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13

A  qualified  engineer  must  commission  the  appliance  before
handing over to the user.

Ensure that no foreign matter is left in the system as this could
cause damage to the appliance.

12.1 

Check  that  the  electrical  supply  to  the  appliance  is

switched off.

12.2 

When commissioning the appliance after initial installation

follow  the  procedure  from  12.3,  otherwise  remove  the  burner
first as described in section 14.3. 

12.3 Prepare the heating system
1. 

After initial installation and checking for leaks, as previously

described, drain down the system sufficiently to add a flushing
agent. Flush the system in accordance with BS 7593:1992.

2.

Refill the system

12.4 Check the Burner
1. 

Check  that  the  nozzle  and  electrode  settings  are  correct  for

the relevant burner. (See Figs. 13, 14 and 15).

2. 

Check that the nozzle lies central with the combustion head hole.

3. 

Check for any visible defects.

12.5 Replace the burner
1. 

Connect the flexible oil supply hose to the isolating valve and

tighten  sufficiently  to  form  a  good  seal.  Where  a  double  pipe
system is being used fit the bypass plug, as described in Fig. 6,
and connect 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  compress  the  gasket  and  tighten  the  two  locking
screws using a 5mm Allen key.

Note: 

It  is  important  that  a  good  seal  is  made  between  the

burner and the boiler to prevent re-circulation of the flue gases
from the combustion chamber to the room.

3. 

Re-connect the electrical lead plug into the control box.

12.6 Check the installation
1. 

Check  that  the  appliance  is  correctly  wired  as  described  in

Section 10.

2. 

Check that all baffles are correctly located and the heat shield

is  correctly  mounted  (70/90  and  90/110  models  only)  as
shown in Fig. 16.

3. 

Check  that  the  baffle  retainer  is  correctly  mounted  (70/90

and 90/110 models only) as shown in Fig. 16.

6. 

Check  that  the  control  thermostat  and  auto  reset  high  limit

thermostat phials are correctly located in the boiler thermostat
pocket positioned in the top front of the boiler.

7. 

Check that the manual reset limit thermostat is located in the

steel  pocket  above  the  electrical  box  mounting  bracket  on  the
front face of the boiler.

8. 

Check  that  all  of  the  air-ways  to  the  burner  are  clear  of  any

obstruction.  

12.7 

Fit a pressure gauge and manifold to the burner pump at

the point indicated in Fig. 6 or the pressure gauge port shown in
Fig. 14 on the 70/90.

12.8 

Turn on the electricity to the appliance.

12.9 Bleed the burner.
Single Pipe System

Release the fuel bleed port on the manifold and place a suitable
receptacle beneath. Turn on the boiler thermostat and allow the
burner  to  run  through  to  lockout.  Wait  two  minutes  and  reset
the  burner  control  box.  Repeat  the  procedure  at  least  three
times  or  until  a  steady  stream  of  oil,  without  air,  is  exhausted
from the bleed port. Re-lock the bleed port.

Two Pipe System

A two pipe system will automatically vent the air back to the oil
tank. Turn on the boiler thermostat and allow the burner to run
through  to  lockout.  Wait  two  minutes  and  reset  the  burner
control  box.  Repeat  the  procedure  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

recommended  in  Tables  2  to  4.  After  a  pre-ignition  period  of
approximately  15  seconds  the  burner  should  ignite.  Flame
sensing  is  carried  out  by  means  of  a  photocell  mounted  in  the
burner  body.  Should  the  boiler  fail  to  establish  a  normal  firing
pattern  (or  should  flame  failure  occur  during  running),  the
absence of a flame is sensed and the control box is monitored to
a  safe  lockout  condition  and  the  boiler  is  shut  down.  The
lockout  indicator  light/reset  button  in  the  burner  control  box
will illuminate indicating that the burner has gone to lockout. In
this  instance  wait  two  minutes  and  press  the  lockout  reset
button to initiate another start sequence. Repeat the procedure
until a flame is established.

Note: 

Persistent  lockout  when  running  indicates  a  fault  and  a

Service Engineer should be consulted.

12.11 

Run  the  boiler  for  approximately  3  minutes  and  switch

off checking that there is no after-spurting from the nozzle. This
can  be  detected  by  oil  saturation  on  the  blast  tube.  If  after-
spurting occurs remove the burner from the boiler, unscrew the
nozzle,  and  while  holding  the  burner  in  a  vertical  position,  fill
the  nozzle  holder  with  oil  and  refit  the  nozzle.  Replace  the
burner  and  continue  to  run  the  boiler  for  three  minute  periods
until after-spurting stops.

Note: 

In  order  that  after-spurting  is  reduced  to  a  minimum

during  the  commissioning  period  it  is  recommended  that  a
pressure  gauge  only  is  fitted  on  the  external  pressure  gauge
port  on  the  Electro  Oil  B11  (See  Fig.  14).  Use  of  a  “T”  piece
pressure  gauge  manifold  will  increase  the  oil  line  volume  and
hence increase 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  CO

2

level

specified in Tables 2 to 4 less 0.5%CO . During this period some
smoke will be emitted due to the burning of the organic binder
in  the  base  insulation  board.  Smoke  readings  will  therefore  be
inaccurate at this point.

Note: 

A  flue  gas  sampling  point  is  located  on  the  boiler  top

plate.

12.13 

Check that the smoke reading is in the range 0-1. If this

cannot  be  achieved  then  check  that  the  burner  head  is  set
correctly and the nozzle is in good condition.

12.14 

Check  that  the  flue  temperature  does  not  exceed  the

value specified in Tables 2 to 4. If this is the case then check that
the  baffles  are  correctly  located.  If  the  baffles  are  correctly
located  then  reduce  the  pump  pressure  since  nozzle  variations
of up to + or – 15% may occur.

12.15 

Remove  the  oil  pressure  gauge  and  manifold  and  check

all oil system joints for any signs of leakage.

12.16 

Refit the cabinet front panel.

12.17 

Allow  the  burner  to  run  for  a  further  five  minutes  and

then  recheck  the  CO

2

level  and  adjust  the  air  setting  if

required.  With  the  cabinet  front  panel  fitted  as  12.16,  repeat
the  previous  test  procedure  and  Check  that  the  smoke
number is in the range 0-1. Repeat the fine tuning procedure
if found necessary.

12.18 

Refit  the  cabinet  top  and  front  panels  in  the  reverse

order to that described in Section 5. 

12.19 

When  the  heating  circuit  has  reached  full  operating

temperature check the whole system for any leaks. 

12. Commissioning the Appliance

Содержание 70/90

Страница 1: ... 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 installed and serviced by a competent person ...

Страница 2: ...r company bye laws The Control of Pollution Oil Regulations 1 6 To ensure that the installation will perform to the highest standards the system and components should conform to those mentioned in the instructions 2 1 The Worcester Bosch range of appliances covered in these instructions have been designed to serve domestic central heating and hot water requirements ranging from 15 kW to 32 kW 51 0...

Страница 3: ...e gas temperature and is for general guidance purposes only NOTE The pump pressure given is for general guidance only as variations in nozzle output can be up to 15 It is therefore essential that the air is adjusted to give the correct CO2 value NOTE The nozzle type used on 28 Sec Kerosene outputs are nozzles calibrated specifically for use with 28 Sec Kerosene which gives less variation in nozzle...

Страница 4: ...t 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 ...

Страница 5: ... compartment two air vents are required one at high level and one at low level The minimum free area of each 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 contain an air inlet as described in 6 1 6 3 There must be sufficient clearance around the appliance to allow proper circulati...

Страница 6: ...ee 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 Directly below an opening air brick window etc Not allowed 600 B Horizontally to an opening air brick window etc Not allowed 600 C Below a gutter or sanitary pipe Not allowed 75 D Below eaves or a balcony Not allowed 600 E From vertical s...

Страница 7: ... of a capillary type valve will allow a neat and simple installation A suitable valve is the KBB manufactured by Teddington Controls Limited A spring clip has been provided behind the electrical panel shown in Fig 2 to allow a fire valve element to be mounted Alternatively a fusible link or electrical system may be used Under no circumstances should a combination isolating fire valve be used as th...

Страница 8: ...stem installation should be carried out in accordance with BS 5449 Part 1 1 Feed and Expansion System The feed and expansion pipes must rise continuously from the appliance and must be of the minimum diameter shown in Figs 8 and 9 The cistern must be arranged to provide a minimum static head of 1 metre above the top of the highest point in the heating circuit 2 Filling and Venting Air in the appli...

Страница 9: ... 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 Typical Open Vent Fully Pumped System Honeywell 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 f...

Страница 10: ...ntrol of the central heating and hot water However it must be noted that the programmer used must be suitable for gravity feed applications when used as shown in Figs 11 and 12 such that the hot water channel is always on when the central heating channel is on otherwise the boiler will not fire when there is a central heating demand 10 5 Safety Check In the event of an electrical fault after the i...

Страница 11: ...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 NO NC E 3 Hot water 5 Amp ...

Страница 12: ...rom the system 4 Check the boiler and all pipework connections for leaks 5 The primary system should be flushed and treated in accordance with the recommendations of BS 7593 1992 11 5 Oil supply installation See Fig 7 Note Never route the oil supply pipe hose directly below the combustion chamber base 1 Fit the oil supply pipe as described in Section 8 The pipe can be routed down either side of th...

Страница 13: ...at the procedure 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 recommended in Tables 2 to 4 After a pre ignition period of approximately 15 seconds the burner should ignite Flame sensing is carried out by means of a photocell mounted in the burner body Shoul...

Страница 14: ... 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 locking screw located at the rear of the nozzle line and rotate the adjusting disc one turn anti clockwise 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 ...

Страница 15: ...east once per year Worcester Heat Systems Limited will be pleased to discuss and offer a comprehensive maintenance contract 13 4 Set the system controls to the users requirements 13 Instructions To The User 15 Fig 16 Location of Boiler Flueway 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 Bu...

Страница 16: ...eparate the main body of the burner from the burner front by removing the M6 allen screw located beneath the air adjustment screw using a 5mm allen key c Note the position of the air damper adjustment and check the air damper moves freely d Check the air path to the burner head is clear e Clean both sides of the fan impeller and remove any debris from the burner housing f Check the impeller rotate...

Страница 17: ...tions shown in Fig 16 14 6 Check that a fire valve is fitted to the incoming oil line with the body located outside the premises and the detection element located within the appliance case A fire valve clip is provided for this purpose as shown in Fig 2 test the operation of the fire valve to ensure that the mechanism operates and that the oil supply is completely isolated 14 7 Recommission the Bu...

Страница 18: ...ension 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 Incor...

Страница 19: ...19 NOTES ...

Страница 20: ...earances are changed in the interests of continued improvement All goods sold are subject to our official Conditions of Sale a copy of which may be obtained on application 8 716 145 074f 05 01 Worcester Heat Systems Limited Cotswold Way Warndon Worcester WR4 9SW Telephone 01905 754624 Fax 01905 754619 www worcester bosch co uk ...

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