENDIX

APPENDIX

APPENDIX

APPENDIX

APPENDIX

AP1-1 Building Regulations

The following Standards and Codes of Practice should be considered when installing
Thermecon Boilers.
BS5449 - 1990

Forced Circulation Hot Water Central
Heating Systems for Domestic Use.

BS5410 Part 1:1977

Oil installations up to 45kW

BS5410 Part 2:1978

Oil installations over 45kW

BS4543 Part 1 & 3:1976

Factory made insulated chimneys.

Current Building Regulations:-

Part JJJJJ England and Wales
Part FFFFF Scottish Regulations
Technical Booklet LLLLL Northern Ireland

Oil Boilers with Conventional Flue installed in rooms where there is an Extractor Fan, the
following Building Regulations apply:-

Part FFFFF England and Wales (also recommended in Northern Ireland)
Part KKKKK Scotland

The Control of Pollution (Oil) Regulations

AP1-2 OFTEC

OFTEC publish Technical Books that summarise and illustrate the requirements of the
above Standards and Regulations.
OFTEC Oil Firing Technical Association
Foxwood House,
Dobs Lane,
Kesgrave,
Ipswich.
IP5 2QQ
www.oftec.org

email:- [email protected]

AP1-3 Electrical Regulations

All wiring should be to IEE Wiring Regulations 16th Edition.

AP1-4 Oil Tanks

Plastic tanks are covered by OFTEC standard OFS T100.
Refer to BS5410 Part 1 and OFTEC Technical Book 3 for further information on tank
installation.
Steel tanks should be manufactured to BS799 Pt 5.

AP1

Regulations

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Summary of Contents for S40/65

Page 1: ...nstallation Section 5 Installation 5 1 Select and Option Internal Floor Standing 11 5 2 Select Internal Wall Mounted 12 5 3 Select External Wall Mounted 14 5 4 Select Free Standing External 16 5 5 Opt...

Page 2: ...i v r e S e c i v r e S e c i v r e S e c i v r e S e c i v r e S e c i v r e S e c i v r e S 1 1 Installer 1 2 Householders Information 1 3 Service History Note The price of fuel has seasonal fluctu...

Page 3: ...23 5 23 5 to 27 6 26 4 to 34 9 29 3 to 44 0 Combistream Combi 65I Combi 65E Model C40 65 Model C40 65E Btu hr x 1000 40 to 65 Btu hr x 1000 40 to 65 kW 11 7 to 19 1 kW 11 7 to 19 1 Select Wall Mounte...

Page 4: ...ter Heating and Hot Water 80 C 2 Summer Hot Water only 65 C A setting below 60 C can on some heating systems induce corrosion and reduce the life of the Boiler 2 1 Control Panel Select Combistream and...

Page 5: ...d Combistream 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...

Page 6: ...AL RESET 2 1 8 Hot Water High Limit Thermostat With Manual Reset A Hot Water High Limit Thermostat with an integral Manual Reset button is fitted to the Boiler When the Hot Water High Limit Thermostat...

Page 7: ...ging to the rear of the Boiler In the event of the pressure within the heating system becoming too high the TPR valves will vent In the event of water steam being seen at the discharge pipe or Tundish...

Page 8: ...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...

Page 9: ...equence 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 second...

Page 10: ...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 t...

Page 11: ...n either side on the top of the Boiler heat exchanger see fig 5 1c The mains electricity supply preferably from a spur switched and fused 5 amp socket should enter the Boiler casing through one of the...

Page 12: ...ll for oil pipes fire check valve and electric cable 7 Remove panel and accurately drill required holes and fit 3 rawl bolts into holes R 8 Remove required knockouts K from back panel For top entry fl...

Page 13: ...eferably from a spur switched and fused 5 amp should enter the Boiler casing through one of the holes or knockouts provided see fig 5 2c The Burner is supplied with a 4 wire cable and plug The plug fi...

Page 14: ...can be wall mounted at ground level however the following conditions must be considered 1 A terminal guard must be fitted not supplied 2 A 50mm free air space must be provided under the Boiler 3 The...

Page 15: ...te Before removing main case study the Burner position and the Boiler wall position and decide on the best oil pipe configuration see Section 5 3 6 and Section 7 K x 2 R R R K R 3 HOLES DRILL 12 FOR R...

Page 16: ...coming pipes should enter the Boiler through the cut outs provided in the bottom panel as shown 5 4 3 Base Details See fig 5 4b The Base must be level impervious to kerosene and non combustible Pipes...

Page 17: ...FF VALVE FILTER SUPPLIED WITH BOILER SEE SECTION 13 Fig 5 4c Recommended Two Pipe Oil Connection 1 2 4 3 1 OIL SUPPLY 2 ELECTRICAL SUPPLY 3 FLOW AND RETURN PIPES FULLY INSULATED 4 RAWL BOLTS FOR BOILE...

Page 18: ...FLOW RETURN OPTIONAL EXTRA PUMP ON RETURN FOR LARGER SYSTEMS COLD MAINS FEED 7 5 1 PUMP 2 PRESSURE GAUGE 3 PRESSURE RELIEF VALVE 4 PRESSURE VENT 5 EXPANSION VESSEL 6 AIR VENT 7 FILLING LOOP Note No o...

Page 19: ...s OS100 150 20 litres for maximum system expansion of 18 litres The expansion vessel supplied is suitable for systems with a static head of up to 5 metres If the static head is greater than 5 metres t...

Page 20: ...essel should be set at 0 5 Bar below the cold fill pressure This should be done prior to filling the system using a conventional car tyre gauge and pump IMPORTANT The pressure of the expansion vessel...

Page 21: ...WAY MOTORISED VALVE 6 HEATING SYSTEM EXPANSION VESSEL 7 HOT WATER SYSTEM EXPANSION VESSEL 9 MIXING VALVE 8 BOILER BURNER 6 1 2 The Combistream System BYPASS MAINS SUPPLY OUTSIDE TAP DOUBLE CHECK VALVE...

Page 22: ...ided for the Boiler when it is sited in a garage or outhouse when it is sited in a garage or outhouse when it is sited in a garage or outhouse when it is sited in a garage or outhouse when it is sited...

Page 23: ...ll pressure it means that the system requires topping up 6 2 3 Pump The pump is a standard 3 speed central heating circulating pump which pumps the heated water from the Boiler through the heating sys...

Page 24: ...cylinder A 15mm bypass pipe with an isolating valve is fitted in the event of the plate heat exchanger becoming blocked e g excessive scale then the valve can be opened and hot water will still be pr...

Page 25: ...ball that is visible through the yellow bowl of the unit when this ball reaches the bottom of the cartridge it indicates that the cartridge should be replaced The Cleanstream unit should be fitted to...

Page 26: ...ion G3 specific details of Tundish installation e z i s t e l t u o e v l a V o t e p i p e g r a h c s i d f o e z i s m u m i n i M h s i d n u T 1 D1 D1 D1 D1 D e p i p e g r a h c s i d f o e z i...

Page 27: ...to move 6 3 4 Connecting the Control Panel Combi Boilers are despatched with the Control Panel fitted The phials of the two heating thermostats are inserted vertically into the pockets situated on eit...

Page 28: ...orage Tanks 7 1 1 Size and Siting of Tank The size and site of the tank should be chosen to be least obtrusive with consideration to the following 1 Access for fuel delivery vehicles 2 Distance of tan...

Page 29: ...tem 7 3 1 Single Pipe System Tank Above Burner Where installations have the bottom of the tank above the Oil Burner a single pipe system can be used see fig 7 3a Fig 7 3a Typical Single Pipe Oil Syste...

Page 30: ...OUTLET PLASTIC TANK ALSO SUITABLE SEE 7 1 2 BOTTOM OUTLET STEEL TANK ALSO SUITABLE SEE 7 1 3 LIFT 1M UP TO 4 0M TIGERLOOP 1 MAY BE ABOVE BURNER 2 MUST BE POSITIONED OUTSIDE BUILDING 3 MUST BE INSTALL...

Page 31: ...Typical Conventional Flue with Brick Chimney CONVENTIONAL FLUE 100mm 4 ADAPTOR TEST POINT AIR DUCT TO BURNER FL FL FL FL FLOOR STANDING OOR STANDING OOR STANDING OOR STANDING OOR STANDING not 190 240...

Page 32: ...Flat Roof Flashings packed separately 160 to 350 LLR100 160 to 350 150 LLE EXS EXT EXL LLR075 100 B A Extensions Kit 590 to 790 B A 590 to 790 150 LLE Extensions LLR075 LLE075 100 Kit LLR100 EXS100 E...

Page 33: ...ternal or external corner 300 600 G Above ground or balcony level 300 H From a surface or a boundary facing the terminal 600 J From a terminal facing the terminal 1200 K Vertically from a terminal on...

Page 34: ...Compartments 9 3 2 Burner Air Duct All Floor Standing Boilers are supplied with an adaptor and flexible air duct fitted for conventional flue connection For balanced flue applications the conventiona...

Page 35: ...es are found This will damage the Burner pump 10 1 2 Two Pipe Oil Supply System Check that a non return valve is fitted in the suction line refer to fig 7 3d page 30 The return pipe should have an ant...

Page 36: ...nd terracotta pot has been used and that the draught stabiliser is working freely if fitted Check that the flexible air duct is correctly fitted from the adaptor to the Burner Check that the test poin...

Page 37: ...Test holes are provided for all flues Check the smoke reading with the Boiler up to temperature and then measure the CO and flue gas temperature Reducing air into the Burner decreases the flue gas tem...

Page 38: ...size for output required see 13 3 2 In very dusty conditions the fan and photocell may need cleaning Flexible oil lines should be carefully inspected It is recommended that flexibles are renewed every...

Page 39: ...storted the Boiler efficiency will be drastically reduced Baffles should be removed cleaned and replaced during routine servicing Care should be taken when replacing baffles to ensure that they are co...

Page 40: ...0 80 O60 80 O60 80 O60 80 O60 80 O60 80 S80 95 S80 95 S80 95 S80 95 S80 95 O80 95 O80 95 O80 95 O80 95 O80 95 S90 120 S90 120 S90 120 S90 120 S90 120 O90 120 O90 120 O90 120 O90 120 O90 120 S140 190 S...

Page 41: ...t r e w o p k c e h C 3 s e Y l a m r o N g n i k r o w r e l i o B e h t s I r o g n i l b b u b g n i k a m t u b e s i o n g n i l g r u g s e Y t l u a F m e t s y s e h t n i r i a s i e r e h t...

Page 42: ...r o t s i s e r o t o h p k c e h C 1 e d a r g t c e r r o c f o d n a t n e i c i f f u s s i y l p p u s l e u f k c e h C 2 t n e s e r p s i r e t a w o n d n a r e n r u B o t w o l f e e r f h...

Page 43: ...e c a l p e R 3 k c e h C r e e n i g n E n o i t u l o S e l b i s s o P t i m i l h g i h t a r e l i o B C 3 9 t a s r u c c o t i m i l e p i p w o l f r e l i o B f o e r u t a r e p m e t e h t...

Page 44: ...n a n a n a n a n g n i c i v r e s t n o r F t n o r F d n a p o t g n i c i v r e s a n a n a n a n a n a n e s a b d e l o o c r e t a W e z i s e u l f d e c n a l a B m m 5 7 m m 5 7 m m 5 7 m m...

Page 45: ...1 x a M 13 3 Burner Setting Data The following Burner settings given for all Option Select and Wall Mounted Boilers are for Kerosene 28 Second Class C fuel For 35 Second Class D Gas Oil the following...

Page 46: ...7 2 2 0 6 5 7 0 5 1 1 9 7 9 3 2 5 1 1 0 1 5 0 2 0 8 4 3 2 0 6 5 7 0 0 3 1 0 9 6 5 2 6 1 1 0 1 0 1 2 5 9 0 8 S 5 9 0 8 S 5 9 0 8 S 5 9 0 8 S 5 9 0 8 S 5 9 0 8 O 5 9 0 8 O 5 9 0 8 O 5 9 0 8 O 5 9 0 8 O...

Page 47: ...en Note Always check electrodes settings after fitting nozzle Fig 13 4a Combustion Air Setting LOOSEN BOLT AND SLIDE ADJUSTMENT SPANNER SUPPLIED AIR NUMBER ON SCALE INDICATED BY THE END OF THE SLIDE 1...

Page 48: ...TION 13 TION 13 13 4 5 Combustion Air Setting Max Series Burners Note The recommended settings for the combustion head and combustion air are shown on pages 45 46 Settings should not differ greatly fr...

Page 49: ...RSE SHOE WASHER FITTED UNDER SCREW INLET Danfoss Type BFP 11 R3 RETURN PORT PLUGGED INLET PORT RETURN PORT Danfoss Type BFP 11 R3 SCREW FITTED WASHER REMOVED SINGLE PIPE OPERATION SINGLE PIPE OPERATIO...

Page 50: ...EARTH GY LIVE BR EARTH YG NEUTRAL BL MAINS PLUG Live Neutral and Earth to be wired to plug Fig 13 5a Wiring Diagram for Floor Standing Select and Wall Mounted Internal Fig 13 5b Wiring Diagram for Op...

Page 51: ...G BEFORE REMO UG BEFORE REMO UG BEFORE REMO UG BEFORE REMOVING VING VING VING VING PANEL CO PANEL CO PANEL CO PANEL CO PANEL COVER VER VER VER VER Notes PERMANENT LIVE Required for frost protection OV...

Page 52: ...ILER PUMP ROOM THERMOSTAT 1 R 1 2 3 4 5 6 7 8 9 10 11 12 R R EARTH STUD 2 N HTG 1 FROM TIME CLOCK YG Fig 13 5d Combistream and Combi 65 Internal Wiring Diagram Time Clock Connections 1 Hot Water ON 2...

Page 53: ...Spare 2 Neutral 5 Earth 6 Time Clock Timed Heating REMO EMO EMO EMO EMOVE MAINS PL VE MAINS PL VE MAINS PL VE MAINS PL VE MAINS PLUG BEFORE UG BEFORE UG BEFORE UG BEFORE UG BEFORE REMO REMO REMO REMO...

Page 54: ...iler 13 6 1 SELECT and OPTION Floor Standing 1 2 3 5 6 7 4 8 Fig 13 6b Wall Mounted m e t I t r a P s e t o N 1 e s o H d e t n u o m l l a w t s o m s a d e i l p p u s e r a s e s o h 2 m e t s y s...

Page 55: ...r e n n a p S s g n i t t e s r i a d n a p m u p r e n r u B g n i t s u j d a r o F 7 r e n n a p S x o B e l z z o n r e n r u B g n i c a l p e r d n a g n i v o m e r r o F 8 p o o L g n i l l i...

Page 56: ...P O N O I T P O N O I T P O N O I T P O 5 6 0 4 O 5 6 0 4 O 5 6 0 4 O 5 6 0 4 O 5 6 0 4 O 0 8 0 6 O 0 8 0 6 O 0 8 0 6 O 0 8 0 6 O 0 8 0 6 O 5 9 0 8 O 5 9 0 8 O 5 9 0 8 O 5 9 0 8 O 5 9 0 8 O 0 2 1 0 9...

Page 57: ...awl Bolts K Knockouts for Electric Oil Pipes FULLY PUMPED SYSTEMS ONLY ALL DIMENSIONS ARE NOMINAL Fig 13 7b Thermecon Boilers Overall Dimensions INTERNAL L E D O M L E D O M L E D O M L E D O M L E D...

Page 58: ...N 13 TION 13 TION 13 13 7 3 W40 50E W50 80E EXTERNAL Fig 13 7c Thermecon Boilers Overall Dimensions EXTERNAL FULLY PUMPED SYSTEMS ONLY ALL DIMENSIONS ARE NOMINAL L E D O M L E D O M L E D O M L E D O...

Page 59: ...oles 12 for M10 Rawl Bolts 320 PLAN ON BASE Base must be level impervious to kerosene and non flammable 38 50 144 147 43 222 390 2 Slots 14 wide 2 Slots 25 wide SUGGESTED PIPE CONNECTION L E D O M L E...

Page 60: ...m HEATING RETURN 1 BSP F F L F F L Right Side Left Side 135 F F L Rear Thermecon 700 F F L 20 20 HOT WATER FLOW 22mm COLD FEED TO BOILER 22mm HEATING FLOW 1 BSP HEATING RETURN 1 BSP Front HOT WATER TP...

Page 61: ...TER TPR 15mm 705 45 HEATING TPR DISCHARGE 15mm Fig 13 7f Thermecon Boilers Overall Dimensions Combi 65 External FULLY PUMPED SYSTEMS ONLY ALL DIMENSIONS ARE NOMINAL E 5 6 I B M O C E 5 6 I B M O C E 5...

Page 62: ...t i W S V n o i t c e S R L H t i K d r a d n a t S S L H t i K d r a d n a t S 0 2 1 0 9 5 9 0 8 0 8 0 6 5 6 0 4 5 7 0 C B V 5 7 0 R L H 5 7 0 C B V 5 7 0 R L H 5 7 0 C B V 5 7 0 R L H 5 7 0 C B V 5...

Page 63: ...r Balanced Flue Dimensions SELECT OPTION RANGE SELECT SHOWN l e d o M t e l t u O e d i S e u l F A B C D t i K d r a d n a t S a r t x e 1 h t i W n o i s n e t x E 0 0 3 s n o i s n e t x E e l b a...

Page 64: ...V t u o h t i W S V n o i t c e S 0 2 1 0 9 5 9 0 8 0 8 0 6 5 6 0 4 5 7 0 B C V 5 7 0 L T V 5 7 0 B C V 5 7 0 L T V 5 7 0 B C V 5 7 0 L T V 5 7 0 B C V 5 7 0 L T V 5 7 0 B C V 5 7 0 L T V 5 7 5 2 1 0...

Page 65: ...T TO LENGTH TELESCOPIC EXTENSIONS AVAILABLE 300MM FLUES CANNOT BE CUT TO LENGTH r a e R r o e d i S A B t i K R L H t i K S L H n o i s n e t x e o n h t i W I 0 5 0 4 W I 0 8 0 5 W 5 7 0 R L H 5 7 0...

Page 66: ...ENGTH Terminal Section VTL Length 1120 Extra Extensions FLUE BRACKETS SCREWS 88 615 A 300mm SCREWS 300mm EXS 075 Extension included 125 200 B PITCHED ROOF l a n r e t n I d e t n u o M l l a W A 0 0 3...

Page 67: ...5 7 0 S X E 5 7 0 R L H 5 7 0 S X E 5 7 0 R L H 5 7 0 S X E 5 7 0 R L H 5 7 0 S X E 5 7 0 R L H 5 7 0 S X E 5 7 0 R L H 5 7 0 S V 5 7 0 S V 5 7 0 S V 5 7 0 S V 5 7 0 S V 0 9 7 1 o t 0 9 1 1 m m 0 0 6...

Page 68: ...ms where there is an Extractor Fan the following Building Regulations apply Part F F F F F England and Wales also recommended in Northern Ireland Part K K K K K Scotland The Control of Pollution Oil R...

Page 69: ...o 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 pos...

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