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Boulter eco-system User Manual

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Eco-System
Boiler
Boulter Boilers Ltd
Magnet House
30 White House Road
Ipswich
IP1 5JA
Tel: 01473 241555
Fax: 01473 241321
Manual Part No.
PL 49021
Issue No
1
Date
April 2002

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Summary of Contents for Boulter eco-system

  • Page 1 Eco-System Boiler Boulter Boilers Ltd Magnet House 30 White House Road Ipswich IP1 5JA Tel: 01473 241555 Fax: 01473 241321 Manual Part No. PL 49021 Issue No Date April 2002...

  • Page 2: Health And Safety

    Boulter Boilers Limited Magnet House, 30 White House Road, Ipswich IP1 5JA Due to a policy of continual development Boulter Boilers Telephone: (01473) 241555 reserves the right to alter or amend the design of its prod- Fax: (01473) 241321 ucts without prior notice.
  • Page 3 Siting & Positioning The Hearth Boiler Spare Parts, 12/19 & 19/26 The Chimney Burner Parts Air Supply SECTION 10 - FAULT FINDING Oil Storage Oil Supply 10:1 Fault Finding Oil Burner 10:2 Fault Finding Chart BOULTER BOILERS Eco-System PAGE 1...
  • Page 4 For further explanation please refer If an engineer is not known, Boulter Boilers will to section 4.6 of this installation manual. be pleased to provide details of commissioning and servicing engineers from their register.
  • Page 5 The Burner is lit by an automatic ignition system and therefore there is no pilot flame. The Boiler should not be operated below 60°C as this will cause corrosion which will reduce the life of the Boiler (Summer position). BOULTER BOILERS Eco-System PAGE 3...
  • Page 6 The Boiler must be serviced at regular intervals by 1. Turning off the mains switch controlling the a qualified service engineer. Failure to have the Boiler, or Boiler serviced at the recommended intervals will 2. Turning the programmer (if fitted to the heating BOULTER BOILERS Eco-System PAGE 4...
  • Page 7 Wait three minutes. Repeat the procedure by pressing the button. Failure to start on the second attempt indicates a fault requiring attention. Switch off the mains supply and call your service engineer. BOULTER BOILERS Eco-System PAGE 5...
  • Page 8 The Eco boiler is: engineer. 1. Designed for Central Heating and Hot Water. If an engineer is not known, Boulter Boilers will be 2. Not suitable for open vented systems. pleased to provide details of commissioning and 3. Suitable for sealed Central Heating systems servicing engineers from their register.
  • Page 9 Regulations. This appliance must be effectively earthed and connection to the supply must be through a double pole isolating switch fused 5 amp. The isolating switch must have all pole contact separations at least 3mm BOULTER BOILERS Eco-System PAGE 7...
  • Page 10 Litres x 1000 11.7/ 12/19 40/65 860 596 446 130 121 540 55 65 92 4" 17.5 19/26 65/90 860 596 446 130 121 540 55 65 92 4" 21.0 26.4 * Conventional Flue Size BOULTER BOILERS Eco-System PAGE 8...
  • Page 11 Control Stat 0 - 85 6.69 9.61 Exit Flue Gas Mass Flow Kg/Sec x 10 8.46 11.84 HIGH 9.24 12.79 Heat Input (Full Load) kW (based on Net 22.1 29.0 efficiency of 91%) Heat Output (Full Load) kW 26.4 BOULTER BOILERS Eco-System PAGE 9...
  • Page 12 BS 4543 Pt. 1 & 3 Factory made insulated Further advice from BOULTER BOILERS should chimneys. be sought where any doubt exists. BS 7593 Code of practice for the treatment of 2.
  • Page 13 Combustion draughts’ will not occur. and Ventilation should be ducted to low level. A high level outlet should be provided for ventilation. Special pots and cowls which might restrict the flow BOULTER BOILERS Eco-System PAGE 11...
  • Page 14 Fig. 4:8b pipe feed as gravity supply or with a Boulter 3K Oil If the bottom of the Oil Tank is above the oil Burner, Loop Deaerator where suction lift is required. (Part install a 10mm copper supply pipe to the Burner No.
  • Page 15 The advantage of this system is gained where a two pipe run from the oil supply tank is long or difficult to achieve. Boulter 3K Deaerators are available as an optional extra from your merchant (Part No. BS 03060). Flexible Hose...
  • Page 16 BS 03101 FITTED Grommet RP00610 PLUG 10MM DIAMETER SUPPLY TUBE BOILER CASE LH & RH FUEL ENTRY AVAILABLE (LH SHOWN) SCHEMATIC DIAGRAM FIT HOSE AS SHOWN IN FIG. 4:8a Fig. 4:8c Schematic Oil Pipe Connectors BOULTER BOILERS Eco-System PAGE 14...
  • Page 17 FITTED 10MM DIAMETER SUPPLY TUBE 10MM DIAMETER BOILER CASE RETURN TUBE LH & RH FUEL ENTRY AVAILABLE (LH SHOWN) SCHEMATIC DIAGRAM FIT BOTH HOSE AS SHOWN IN FIG 4:8a Fig. 4:8e Schematic Oil Pipe Connectors BOULTER BOILERS Eco-System PAGE 15...
  • Page 18 '' BSP x 10mm Coupling FS 00151 Longlife Hose 900mm BS 03103 ITEMS 7, 8, & 10 ARE AVAILABLE AS A KIT NO. BS 03058C. '' x 10mm Coupling FS 00157 Fig. 4:8g Schematic Oil Pipe Connections. BOULTER BOILERS Eco-System PAGE 16...
  • Page 19 The burner is supplied set for single pipe operation. The return port is plugged and the Bypass Screw is not fitted. See Fig. 4:9b. RETURN PLUGGED BYPASS SCREW NOT REQUIRED FLOW Fig. 4.9b Burner Pump for Single Pipe Operation BOULTER BOILERS Eco-System PAGE 17...
  • Page 20 Vertical Balanced Flues may also be preferred in be referred to BOULTER BOILERS LTD. who will cases where close proximity to adjoining houses or be pleased to consider and discuss it.
  • Page 21 BOULTER BOILERS would be pleased to advise on any difficult positioning Fig. 5.4a Balanced Flue Terminal Positions BOULTER BOILERS Eco-System PAGE 19...
  • Page 22 (Boulter Code FL26160). Generally, exhaust 2 metres above ground level alleviates the necessity for a guard. A suitable guard is available from BOULTER BOILERS as shown below. Fig. 5.7a Side Panel Blanking Plate 5:7 BLANKING PLATES The Boiler is supplied in Balanced Flue form.
  • Page 23 3. Ensure that the outlet of the Terminal points downward (TOP upper-most and Boulter correct way up). 4. Ensure that the boiler to offtake gasket is fitted (foil face upwards) and the clamp is made with four nuts and washers securely fixed.
  • Page 24 6:2 LOW LEVEL HORIZONTAL FLUE 6:2.1 Rear Model 12/19 19/26 Dim A 770mm 770mm Fig. 6:2a Low Level Horizontal Rear 6:2.2 Side - Right or Left Hand See attached colour leaflet for dimensions Fig. 6:2b Low Level Horizontal Side BOULTER BOILERS Eco-System PAGE 22...
  • Page 25 (rear, LH or RH side). Move blanking align. NB Ensure that TOP is on the upper most plate to appropriate position using nuts and surface of the terminal and ‘Boulter’ is upright. washers. 15. Secure the terminal to the flange using the 5.
  • Page 26 6:3 HIGH LEVEL HORIZONTAL FLUE 6:3.1 Rear attached colour leaflet for details DIM ‘A’ 135mm Fig. 6:3a High Level Horizontal Rear BOULTER BOILERS Eco-System PAGE 24...
  • Page 27 Fig. 6:3b High Level Horizontal Flue Assembly BOULTER BOILERS Eco-System PAGE 25...
  • Page 28 6:3.2 Side - Right or Left Hand See attached colour leaflet for details 323mm Fig. 6:3d High Level Horizontal Flue Side BOULTER BOILERS Eco-System PAGE 26...
  • Page 29 Joints in the flue must not be situated within the flue offtake spigot. joist space. Joints must be a minimum of 150mm below ceiling height. BOULTER BOILERS Eco-System PAGE 27...
  • Page 30 6:4 VERTICAL FLUE FLAT ROOF INSTALLATION Fig. 6:4a Vertical Flue - Flat Roof BOULTER BOILERS Eco-System PAGE 28...
  • Page 31 Rain Cap Air Entry Shield Vertical Terminal Body Ceiling Trim Fig. 6:4b Vertical Flue - Flat Roof Assembly BOULTER BOILERS Eco-System PAGE 29...
  • Page 32 6:4 VERTICAL FLUE PITCHED ROOF INSTALLATION Fig. 6:4c Vertical Flue - Pitched Roof BOULTER BOILERS Eco-System PAGE 30...
  • Page 33 Rain Cap Air Entry Rain Shield Vertical Terminal Body Flue Support Quadrant Kit Fig. 6:4dVertical Flue - Pitched Roof Assembly BOULTER BOILERS Eco-System PAGE 31...
  • Page 34 There is a certain amount of adjustment available on the vertical height and horizontal length. This is attained by pushing two telescopic flues together until the desired dimension is obtained. Secure any vertical lengths by using a drill and 4 self tapping screws supplied. 6:6 QUICK FIT FLUE SYSTEMS BOULTER BOILERS Eco-System PAGE 32...
  • Page 35 OFTEC commissioning engineer. If an engineer is not known Boulter Boilers will be pleased to provide details of commissioning and servicing engineers from their register. Commissioning must be carried out at the point of first firing.
  • Page 36 7:4 BOULTER BOILERS RECOMMENDED COMMISSIONING CHECK LIST - SHEET 1 OF 2 Customer ..........Appliance Model ........Site Address .......... Serial No....................... Fuel............Tick off each item Is the oil supply clean and free of water or other contamination?

  • Page 37: Electrical Power Supply

    7:4 BOULTER BOILERS RECOMMENDED COMMISSIONING CHECK LIST - SHEET 2 OF 2 CASING PANELS VENTILATION Have grommets been fitted to relevant oil CONVENTIONAL FLUED BOILERS supply entry points (knockouts)? Is the ventilation opening from the outside to Does electrical cabling pass through a...

  • Page 38: Commissioning Tests

    Winter positions, see fig. 1. Complete commissioning report and enter the details on to the guarantee form which should be returned to BOULTER BOILERS in the envelope Switch on the electrical supply to the boiler, provided. checking that programmers are switched to the ‘ON’...
  • Page 39 Limit thermostat once appliance hoses that are detailed in the spare parts section of temperature has dropped sufficiently. this manual. Complete a maintenance report and give the customer a copy, retaining a copy for your records. BOULTER BOILERSEco-System PAGE 37...
  • Page 40 Fig. 8.3a Baffle Arrangement To ensure correct placement of baffles ensure that castellated edges are positioned towards the heat exchanger and: 1. All baffles are horizontal 2. All baffle handles are in the forward position. BOULTER BOILERS Eco-System PAGE 38...
  • Page 41 9:2 BOILER SPARE PARTS 12/19 & 19/26 BOILERS SAMPLE POINT Fig. 12/19 SAMPLE POINT Fig. 19/26 BOULTER BOILERS Eco-System PAGE 39...
  • Page 42 PN49108 Control Panel Complete PN57050C PN57050C Riello Burner Complete Type 484T50 483T50 Part No. 3748455 3748355 Burner Airduct RP47001 RP47001 Side Panel Bracer PN47214C PN47214C Side Flue Plate PN47118C PN47118C Note: Items 22-26 not shown. BOULTER BOILERS Eco-System PAGE 40...
  • Page 43 Air Box Seal 3008642 Nozzle Holder 3008878 Fan Box Seal 3008861 Nozzle Holder (484T50) 3008878 O Ring Seal 3007178 O Ring 3008876 Pressure Gauge Extension 3008543 Collar (Includes O Rings) 3008875 Electrode Clamp (484T50) 3008862 Collar (484T50) BOULTER BOILERS Eco-System PAGE 41...
  • Page 44 Photo-electric cell Check and tighten if necessary. connections loose Control box photo- Replace control box. electric cell circuit faulty Flame instability Check combustion setting out and reset if necessary. BOULTER BOILERS Eco-System PAGE 42...
  • Page 45 Inspect and reset or remove blockage. (a) continuously incorrect or fan inlet blocked Grossly oversized Checked and replace with correct size and type nozzle (see Technical Data) Air supply inadequate Check fan operation and cleanliness. BOULTER BOILERS Eco-System PAGE 43...
  • Page 46 Check all Baffles are in place and correctly located. High flue gas Check: air shutter, nozzle size (see Technical temperature Data), clean heat exchanger surfaces. 12. Oil odour Leaking joints Break all leaking joints and re-make BOULTER BOILERS Eco-System PAGE 44...
  • Page 47 CO2 indicator and intermittently or faulty nozzle or draught gauge, adjust settings as necessary, unsatisfactory draught replace nozzle if necessary. conditions or fault in See Commissioning Check List and Servicing oil supply Notes. BOULTER BOILERS Eco-System PAGE 45...

  • Page 48: Section 1 - Introduction

    Filling the System Pressure Relief Valve Expansion Vessel Pressure ECTION 3 - SERVICING 3:1 Access 3:2 Water System 3:3 Additional Servicing SECTION 4 - SPARE PARTS 4:1 Sealed System 12/19 & 19/26 SECTION 5 - PUMP PERFORMANCE BOULTER BOILERS Eco-System PAGE 46...
  • Page 49 Boilers are supplied with an expansion vessel and associated components arranged to minimise installation time. Sealed System Boilers can be used for Conventional Flue or with any of the Boulter Balanced Flue options available for the Camray 5, except side low level.
  • Page 50 1:3 BOILER ARRANGEMENT 1-3. FILLING LOOP PUMP ISOLATING VALVES 7. PRESSURE RELIEF VALVE 6. PRESSURE GAUGE 4. CIRCULATING PUMP 9. EXPANSION VESSEL TRANSIT BRACKET Fig. 1:3 Boulter Eco System Boiler Arrangement (12/19 shown) BOULTER BOILERS Eco-System PAGE 48...
  • Page 51 Boiler. The remaining top socket must be plugged. For systems having a larger capacity multiply the total system capacity by the factor to 0.08 0.11 0.16 obtain the total minimum expansion vessel capacity required. BOULTER BOILERS Eco-System PAGE 49...
  • Page 52 IMPORTANT 2:1 WIRING DIAGRAMS ENSURE GOOD EARTH ECO SEALED SYSTEM - CONTROL PANEL SCHEMATIC WIRING DIAGRAM BOULTER BOILERS Eco-System PAGE 50...
  • Page 53 Boiler. 19/26 The Tundish must be located in a position clearly visible to the Householder. Installation of the Tundish must comply with Part G3 of The Building Regulations typically as fig. FIG. 2:3 Tundish Installation BOULTER BOILERS Eco-System PAGE 51...
  • Page 54 2:4 PIPE CONNECTION DETAILS NB Alternative locations for the PRV are shown in Figure 2.2 (Blank off existing position) FIG. 2:4 Pipe Connection Details (12/19 shown) BOULTER BOILERS Eco-System PAGE 52...
  • Page 55 6. Flush system thoroughly and refill. to the Cold Fill pressure. Refer to 1:4.6. Vent radiator and any other manual Air Release Vents. Check for leaks particularly on an older system which may have operated on a lower pressure. BOULTER BOILERS Eco-System PAGE 53...
  • Page 56 This should be checked for operation during annual servicing by increasing the system pressure outlined in Section 2:7. Expansion Vessel Pressure Should be checked to be in accordance with the cold design pressure of the system. FIG. 3:1 Removing Expansion Vessel BOULTER BOILERS Eco-System PAGE 54...
  • Page 57 HE 49001C Circulating Pump EL 49012 Isolating Valve EL 49022 Pressure Gauge BS 31004 1st Flow Pipe Assy. BS 49051C Pressure Relief Valve 26775 2nd Flow Pipe Assy. BS 49052C Expansion Vessel (10l.) 207291 Tundish 99537 BOULTER BOILERS Eco-System PAGE 55...
  • Page 58 Speed 11. Repeat this process until adequate circulation is achieved. Remember, if the speed setting is too high, noise may be caused in the system and the power consumption will be unnecessarily high. BOULTER BOILERS Eco-System PAGE 56...
  • Page 59 Due to a policy of continual development Boulter Boilers reserves the right to alter or amend the design of its products without prior notice. Indicates changes from previous issue...