Indoor Wall Hung Oil Boiler Range Installation & Servicing .

3 Oil Storage & Supply System3.1 Fuel SupplyFuel StorageThe tank should be positioned inaccordance with the recommendationsgiven in BS 5410:1:1997, which givesdetails of filling, maintenance andprotection from fire.A steel tank may be used and must beconstructed to BS 799:5:1987 andOFS T200.!CAUTIONA galvanized tank must NOT be used.A plastic tank may be used and mustcomply with OFS T100.!NOTEPlastic tanks should be adequatelyand uniformly supported on asmooth level surface, across theirentire load bearing base area, that is,the area in contact with the ground.Fuel PipesFuel supply pipes should be of coppertubing with an external diameter of atleast 10mm.!CAUTIONFlexible pipes must NOT be usedoutside the boiler case.A remote sensing fire valve must beinstalled in the fuel supply line (outside)where it enters the building, with thesensing head located above the burner.Recommendations are given inBS 5410:1:1997.A metal bowl type filter with areplaceable micronic filter must be fittedin the fuel supply line adjacent to theboiler. A shut-off valve should be fittedbefore the filter, to allow the filter to beserviced.Two flexible fuel lines, adaptors and 1/4"BSP isolation valves are supplied loosewith the boiler for the final connection tothe burner, with a two pipe system or'Tiger Loop' type de-aerator.Metal braided flexible pipes should bereplaced annually when the boiler isserviced. Long life flexible pipes shouldbe inspected annually and replaced atleast every 60 months.Galvanised pipe must not be used.Oil Storage &Supply SystemAll pipe connections should preferablyuse flared fittings. Soldered connectionsmust not be used on oil pipes.9

Two Pipe System - (See Figure 3-1)With the storage tank outlet below theburner, a two pipe system should beused. The pipe runs should be as shownin Figure 3-1. The return pipe should be atthe same level in the tank as the supplypipe, both being 75 to 100mm above thebase of the tank. The pipe ends shouldbe a sufficient distance apart so as toprevent any sediment disturbed by thereturn entering the supply pipe.Avoid the bottom of the tank beingmore than 3m below the burner.Fire valve sensorFire valveShut-off valveSupplyFilterFill pipeALevel GaugeNon return valveSludgevalveShut-off valveThe pump vacuum should not exceed0.4 bar.For guidance on installation of topoutlet fuel tanks and suction oil supplysizing, see OFTEC Technical InformationBook 3. Available from OFTEC.Vent pipeReturnSee section 4.4A non-return valve should be fitted inthe supply pipe together with the filterand fire valve. A non-return valve shouldbe fitted in the return pipe if the top ofthe tank is above the burner.Beyond this limit gas is released fromthe oil.Shut-off valveFuel storage tankFigure 3-1: Two pipe systemFire valve sensorDe-aeration device e.gTiger Loop see Figure 3-3Vent pipeHPipe Length (m)(m)ø 29911003.53198100Tiger Loop System (See Figures 3-2 and 3-3)When the storage tank outlet is belowthe burner, an alternative to a two pipesystem can be achieved using a'Tiger Loop' type oil de-aerator.This effectively removes the air fromthe oil supply on a single pipe lift.Oil Storage &Supply SystemFill pipeø 8mm ø 10mmSupplyReturnSee section 4.4Fire valveTankmasterFigure 3-2: De-aeration device systemThe de-aerator is connected close to theboiler as a two pipe system (omitting thenon-return valve) as shown in Figure 3-2.Refer to the manufacturers instructionssupplied with the de-aerator.The de-aerator must be mountedvertically, Figure 3-2.To burnerFrom burner!WARNINGFrom tankFigure 3-3: Tiger loop de-aeration device10To prevent any possibility of fuelfumes entering the building, thede-aerator must be fitted outside inaccordance with BS 5410:1:1997.FuelstoragetankSludgevalve

3.2 Burner Oil ConnectionBurner head (blast tube)The burner fuel pump is supplied for usewith a two-pipe fuel supply system. Foruse on a single pipe system, it isnecessary to fit the ‘horseshoe’ washerinto the tapping in the pump - refer toFigure 3-5.Combustion air inletIgnition sparkgeneratorCombustionair adjusterFan housingOil pumpPhotocellControl boxLockout reset buttonMotorOil Storage &Supply SystemFigure 3-4: Burner componentsFigure 3-5: Fitting/location of ‘horseshoe’ washer11

Burner fixing nutMain Burner ComponentsRemove the control panel (secured bytwo screws) to gain access to theburner. It may be necessary to removethe burner from the boiler to accessconnections in the fuel pump.To do this, unscrew the single nut atthe top of the burner (using a 13mmspanner) and rotate the burnerclockwise and withdraw the burner fromthe boiler, as shown in Figure 3-6.Figure 3-6: Burner removalBurner ConnectionThe procedure is as follows:1. Remove and discard the blankingplugs from the suction (inlet) andreturn connections of the pump.Refer to figure 3-7.2. Connect the suction and return oilflexible fuel lines to the pump.3. Connect the 3/8" to 1/4" BSPadaptor to the flexible fuel line usingthe adaptor supplied. The supplyenters through one of the holes inthe casing.Item Description01Inlet (suction) port02Return port03Bleed and pressure gauge port04Vacuum gauge port05Pressure adjustment06Nozzle outlet06030405Oil Storage &Supply System011202Figure 3-7: Danfoss BFP11 R3 oil pump

4 Boiler Installation Information4.1 Introduction4.4 Dismantling the BoilerThe boiler is supplied already fullyassembled in a carton which is carefullypacked with packing materials. As theboiler is wall mounted all of the contentof the boiler casing must be removedwith the packaging before installationcan begin, to give access to the rearfixing panel. The installation proceduretherefore begins with unpacking anddismantling of the packed boiler.Dismantle the boiler as follows, keepingall components, screws and washers forre-assembly:6. Remove thermostat phials from theirpocket (in right side of heatexchanger – below returnconnection).1. Slacken off hose clip on burner airinlet and remove snorkel tube fromboiler.4.2 Boiler LocationThe boiler should be fixed to a wall thatis firm, flat and vertical. It does notrequire any special base provisions asthe temperature of the boiler casing isless than 50 C.Sufficient clearance must be allowed atthe front of and below the boiler toremove the burner and baffles forservicing.4.3 Preparation for InstallationThe following procedure must beperformed before you can begindismantling the boiler for installation:1. With the boiler on the pallet, openthe carton and remove all packingmaterials and the carton from theboiler.2. Lift open lower front panel, slidepanel to left or right and detach fromthe boiler.Figure 4-2: Dismantling the boiler2. Unscrew earth wire from undersideof top casing panel.Figure 4-3: Removing thermostat phials3. Slacken screws at rear of top casingpanel and remove screws securingtop panel to side panels. Pull panelforwards to remove from boiler.7. Slacken control panel retainingscrews and remove control panelfrom boiler.4. Disconnect burner plug.5. Unscrew inlet connection tocondensate trap and remove trapfrom boiler.3. Remove upper front panel. Pullbottom edge of panel sharplyupwards to disengage retainingclips and lift off from boiler.4. Remove internal packaging fromwithin boiler casing.5. Remove filling loop and flexible oilhose packs from within boiler.Boiler InstallationInformationFigure 4-1: Boiler front panel open13

11. Remove screws securing right handside panel to bottom panel. Removeright hand side panel from boiler bylifting upwards to disengage tabs.12. Repeat procedure to remove lefthand side panel from boiler.17. Using a 13mm socket, slackenburner retaining nut (on top ofburner). Rotate burner clockwise(towards rear of boiler), pull burnerto the right until burner head is clearof mounting flange and removeburner from boiler.19. Remove baffles from boiler shell.13. Slacken screws at rear of bottomcasing panel and remove bottompanel from boiler.Figure 4-7: Removing baffles fromboiler shell20. Undo retaining screw and removetransit bracket from top of boilershell.Figure 4-5: Removing burnerFigure 4-4: Removing flow & return pipe15. Unscrew compression connectionon boiler shell and remove flow pipefrom boiler.18. Using 13mm spanner, unscrew thetwo clean-out door retaining nutsand remove door from front of boilershell.Figure 4-6: Removing clean-out doorBoiler InstallationInformation22. Lift boiler shell away from backpanel and stand it upright on thefour feet.23. Unscrew and remove the two transitscrews & nuts securing mountingbracket and back panel to pallet.16. Unscrew top right compressionconnection and remove return pipefrom boiler.1421. Push boiler shell upwards todisengage it from mounting bracketon back panel of boiler.

4.5 Installing the BoilerYou are now ready to install the boiler.The procedure is as follows:1. If a back outlet flue system is to beused, remove the large circular flueknockout from back panel. If the rearoutlet PRV discharge is to be used,remove the knockout from the backpanel (as shown in the figure below.7. Locate the mounting bracket on tothe back panel, aligning the fourholes in the bracket with those inthe back panel. Ensure that themounting ‘hooks’ are pointingupwards and secure using thefixings supplied.10. Re-fit flow pipe to compressionconnection on boiler shell. Pass flowpipe from system through hole inback panel (either at top or bottomof panel, as required) and connect toboiler flow pipe.!NOTEIt is recommended that the systemflow and return pipes are connected tothe boiler at this point in theinstallation.Figure 4-9: Fixing the back panelFigure 4-8: Installing the back panel2. Locate and hold the back panel in therequired position on the wall. Check itis level using a spirit level on the topflange. Mark position of the holes forthe two keyhole slots. Remove theback panel from the wall.3. Drill and fit wall fixing plugs in the twoholes. Fit suitable screws and mountthe back panel on the wall using thetwo keyhole slots. Check again thatthe back panel is level beforeproceeding.8. Lift the boiler shell and hang it on themounting bracket – ensuring that themounting plates on either side of theshell are fully located in the verticalslot of both mounting hooks.9. Re-fit the return pipe to top righthand connection on boiler shell.Pass return pipe from systemthrough hole in back panel (either attop or bottom of panel, as required)and connect to boiler return pipe.11. Re-fit burner. First remove burnersecuring nut, locate burner headinto hole in burner flange/boiler shelland locate mounting screw throughhole on top of burner. Re-fit nut andtighten to secure burner in place.Connect flexible oil lines from oilsupply pipework to burner. It isrecommended that the copper oillines are installed at this stage whilethe side panels are not in place.12. Re-fit baffles into boiler shell –ensuring they are in the correctorder (check marking on each baffle)as shown below4. Mark the position of the fourmounting bracket fixings on to thewall from the back panel. Also markthe positions of the flow and returnpipes, the electrical power supply,and the condensate discharge pipe.5. If using a back outlet flue and/orrear PRV outlet is to be used, alsomark these holes on to the wall.43NOTEIf side outlet flue is to be used (toeither left or right) then mark positionas it may be necessary to cut flue holeBEFORE installing boiler on to wall.6. Remove the back panel from thewall. Drill the holes for the mountingbracket fixings and fit the wall plugsprovided. Drill all other necessaryholes. If required, core drill the wallfor a back outlet flue and drill a holefor the PRV discharge pipe.Re-mount the back panel on thetwo keyholes slots.21Figure 4-11: Re-fitting baffles intoboiler shellBoiler InstallationInformation!Figure 4-10: Re-fitting flow & return pipe15

13. Locate clean-out door onto the twostuds, re-fit nuts and tighten tosecure door in place.23. Re-fit condensate trap. Connectcondensate discharge pipe to outletof trap.14. If side outlet flue system is to beused, remove flue ‘knockout’ fromeither the left or right side casingpanel, as required.15. Re-fit left hand casing panel locatingtabs on rear edge of panel into slotsin back panel. Firmly push sidepanel downwards to fully engagetabs.16. Repeat process to re-fit right handcasing panel.4.6 Regulations ComplianceInstallation of a Grant CONDENSINGWall Hung boiler must be in accordancewith the following recommendations: The Department of the Environmentand any local Byelaws which youmust check with the local authorityfor the area. Model and local Water UndertakingByelaws. Applicable Control of PollutionRegulations. The following OFTEC requirements:- OFS T100 Polythene oil storagetanks for distillate fuels.17. Re-fit bottom casing panel andsecure in place with screws (withwashers).18. If top outlet flue system is to beused, remove the flue ‘knockout’ inboth the top casing panel and thetop flange of the back panel. Fit theboiler connector (supplied in the fluekit) to the top of the boiler shell,ensuring it is firmly connected andmaking a seal on the neoprenegasket. Refer to flue installationinstructions for further details.- OFS T200 Fuel oil storage tanksand tank bunds for use withdistillate fuels, lubrication oils andwaste oils.Figure 4-12: Re-fitting condensate trap24. Re-fit snorkel tube to air inletconnection on burner. Tighten hoseclip to secure.19. Re-fit top casing panel and securein place with screws (with washers).Ensure that the ends of the frontflange fit into the slots in the topfront of side panels.20. Re-fit control panel – locating fixingscrews into slots in front flange ofbottom panel. Tighten screws tosecure.21. Re-locate thermostat bulbs inpocket at rear right hand side ofboiler shell.Boiler InstallationInformation22. Re-connect burner plug.16Figure 4-13: Re-fitting snorkel tube25. If balanced flue system is fitted,connect other end of snorkel tube toair inlet spigot of flue system.26. If a conventional flue system isused, locate other end of snorkel intop of boiler, ensuring that inlet totube is not restricted.27. Fit flue system to boiler – refer toflue system installation instructions.28. Re-fit upper front casing panel –hook top edge over front edge oftop panel, locate pins into springretaining clip on each side panel andpush firmly home to secure.29. Re-fit lower front panel – with thepanel at 45 to vertical, locate thetabs into the horizontal slots in frontof bottom panel. Slide to either leftor right and lift into closed positionagainst magnetic catches.Further information may be obtainedfrom the OFTEC Technical InformationBook 3 (Installation requirements for oilfired boilers and oil storage tanks).The installation should also be inaccordance with the latest edition of thefollowing British Standard Codes ofPractice: BS 715 Metal flue pipes, fittings,terminals and accessories. BS 799:5 Oil storage tanks. BS 1181 Clay flue linings and flueterminals. BS 4543:3 Factory made insulatedchimneys for oil fired appliances. BS 4876 Performance requirementsfor oil burning appliances. BS 5410:1 Code of Practice for oilfiring appliances. BS 5449 Forced circulation hotwater systems. BS 7593 Code of Practice fortreatment of water in heatingsystems. BS 7671 Requirements for electricalinstallations, IEE Wiring Regulations.

NOTEFailure to install and commissionappliances correctly may invalidatethe boiler warranty.!WARNINGBefore starting any work on theboiler, or fuel supply please read thehealth and safety information given inSection 14.4.7 CompletionPlease ensure that the OFTEC CD/10installation completion report (providedwith the boiler) is completed in full.Leave the top copy with the User.Retain the carbon copy.Ensure that the User Information pack(supplied with the boiler) is handed overto the Householder.4.8 Before you CommissionTo avoid the danger of dirt and foreignmatter entering the boiler the completeheating system should be thoroughlyflushed out - before the boiler isconnected and then again after thesystem has been heated and is still hot.This is especially important where theboiler is used on an old system.For optimum performance afterinstallation, this boiler and its associatedcentral heating system must be flushedin accordance with the guidelines givenin BS 7593:1992 'Treatment of water indomestic hot water central heatingsystems'.This must involve the use of aproprietary cleaner, such asBetzDearborn's Sentinel X300 or X400,or Fernox Restorer. Full instructions aresupplied with the products, but for moredetails of BetzDearborn’s products, viewthe website www.sentinel-solutions.netand for more details of Fernox productsview the website www.fernox.com.Failure to implement these guidelineswill invalidate the warranty.4.9 Heating System DesignConsiderationsTo achieve the maximum efficiencypossible from the Grant CONDENSINGWall Hung boiler, the heating systemshould be designed to the followingparameters:Radiators: Flow temperature 70 C Return temperature 50 C Differential 20 CUnderfloor: Flow temperature 50 C Return temperature 40 C Differential 10 CSize radiators with a mean watertemperature of 60 C.Design system controls withprogrammable room thermostats or useweather compensating controls tomaintain return temperatures below55 C.The boiler should not be allowed tooperate with return temperatures ofless than 40 C when the system is upto operating temperature.4.11 Pipework MaterialsGrant boilers are compatible with bothcopper and plastic pipe. Where plasticpipe is used it must be of the oxygenbarrier type and be of the correct class(to BS 7291:Part 1:1990) for theapplication concerned.!NOTEThe first metre of pipeworkconnected to both the heating flowand return connections of the boilermust be made in copper.!WARNINGThe system should incorporate alow-pressure switch to shut offpower to the boiler if the systempressure drops below 0.2 bar.A suitable low pressure switch kit isavailable to purchase from GrantEngineering (IRELAND) Limited, PartNo. MPCBS 62.4.12 Underfloor PipeworkPlastic pipe may be used on Underfloorsystems where the plastic pipe is fittedafter the thermostatic mixing valve.Copper tube must be used for at leastthe first metre of flow and return primarypipework between the boiler and theunderfloor mixing/blending valves.The use of a pipe stat is recommendedto control the return temperature whenusing weather compensating controls.4.10 Underfloor Heating SystemsIn underfloor systems it is essential thatthe return temperature must bemaintained above 40 C to preventinternal corrosion of the boiler waterjacket.Boiler InstallationInformation!For Long term protection againstcorrosion and scale, after flushing, it isrecommended that an inhibitor such asBetzdearborn's Sentinel X1

5 Pipe Connections 18 5.1 Water connections 18 6 Condensate Disposal 19 6.1 General requirements 19 6.2 Connections 19 6.3 Pipework 19 6.4 External pipework 19 6.5 Condensate soakaway 19 6.6 Condensate trap 20 6.7 Condensate disposal pipework 20 6.8 Inspection and cleaning of trap 20 7 Electrical 21 7.1 Connecting the power supply 21 7.2 Frost .