Heatese 80 Installation, Commissioning And Instruction Manual

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Installation, Commissioning and Instruction manual

HEATESE

Unique heating system

"Lavish on heat, miserly on fuel"

Always On, Always Warm

HEATESE issue (1) 08/2016

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Page 1 Installation, Commissioning and Instruction manual HEATESE Unique heating system “Lavish on heat, miserly on fuel” Always On, Always Warm HEATESE issue (1) 08/2016...
Page 2: Layout And Components
Insulated and Baffled 80L Copper Cylinder with Heat-Sync on base 3 off Small Cleaning Ports 1 off Large Cleaning Port to facilitate Flue Cleaning Oil Fired Burner with Fuel Safety Valve located externally at rear of enclosure (sensor located internally above burner) Page 1...
Page 3 Page 2...
Page 4 Automatic Air Vents at high points in circuits 1107 Pressurised Closed Loop (Blue, Orange & Thermostats Green) Return From Electrical Panel Dwelling Trip switch, Timer, Relay Removable Cleaning Port Hot Feed to Covers Mains Cold Water Feed (1.5 Bar G Max) Pressure Relief set at 3.0 bar G max.
Page 5 Weather Cowl Flue Gas Exhaust Flue Gas Condenser Heat Exchanger Return Feed from Dwelling Hot Feed to Dwelling Mains Feed (1.5barG Max) 18 L Pressure Pressure Safety Valve Vessel opens to relieve pressure at 3.0barG Condensate Out Page 4...
Page 6 Condenser preheats return Dwelling water before C Shaped Baffled Boiler Motorized Valve is open until the Cylinder Thermostat (B) reaches 50°C, the valve then closes and feeds to dwelling, which thermostat (A) would be set at 60 C Shaped Baffled Boiler transfers Heat to preheat cylinder contents in addition to Cylinder Coil...
Page 7 Jacketed Flue Pipe transfers Heat into Loop which is circulated through Cylinder Coil Mains Cold Water Feed for Initial Fill and Top- L-Shaped Baffled Boiler Wall transfers Heat into Loop which is circulated through Cylinder Coil Closed Loop System Flow Diagram Page 6...
Page 8 Page 7...
Page 9 CONVECTOR RADIATORS Page 8...
Page 10: Table Of Contents
PRE-INSTALLATION..........INSTALATION GUIDE........... HEATESE USER GUIDE ........ELECTRICAL CONNECTIONS ......WIRING DIAGRAM ..........POSITIONING GUIDE........... TECHNICAL DATA TABLE – HEATESE 80 ..CONVECTOR RADIATORS......... CONVECTOR RADIATOR WARRANTY ... CONVECTOR RADIATOR DATA………………...40 HEATESE 80 HEATING SYSTEM FAULT FINDING GUIDE ............ HEATESE COMMISIONING CHECKLIST..
Page 11 This symbol indicates Caution and it is placed next to all safety warnings. Strictly follow these instructions to avoid danger and damage to persons, animals and things. This symbol calls attention to a note or important notice. Declaration of conformity Manufacturer: Low Flame Boilers Ltd.
Page 12: Introduction /Warranty
INTRODUCTION /WARRANTY Thank you for choosing a HEATESE Heating System. We are sure that you will be satisfied with the performance of your new heating system and with the ongoing service that you will receive. Reliability Every new HEATESE Heating System leaving our factory and installed by a HEATESE approved engineer carries a five years guarantee on parts (certain consumable parts are excluded –...
Page 13 A call out charge may be applicable if: The authorised HEATESE service engineer who calls to your home finds no fault with the HEATESE Heating System. Other parts of your plumbing system are either faulty or do not comply with the appropriate installation instructions.
Page 14: Safety Instructions
SAFETY INSTRUCTIONS General information: These operating instructions are intended for the user of the heating system. Read any operating instructions (heating system, heating controls, ect.) carefully before operation and keep them. Observe the safety instructions and warnings. Oil fumes or leaks from the appliance If you smell oil fumes, observe the following rules: Extinguish any naked flames Isolate the electricity supply...
Page 15: Maintenance Tips
Intended use This appliance must only be used as a heat appliance in an open vented hot water heating system for domestic purposes. Any misuse or unauthorised modifications to the appliance, flue or associated accessories and heating system will invalidate the guarantee. Do not modify the appliance or flue system in any way.
Page 16: Regular Servicing
Regular maintenance is an essential part of keeping your HEATESE Heating System running safely and efficiently. Since your HEATESE Heating System operates for long intervals it is important to ensure regular servicing is undertaken by your Authorized HEATESE engineer. Only genuine HEATESE spare parts should be used.
Page 17: General Information
Failure to comply with these guidelines could affect the safety and operations of the unit. Yearly maintenance has to be carried out by a qualified HEATESE engineer to guarantee good operation of the unit. This unit must only be used for the purpose for which it was designed for i.e., for domestic use only.
Page 18: Frost Protection
When excessive venting or water leaks are found in the system you must contact a HEATESE service engineer to inspect the installation and rectify any fault. Only use additives compactible with the heating system. Use of incompatible additives can cause damage and will invalidate the guarantee.
Page 19: Pre-Installation
Building Regulations to flush and inhibit the primary water system in accordance with BS 7593. HEATESE states you must fit a filter that will help remove both magnetite and non-magnetite debris. Before cleaning the system Ensure that the system and pipe work is in good working order.
Page 20 Close drain cocks and add suitable flushing agent at the correct strength for the system conditions in accordance with the manufacturer’s instructions. Run the heating system at normal operating temperature as directed by the manufacturer for the flushing agent. Drain and thoroughly flush the system to remove the flushing agent and debris.
Page 21: Instalation Guide
Installing the HEATESE heating system Introduction When you purchase a HEATESE Heating System, it comes fully setup and commissioned prior to delivery. It can only be installed by a fully certified HEATESE installer. Dimensions The HEATESE Heating System has the following dimensions:...
Page 22 Comes pre-fitted at the rear of the unit at the base. FLOW and RETURN pipes HEATESE has a one inch FLOW and RETURN pipes. They are labelled clearly at the rear of the cabinet. They must be connected to the FLOW and RETURN coming from the property.
Page 23 cistern for expansion of the system water. No valve shall be fitted in the open vent pipe, or the feed and expansion pipe. The open vent pipe must be at least 22mmØ. If the heating system is installed in an existing system, it is necessary to remove any unsuitable additives by thoroughly cleaning the system.
Page 24 Internal connections In order to minimize risk of freezing during prolonged cold spells, the following methods of installing condensate drainage pipe should be adopted, in order to priority. Whenever possible, the condensed drainage pipe should be routed and terminated so that the condensate drains away from the heating system under gravity to a suitable internal foul water discharge point such as an internal soil and vent stack internal kitchen or bathroom waste pipe, washing machine waste pipe etc.
Page 25 When all the listed connections are complete the HEATESE should be filled from the header tank which is usually located in the attic of the property. Once HEATESE and all radiators have been bleed, this part of the system is ready.
Page 26 The installation will be performed by a HEATESE engineer that has qualifications listed below. Installation regulations Complying with the building regulations This heating appliance form part of the controlled services for the building. It is law that all controlled services for buildings must comply with building regulations. You...
Page 27 BS 5410 : part 1: Code of practice for Oil Fired Boilers BS 799 : part 5: Specification for Oil Storage Tanks BS 7593 : Code of Practice for treatment of water in domestic hot water central heating systems BS 5449 : part 1: Specification for forced circulation hot water central heating for domestic premises.
Page 28: Heatese User Guide
Please Note: A house timer has to be used, so the heating system could be turned on or off, or could be set at the selected times for operation. Once installed, the HEATESE Heating System is turned on and off by the house timer. The HEATESE Heating System has two thermostats – Control Thermostat A (see Figure 1) and Single Thermostat B (see Figure 2).
Page 29 The Reset Button At the front of the HEATESE system there is a Reillo burner (which is red in color) and contains a reset button (See Figure 3). This button can be accessed while the panels are in place through an inspection cover.
Page 30: Electrical Connections
ELECTRICAL CONNECTIONS Connections to the electrical grid This heating system’s electrical safety is only guaranteed when correctly connected to an efficient earthing system and executed according to current safety standards. You must have the efficiency and suitability of the earthing system checked by a qualified professional. The manufacturer is not responsible for any damage caused by the failure to earth the heating system.
Page 32: Positioning Guide
POSITIONING GUIDE HEATESE heating system must have a solid base, that can support it’s weight. Heating system locations and clearances This heating system is only suitable for installation externally, outside the property at a suitable location onto a fixed ridged surface of the same size as the heating system and capable of supporting it’s own weight.
Page 33 Positioning of the HEATESE heating system – please follow these guides: Minimum dimensions of fume exhaust terminals Directly under an opening, air inlet, openable window, etc. 600mm Above an opening, air inlet, openable window, etc. 300mm Horizontally to an opening, air inlet, openable window, etc.
Page 34: Technical Data Table - Heatese 80
TECHNICAL DATA TABLE – HEATESE 80 Data Unit HEATESE 80 CH Max working pressure (sealed system) ½ to 1½ CH Max working pressure Gravity feed only CH Max temperature Stat A safety limit CH water content ( sealed system) litres 30 approx.
Page 35 Nominal heating system rating at normal operating temperature using 28 second kerosene Nozzle Oil pump Fuel Approx. pressure flow flue gas temp. (bar /psi) rate Kg/h 0.50x80 100 / 7.0 1.87 10.1 Approx air Input(NET) Output Burner setting damper head disk setting 17.4...
Page 36 The following product data satisfy the requirements of the EU Regulations No.811/2013supplementing Directive 2010/30/EU Product Data Symbol Unit HEATESE Condensing Heating System Low temperature Heating System B1 Heating System Cogeneration space heater (CHP) Combination heater Rated heat output 16.3 rated Ƞ...
Page 37 Product data for energy consumption 1) High temperature regime means 60 C return temperature at heater and 80 C feed temperature at heater outlet. 2) Low temperature means for condensing heating systems 30 C, for low temperature heating systems 37 C and for other heaters 50 return temperature ( at heater inlet).
Page 38: Convector Radiators
CONVECTOR RADIATORS Installation The HEATESE 80 Convector Radiators must be installed by a HEATESE engineer. Requirements for installation: To place the convector radiator on the wall, the front panel must be removed by removing the white screws that are located on the top, sides and bottom of the cabinet.
Page 39 The front cabinet door can now be replaced with the screws provided. Operation To use HEATESE 80 Convector Radiator there is a room stat on the right hand side of the unit. This stat can be adjusted to bring the room to the desired temperature.
Page 40: Convector Radiator Warranty
CONVECTOR RADIATOR WARRANTY What is under guarantee: 1 year warranty for the finned heating core 6 year warranty for the fans 1 year warranty for the room stat 1 year warranty for the pipe stat 1 year warranty for the 12V AC/DC adaptor Convector Radiators Electrical test passed as per EN 61010 –...
Page 41: Convector Radiator Data
CONVECTOR RADIATOR DATA HEATESE 80 – 2 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x280/10-1 at 55 C fluid Results Total output: 1.256 kw Liquid leaving: 54.1 °C Sensible output: 1.256 kw Fluid pressure drop : 1584 kPa Latent heat: 0.000 kw...
Page 42 HEATESE 80 – 2 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x280/10-1 at 60 C fluid Results Total output: 1.436 kw Liquid leaving: 58.9 °C Sensible output: 1.436 kw Fluid pressure drop : 1566 kPa Latent heat: 0.000 kw...
Page 43 HEATESE 80 – 2 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x280/10-1 at 65 C fluid Results Total output: 1.616 kw Liquid leaving: 63.8 °C Sensible output: 1.616 kw Fluid pressure drop : 1550 kPa Latent heat: 0.000 kw...
Page 44 HEATESE 80 – 2 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x280/10-1 at 70 C fluid Results Total output: 1.796 kw Liquid leaving: 68.7 °C Sensible output: 1.796 kw Fluid pressure drop : 1534 kPa Latent heat: 0.000 kw...
Page 45 HEATESE 80 – 3 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x420/10-2 at 55 C fluid Results Total output: 1.360 kw Liquid leaving: 54.0 °C Sensible output: 1.360 kw Fluid pressure drop : 355 kPa Latent heat: 0.000 kw...
Page 46 HEATESE 80 – 3 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x420/10-2 at 60 C fluid Results Total output: 1.555 kw Liquid leaving: 58.9 °C Sensible output: 1.555 kw Fluid pressure drop : 351 kPa Latent heat: 0.000 kw...
Page 47 HEATESE 80 – 3 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x420/10-2 at 65 C fluid Results Total output: 1.750 kw Liquid leaving: 63.7 °C Sensible output: 1.750 kw Fluid pressure drop : 348 kPa Latent heat: 0.000 kw...
Page 48 HEATESE 80 – 3 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x420/10-2 at 70 C fluid Results Total output: 1.945 kw Liquid leaving: 68.6 °C Sensible output: 1.945 kw Fluid pressure drop : 345 kPa Latent heat: 0.000 kw...
Page 49 HEATESE 80 – 4 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x560/10-2 at 55 C fluid Results Total output: 1.447 kw Liquid leaving: 53.9 °C Sensible output: 1.447 kw Fluid pressure drop : 389 kPa Latent heat: 0.000 kw...
Page 50 HEATESE 80 – 4 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x560/10-2 at 60 C fluid Results Total output: 1.654 kw Liquid leaving: 58.8 °C Sensible output: 1.654 kw Fluid pressure drop : 385 kPa Latent heat: 0.000 kw...
Page 51 HEATESE 80 – 4 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x560/10-2 at 65 C fluid Results Total output: 1.861 kw Liquid leaving: 63.7 °C Sensible output: 1.861 kw Fluid pressure drop : 381 kPa Latent heat: 0.000 kw...
Page 52 HEATESE 80 – 4 FAN Water Coil; Both – Metric units Coil Model: 15/2x8x560/10-2 at 70 C fluid Results Total output: 2.068 kw Liquid leaving: 68.5 °C Sensible output: 2.068 kw Fluid pressure drop : 378 kPa Latent heat: 0.000 kw...
Page 53: Heatese 80 Heating System Fault Finding Guide
These checks are some of the common causes are listed in the table below. Should the problem persist, please contact your HEATESE engineer. Under no circumstances must an appliance be left to operate with any control linked out or overridden.
Page 54 Ignition failure Faulty ignition transformer Replace Open circuit ignition Check and replace electrodes if necessary Faulty control box or Correct electrical control box electrical connections not connections or replace control properly made Burner fails to start No power to heating system Check electrical control unit located in white cabinet Faulty heating thermostats Check the temporarily linking out...
Page 55: Heatese Commisioning Checklist
HEATESE PRE- COMMISIONING CHECKLIST Check that the service and water pipes are connected correctly. Check that the oil supply is Class C2, 28 second Kerosene and that the pipe work is connected correctly to the oil filter. Turn on the main supply valve at the tank, check the oil supply pipework and connections.
Page 56 Heating system details Make and Model_ Serial Number Commissioning Engineer Company Name Company Address Telephone Number_ Commissioned by (signature) (print name)_ Commissioning Date_ Commissioning Checks Oil Type Used is Kerosene Pump Pressure % CO ppm CO/CO ratio Smoke Reading Flue Gas Temperature Flue Pressure Burner Model All Systems...
Page 57 What inhibitor was used? Quantity litres Has a system filter been fitted? The condensate drain has been installed in accordance with the manufacturer’s instructions and /or BS5546/BS6798 The Class VII temperature control stat has been installed in accordance with the manufacturer’s instructions? If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted? All Installations...
Page 58: Service Record
SERVICE RECORD Service 1 Date Engineer Name Company Name Telephone No._ Authorized Register No._ Nozzle Changed? Pump Pressure % CO CO/CO ratio F.G.T._ Flue Pressure Comments:_ Signature Service 2 Date Engineer Name Company Name Telephone No._ Authorized Register No._ Nozzle Changed? Pump Pressure % CO CO/CO...
Page 59 SERVICE RECORD Service 1 Date Engineer Name Company Name Telephone No._ Authorized Register No._ Nozzle Changed? Pump Pressure % CO CO/CO ratio F.G.T._ Flue Pressure Comments:_ Signature Service 2 Date Engineer Name Company Name Telephone No._ Authorized Register No._ Nozzle Changed? Pump Pressure % CO CO/CO...
Page 60 SERVICE RECORD Service 1 Date Engineer Name Company Name Telephone No._ Authorized Register No._ Nozzle Changed? Pump Pressure % CO CO/CO ratio F.G.T._ Flue Pressure Comments:_ Signature Service 2 Date Engineer Name Company Name Telephone No._ Authorized Register No._ Nozzle Changed? Pump Pressure % CO CO/CO...
Page 61: Heatese Contact Numbers
HEATESE CONTACT NUMBERS Before contacting HEATESE please have available the completed Benchmark document (located inside this manual), heating system, serial number and model detail. For Technical assistance during the installation, call our Technical Helpline on 086 2438990 Should you require a Service Engineer to visit, call our Service Centre on 086 2438990...