22.
Insert the baffle into the heat exchanger ensuring the baffle is
pushed hard against the back of the heat exchanger (see fig. 26).
23.
Check the three rope seals in the insulation box as shown in
fig. 27, adjust if necessary or replace if damaged. Push the insula-
tion box on to the heatexhanger and tighten up using the four
M8 wing nuts and washers provided.
24.
Insert the burner into the burner-mounting flange.
25.
Remove the wall trim and pack the gaps between the outside
wall and external duct with cement. Refit the wall trim as described
previously making any necessary adjustments to ensure the trim is
a tight fit around the external duct before the cement sets. It is
recomended that a bead of silicone sealant is applied around the
duct to the cement joint before fitting the wall trim. If required apply
silicone sealant to the back of the wall trim to aid fixing to the wall.
26.
Pack the gaps between the inside wall and the wall mounting
duct with cement.
11.4 Heating system installation.
1.
Plumb the boiler into the central heating system.
2.
Fill the system and vent all radiators and high points to
remove air from the system.
3.
Check the boiler and all pipework connections for leaks.
4.
The primary system should be flushed and treated in accordance
with the recommendations of BS 7593:1992.
11.5 Oil supply installation
(See figs. 9 to 11)
(a) Double pipe system
1.
Disconnect the two flexible lines from each other and remove
the
1
/
4
inch nipple. Connect the two
1
/
4
inch nipples and copper
washers to the connection block. Ensure the conical end pro-
trudes from the connection block. Connect the flexible oil line
that is connected to inlet on the oil pump to the
1
/
4
inch male inlet
fitting on the connection block. Connect the flexible oil line that
is connected to return on the oil pump to the
1
/
4
inch male return
fitting on the connection block. (See fig. 11)
2.
The oil pipes from the oil supply tank should be routed tidily
up the external wall of the property and connected into the con-
nection block. The connection block has two female
1
/
4
inch BSP
fittings for connection to either a 10mm or 12mm compression
to
1
/
4
inch BSP mail fitting.
Note:
On a double pipe system it generally not possible to check for
leaks due to the position of the oil supply tank, therefore, use the oil
pump as described in Section 12 and remove and clean the oil
pump filter to remove any debris collected as a result of installation.
(b) Single pipe system
1.
Disconnect the two flexible lines from each other and remove
the
1
/
4
inch nipple. Remove the flexible oil line which is connected
to the return on the oil pump and convert the burner to a single
pipe system, see fig. 10 (Section 8 Oil Supply). Insert the
1
/
4
inch
plug into the return port on the oil pump. Connect the
1
/
4
inch
nipple and copper washer to the inlet on the connection block.
Ensure the conical end protrudes from the connection block.
Connect the flexible oil line which is connected to inlet of the oil
pump to the
1
/
4
inch male inlet fitting on the connection block.
2.
The oil pipe from the oil supply tank should be routed tidily up
the external wall of the property and connected into the connec-
tion block. The connection block has two female
1
/
4
inch fittings
for connection to either 10mm or 12mm compression to
1
/
4
inch
mail fitting. Ensure the oil pipe from the oil supply tank is con-
nected to the inlet connection only on a single pipe system.
3.
Open the main oil supply valve at the tank and check for any leaks.
4.
Remove the flexible oil line from the inlet of the oil pump and
place in a suitable container. Open the isolating valve between
the oil filter and burner.
5
. Draw off at least 2.5 litres of oil until a steady flow of clear
uncontaminated oil can be seen and turn off the isolating valve.
Note:
never use soldered joints on oil supply pipes as this could
cause a hazard in the case of a fire.
11.6 Flue Installation
1.
Attach the telescopic flue to the insulation box with the two
wing nuts and washers.
2.
Set the approximate flue length by sliding the flue locating slot
onto the tab which protrudes from the external duct.
3.
Fit the external cover and insert two fixing screws and wash-
ers, do not tighten.
4.
Adjust the flue so the end protrudes through the external
cover ensuring the seal and splash plate are hard up against the
external cover to prevent water ingress (see fig. 7).
5.
Remove the external cover being careful not to knock the flue.
6.
Tighten the telescopic section of the flue and re-fit the external
cover onto the appliance.
7.
Check to see the flue protrudes through the cover, ensuring the
seal and splash plate are hard up against the external cover to pre-
vent water ingress and make any necessary adjustments (see fig. 7).
Note.
Ensure the splash plate/seal on the end of the flue is hard
up against the external cover. Ensure the tab on the external
duct protrudes through the locating slot.
8.
Remove the external cover and remove the complete flue sys-
tem by undoing the two wing nuts and washers holding the flue
to the insulation box.
9.
Using the sealant provided seal the two sections of flue togeth-
er all the way round to prevent the recirculation of flue gases
from the flue to the burner inlet.
10.
Attach the telescopic flue to the insulation box with two wing
nuts/washers and make any necessary adjustments before the sealant sets.
WARNING: This appliance is serviced and repaired externally.
External equipment operated at 230volts should not be ser-
viced or repaired under adverse weather conditions.
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 installation
1.
Check the appliance is correctly wired as described in Section 10.
2.
Check the baffle is correctly located making sure it is pushed
hard up against the back of the heat exchanger as shown in fig. 26.
5.
Ensure the rope seals are in good condition (see fig. 27) and the insula-
tion box is mounted correctly onto the heat exchanger, as shown in fig. 3.
6.
Check the control thermostat and auto reset high limit ther-
mostat phials are correctly located in the boiler thermostat
pocket positioned in the top right hand side of the boiler (see fig. 2).
7.
Check the manual reset limit thermostat is located in the phial
retaining spring on the top left hand side of the heatexhanger (see fig. 2).
8.
Check the Duct thermostat is located in the phial retaining
spring on the top of the wall mounting duct as shown in fig. 2.
9.
Check the frost thermostat is located in the phial retaining
spring on the bottom left hand side of the heatexhanger (see fig. 2).
12. Commissioning the Appliance
26