DANESMOOR UTILITY 12/14, 15/19, 20/25, 26/32 WORCESTER BOSCH 50/70, 70/90, 90/110 FLOOR STANDING OIL-FIRED PRESSURE-JET BOILERS WHEN FITTED INSIDE OUTDOOR PACK INSTALLATION AND SERVICING INSTRUCTIONS IMPORTANT: Please discard all previous Installation and Servicing instructions. Retain ONLY the Worcester Outdoor Pack Installation and Servicing Instructions.
Contents 1. 2. 3. 4. 5. 6. 7. Installation Regulations ...........................................Page General Information .................................................Page Technical Data...........................................................Page Siting the Appliance .................................................Page Removal of the Cabinet............................................Page Air Supply..................................................................Page Flue System..................
. Technical Data Table 1 Danesmoor Utility MODEL Worcester Bosch MODEL POWER SUPPLY IP RATING 12/14 / 230V 50 Hz IP 45 SPECIFICATIONS 15/19 50/70 230V 50 Hz IP 45 20/25 70/90 230V 50 Hz IP 45 26/32 90/110 230V 50 Hz IP 45 1 in. BSP 1 in. BSP 1 in. BSP 11/4 in. BSP HEATING FLOW 1 in. BSP 1 in. BSP 1 in. BSP 11/4 in.
Fig. 2. Outdoor Pack Principal Dimensions. (All Dimensions are in millimetres) 670 Flue terminal Flue terminal guard 760 212 267 740 975 68 X 798 148 238 142 X= 806 (26/32 and 90/110) X= 811 (on all other models) Danesmoor Utility 12/14 Table 2. Electro Oil Inter B9A Burner (See Fig. 29) NOMINAL BOILER RATING AT NORMAL OPERATING TEMPERATURE Fuel 28 Sec. Kerosene 28 Sec. Kerosene Nozzle Pump Pressure (p.s.i.) 0.40 60°ES 0.50 60°ES 130 100 Fuel Flow Rate Kg/h l/h 1.11 1.41 1.30 1.
Fig.3. Conventional Flue Appliance (CF/LLD). Fitted within Outdoor Conversion Kit.
Fig.4. Outdoor Pack. Top panel Rear panel Top panel bracket Rear panel bracket Open side panel Silencer blanking plate Clamping collar Gasket Handlewheel Brace Clamp Silencer bracket Outdoor control box Frost thermostat phial Water plate (A) Water plate (B) Closed side panel Fire valve plate Front panel Oil plate Rear panel locating tabs M8 nut Rail Template For fixing the base to the hard standing use the 4 holes provided in the base.
4. Siting The Appliance 7. Flue System 4.1 The appliance is only suitable for external installation. WARNING: This appliance should not be installed where there is potential for excessive ground water. 4.2 The appliance should be positioned and fastened on a noncombustible solid base and care should be taken to ensure that the appliance is level. 4.3 When siting the appliance the flue terminal must be positioned such that the flue terminal can safely discharge the flue gases as described in Section 7. 4.
Fig.5. Flue outlet terminating positions for oil-fired appliances NOTE: The dimensions given are for general guidance only. Other surrounding buildings or objects may affect the clearance of combustion products. An alternative flue terminal position should be sought when there is any possibility of a nuisance being caused by inadequate dispersal of flue products. Terminals should be positioned so as to avoid products of combustion entering into buildings. Boundry C.D.
3. An oil filter should be fitted close to the oil storage tank. If there is doubt about the internal oil line condition, a further filter should be fitted near the boiler. 8. Oil Supply (See Figs. 6, 7 and 11). 8.1 Plastic or steel tanks should be installed to BS5410. A steel tank should also conform to BS799: part 5 and be arranged with a slope of 1 in 24 away from the outlet valve with a sludge cock at its lower end. 8.2 Do not use galvanised steel tanks or pipework for the oil supply system. 8.
TABLE 8 Single Pipe Suction Lift with De-aerator MAXIMUM ALLOWABLE PIPE RUN FROM TANK TO DE-AERATOR (metres) Fuel Flowrate HEAD (metres) 0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 2.5 (kg/h) 5.0 (kg/h) 100 95 80 70 60 45 35 25 6 mm inside dia. pipe (8 mm O.D. copper) 55 45 40 35 30 25 15 10 10.0 (kg/h) 10.0 (kg/h) 26 23 20 17 14 11 8 5 8 mm inside dia. pipe (10 mm O.D. copper) 100 100 90 75 65 50 35 20 Fig. 6. Oil Supply.
Open Vent Primary System (See Fig. 8). The following points are for guidance only. The system installation should be carried out in accordance with BS 5449: Part 1. 1. System Pipework The first metre of pipework from all appliance connections must be in copper; afterwards copper or plastic pipe can be used. The plastic pipe must be manufactued to BS 7291 and installed to BS 5955 part 8. It is recommended to protect the system components the plastic pipe specified must be resistant to the ingress of oxygen.
Fig. 9. Typical fully pumped sealed system (Honeywell ‘Y’ plan). Automatic air vent Domestic hot water cylinder Diverting valve Safety valve N.B. A drain cock should be installed at the lowest point of the heating circuit Pressure gauge Boiler Boiler Pump Radiator Expansion Vessel To system filling device (see Fig.10) Automatic bypass valve to be fitted where thermostatic radiator valves are fitted on all radiators Fig. 10.
10.5 Safety Check In the event of an electrical fault after the installation of the appliance, the electrical system shall be checked for short circuits, fuse failure or incorrect polarity of connections. 10.6 Pre-wired Remote Y Plan or S Plan System (See Fig.13). If the system is fully pre-wired at a junction box remotely from the boiler it can be connected to the boiler.
Fig. 12. Wiring Diagram (Standard).
11. Installation open side panel. 7. For ease of installation fix the relevant fittings to the boiler and plug any unused sockets. The outdoor appliance is installed and serviced externally to the property, but the engineer must have access to inside of the property when servicing the appliance. 8. Hold the open side panel (with the pipework exit holes) on the side, which the pipework will be protruding from the boiler. WARNING: This appliance is serviced and repaired externally.
Fig.16. Water Plate Positions. (Panel viewed from inside) Top of Open Side Panel For 12-25 (50-90) models use the bottom holes to fasten For 26/32 (90/110) models use the top holes to fasten N.B. The plates should be fastened on the inside of the open side panel. Electrical cable entry N.B. Ensure the open/close bush is in position. Water plate (A) For all models use the top holes to fasten Water plate (B) N.B.
Fig.17. Assembly of the Base/Side/Rear Panels.
8. Blank the top flue hole using the blanking disc as shown in Fig.24. 9. Fully tighten the flue silencer outlet plate to the rear panel. 10. Place a fillet of silicone sealant around the flue terminal to prevent water entering the rear panel (see Fig.26). 14. Check the boiler sockets line up with the water plate holes in the open side panel and make any adjustments required. 15.
3. Open the main oil supply valve at the tank and check for any leaks. 4. Place a suitable container below the bulkhead fitting and open the valve. 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. and remove and clean the oil pump filter to remove any debris collected as a result of installation. 11.
Fig.21. Fastening the Top panel Bracket to the Top Panel Top panel bracket Top Panel (under side) Fig.22. Flue Terminal Assembly. Silencer bracket Gasket Clamping collar locking band Flue terminal Flue outlet plate Gasket No.6 screws supplied with RS Short Silencer Kit Nut Fig. 24. Flue Blanking Arrangement. Fig. 23. Rear Flue Outlet Seal. Fixing screws Gasket Form a bead of fire cement or silicone sealant around the collar before inserting the flue terminal.
Fig.25. Assembling Top panel to the Outdoor Pack. Top panel Rear panel bracket Fasten the top panel to the brace using two of the screws provided. Brace (b) Top panel in position (a) Fitting of the top panel Fig.26. Flue Guard Position. N.B. Ensure that there is a 1mm gap between the top of the flue guard and top panel. Locating eyes A A Seal around the top and sides of the flue terminal to prevent water ingress.
12. Commissioning The Appliance WARNING: This appliance is serviced and repaired externally. External equipment operated at 230volts should not be serviced or repaired under adverse weather conditions. NOTE: The Outdoor Pack is not load bearing, it only provides weather proofing for the boiler inside. 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.
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.30).
Fig. 29. Electro Oil Inter B9B Burner. Danesmoor Utility (15/19 Model) Worcester Bosch (50/70 Model) Locking screw Combustion Head All Dimensions are in mm A 2mm Combustion head Spark gap 2-2.5mm Photocell 10mm Adjusting disc Transformer Draught tube Nozzle Nozzle block To adjust the nozzle position, undo the locking screw located Pressure adjuster at the rear of the nozzle line and screw rotate the adjusting disc one turn anti-clockwise to move Oil pump forward by 1mm.
Fig. 31. Electro Oil Sterling Burner. Danesmoor Utility (26/32 model) Worcester Bosch (90/110 Model) Control box Combustion Head - PL 6/7/21.5/10 x 78mm All Dimensions are in mm 3.5mm Spark gap 2.5 – 3.0 0mm Transformer Combustion head Lockout reset button Connecting pipe 7.5mm Solenoid valve Draught tube Nozzle Nozzle block Pressure Gauge Port Motor Pump Photocell Fig. 32.
Allen key, and remove the burner. 2. Clean the fan impeller using the following procedure: 13. Instructions To The User Electro-oil Inter B9 Burner (a) Remove the two screws holding the combustion head in position and withdraw the combustion head and air guide collar (where fitted). (b) Remove the three remaining screws holding the front cover plate in position and withdraw the cover to expose the fan impeller. (c) Clean both sides of the fan impeller and remove any debris from the burner housing.
11. Re-assemble the burner components. 12. Check the sponge O-ring seal located around the combustion head and replace if necessary. It is imperative that this seal is in good condition since failure will cause the flue gases to be recirculated into the burner inlet. 14.4 Remove the paper element from the external oil filter and replace. If the filter contains a washable element then thoroughly clean in Kerosene or white spirit and re-assemble into the filter. 14.5 Clean the Boiler 1.
15.
LOCKOUT INDICATED BY RED LAMP ON CONTROL BOX To Re-set wait 2 minutes and press re-set button Ignition failure Oil at oil pump. Air adjustment fault. CO2 should be as specified in tables 2 to 5. Flame detection fault. Photocell filmed over. Clean. No oil at oil pump. Photocell faulty. Replace. Burner motor fails to operate. Intermittent lockout. Faulty control box. Replace if necessary. Bad electrical connection. Intermittent flame detection fault. See flame detection fault.
Worcester Heat Systems Limited (Bosch Group), Cotswold Way, Warndon, Worcester, WR4 9SW. Telephone: (01905) 754624. Fax: (01905) 754619. Technical Helpline: 08705 266241. www.worcester-bosch.co.uk This booklet is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances 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.
