Oil Fired Installation Guide
Contents
1. Noo v n E E E Bon b de DL TU I wo Nem ep po DNA URN x Wc Mm D E E ee OR E M cr c xu ET pu tradu M E cL Hot Outlet Rear n Hin M dcc au s Do m ee Weight Empty inc Burner Weight Empty inc Burner Weight Full inc Burner Weight Full inc Burner Shipping Height Shipping Width Shipping Depth SECTION 3 INTRODUCTION LOCATION BURNER ASSEMBLY THE LAW REQUIRES THAT INSTALLATION IS CARRIED OUT BY A PROPERLY QUALIFIED PERSON Installations must be carried out in accordance with current Building Regulations The Water Supply Water Fittings Regulations 1999 and any requirements of the Local Authority Water and Fire Authorities and the current British Standards and Codes of Practice listed in Section 1 The location selected for installation of the heater must allow the provision of a satisfactory flue adequate air supply drain facilities and must be well illuminated A purpose built boiler room or compartment is strongly recommended If a purpose built boiler room is not available measures should be taken to protect the heater from damage and prevent any extraneous matter from being stored on or around the heater There must be easy access to the boiler room and heater at all times The heater must not2. Ref Part No Description Qty B171 Unvented Systems Kit Complete 1 C1 C780 Pressure Reducing Valve Strainer 1 C2 C781 Check Valve Expansion Valve 1 C3 C782 Expansion Vessel 1 C4 E462 Temperature Pressure Relief Valve 1 5 C783 Tundish 1 C6 C772 Adaptor 1 B173 Wall Mounting Kit for Expansion Vessel C7 C788 Hose Assembly 1 C8 Wall Bracket Assembly 1 PARTS LIST AND ILLUSTRATIONS SECTION 8 J UNVENTED SYSTEM KIT OFS63 amp OFS90 Ref Part No Description Qty B172 Unvented Systems Kit Complete 1 C1 C784 Pressure Reducing Valve Strainer 1 C2 C785 Check Valve 1 C3 C782 Expansion Vessel 1 4 C380 Temperature Pressure Relief Valve 1 C5 C384 Tundish 1 C6 C786 Expansion Valve 1 B173 Wall Mounting Kit Optional C7 C788 Hose Assembly 1 C8 Wall Bracket Assembly 1 SECTION 8 PARTS LIST AND ILLUSTRATIONS UNVENTED SYSTENI KIT OFS108 amp OFS163 Ref Part No Description Qty B267 Unvented Systems Kit Complete 1 C1 C784 Combined Reducing Valve Strainer 1 C2 C785 Check Valve 1 C3 C786 Expansion Valve 1 C4 C782 Expansion Vessel 25 Litre 1 C5 E675 Temperature Pressure Relief Valve 2 1 C6 C908 2 Square Equal Tee 1 C7 E497 Tundish from Expansion Valve and T P Valve 2 x 212 1 B173 Wall Mounting Kit Optional C8 C788 Hose Assembly 1 C9 Wall Bracket Assembly 1 Publication Date JAN2012 PART OF
3. THERMEA VE ES Baxi Commercial Division Wood Lane Erdington Birmingham B24 9QP Sales Technical 0845 070 1056 0845 070 1057 INVESTORS Xa IN PEOPLE mt Email andrews baxicommercialdivision com www andrewswaterheaters co uk e WATER HEATERS
4. It should be noted that the failure of the storage vessel due to scale formation on the base will not be covered by the terms of the warranty Any scale formation which cannot be removed by normal means of cleaning should be removed by chemical descaling See below DESCALING INFORMATION When descaling the water storage heater your attention is drawn to the following guidelines SAFETY FIRST DUE TO THE CORROSIVE NATURE OF THE DESCALING FLUID ITS ESSENTIAL THAT SUITABLE PROTECTIVE CLOTHING EQUIPMENT IS USED AND ADEQUATE VENTILATION IS AVAILABLE WHEN DESCALING IT I5 IMPORTANT TO FOLLOW DESCALING MANUFACTURERS INSTRUCTION BEFORE AND DURING USE 1 Isolate the electrical power supply to burner Close water inlet valve and drain heater tank 3 Remove magnesium sacrificial anode Note It is recommended that a new anode is fitted Add suitable hydrochloric based descale acid the requirement is normally 5 litres for OFS25 amp OFS29 and 10 for OFS63 OFS90 OFS108 amp OFS163 After a minimum of one hour relight the burner for 2 minutes Maximum Turn the burner off and drain off descale fluid through drain port Open cold water feed valve and fill heater tank Drain and flush out heater for minimum of 30 minutes Replace hot outlet nipple anode OFS25 amp OFS29 0 Replace anodes using service anode articulated part no C333 1 Relight the burner and allow the heater to come to its working temperature B
5. The two control thermostats where applicable OFS108 amp OFS163 should both be set to the same operating temperatures This will ensure stacking does not occur and will avoid high water temperatures when small amounts of water are drawn off during peak times of use SECTION 6 INTRODUCTION PRE SERVICE OPERATIONS BURNER ASSEMBLY FLUEWAY Servicing must be carried out be a properly qualified person Whilst giving these instructions for the care of the Heater it is recommended that checks are carried out by the installer at least every 6 months Ensure good ventilation by keeping the heater free of extraneous materials and clear of dust and lint Keep pipework flue and tops of heaters clear of any combustible materials A water softener or lime inhibitor should be employed in hard water areas The heater should be inspected every few months via the hand hole cleanout and lime and silt deposits removed failure to do so will shorten heater life and may invalidate the warranty Note The cleanout hole gasket must be renewed whenever the cover is removed See parts lists pages 32 34 36 amp 38 Before servicing carry out the following operations 1 Turn off the fuel supply to the heater 2 Turn off the electrical supply to the heater 3 Turn off the cold water supply to the heater 4 Turn on the hot water draw off taps served by the water heater or for multiple installations turn off the hot water outlet connect
6. OFS 29 SECTION 8 PARTS LIST AND ILLUSTRATIONS HEATER SPARES OFS 63 2 2 S Z Ref Part No Description Qty A1 C333 Articulated Service Anode 3 A2 C534 Hot Outlet Nipple 1 5 BSP 3 A3 E050 Hydrojet Hot Outlet Cold Inlet Nipple 1 5 BSP 1 4 713 Flue 11 5 299 Cleanout Pad Seal 1 A6 C381 Drain Valve 1 A7 C103 Drain Valve Socket 1 A8 C247 Drain Valve Nipple 1 A9 C719 Control High Limit Thermostat 1 B1 E731 Burner Assembly 1 PARTS LIST AND ILLUSTRATIONS SECTION 8 Ref Part No Description Qty A1 E676 Blast Tube 1 A2 E680 Brake Plate 1 A3 E683 Electrode 2 A4 E685 H T Cable 2 A5 E687 Fan 1 A6 E689 Photocell 1 A7 E691 Transformer 1 A8 E694 Transformer Cable 1 A9 E696 Control Box 1 A10 E699 Motor 1 A11 E702 Pump 1 A12 E610 Nozzle Kerosene 1 65 x 80 s 1 A13 E704 Nozzle Gas Oil 1 25 x 80 s 1 BURNER SPARES BTL6 OFS63 SECTION 8 PARTS LIST AND ILLUSTRATIONS HEATER SPARES OFS 90 A2 Rear A2 Rear A Ref Part No Description Qty A1 C333 Articulated Service Anode 3 A2 C534 Hot Outlet Nipple 1 5 BSP 3 A3 E050 Hydrojet Hot Outlet Cold Inlet Nipple 1 5 BSP 1 A4 E713 Flue Baffle 11 5 299 Cleanout Pad Seal 1 A6 C381 Drain Valve 1 A7 C103 Drain Valve Socket 1 A8 C247
7. 070 1055 Fax 0845 070 1059 Sales 0845 070 1056 Technical 0845 070 1057 Service 0845 070 1058 Email andrews andrews waterheaters co uk www andrewswaterheaters co uk THE ANDREWS WATER HEATERS COVERED IN THIS MANUAL ARE FOR USE WITH KEROSENE CLASS C2 BS2869 OR GAS OIL CLASS D BS2869 SECTION 1 GENERAL AND SAFETY INFORMATION General Information 2 British Standards 2 Health and Safety Regulations 1993 3 Legionellae in Water Heaters 3 SECTION 2 TECHNICAL DATA Fu a SECTION 3 INSTALLATION Introduction 6 Location 6 Burner Assembly 6 Flue Systems 8 Installation of Flue 8 Terminal Location 8 Common Header 10 Air Supply and Ventilation 11 Water Quality and Treatment 12 Water Connections Hydrojet System 13 Water Connections Vented Systems 14 Water Connections Unvented Systems 16 Electrical Supply 18 Fuel Supply 19 SECTION 4 COMMISSIONING Cfo eee Air Adjustment 21 Pump Adjustment 21 Instructing the Users 22 Users Safety Guide 22 SECTION 5 OPERATION 23 SECTION 6 SERVICING Besa a IR Pre Service Operations 24 Burner Assembly 24 Flueway 24 Magnesium Anode s 25 Cleaning the Storage Vessel All Models 26 SECTION 7 FAULT FINDING MINAS qum eo aE NOD RT RE SECTION 8 PARTS LISTS AND ILLUSTRATIONS Usaq RES e NEA UD ead Heater Spares OFS25 28 Burner Spares BTL4 OFS25 29 Heater Spares OFS29 30 Burner Spares BTL4 OFS29 31 Heater Sp
8. 5 5 b PUMP PRESSURE E ADJUSTMENT GAUGE au 5 E PUMP PRESSURE 4 ADJUSTMENT J The pump pressure must be adjusted and set correctly to suit the fuel type being used See table below Andrews Model No OFS25 OFS29 OFS63 OFS90 OFS108 OFS163 Nozzle fitted _ Kero 0 75 805 0 85x80s 1 65x80s 2 50x80s 3 00 805 4 50x80s Pressure PSI 113 110 127 113 113 113 Pressure Bar 7 8 7 6 8 6 7 8 7 8 7 8 Nozzle Gas 0 55x80s 0 60x80s 1 25x80s 1 75x80s 2 25 805 3 50x80s Supplied Oil Pressure PSI 195 211 206 214 187 174 Pressure Bar 13 5 14 5 14 2 14 8 12 9 12 SECTION 4 INSTRUCTING THE USERS USERS SAFETY GUIDE When satisfactory commissioning and testing has been achieved hand this manual to the user or purchaser and explain the method of economic and efficient operation Explain that 1 Other than for long shutdown periods the heater must be left operating normally 2 It is important that the control thermostat is set at the lowest temperature consistent with the user s needs Ensure that the user or purchaser is fully conversant with the lighting shutdown and general operating procedures Advise that any air vents must be kept clear and items must not be placed or stored in the vicinity of the heater Advise of precautions necessary to prevent damage to the heater and systems in the event of the system remaining inoperative during frost condi
9. Drain Valve Nipple 1 A9 C719 Control High Limit Thermostat 1 B1 E732 Burner Assembly 1 PARTS LIST AND ILLUSTRATIONS SECTION 8 v BURNER SPARES BTL10 OFS90 Ref Part No Description Qty A1 E677 Blast Tube 1 A2 E687 Fan 1 A3 E681 Brake Plate 1 A4 E685 H T Cable 2 A5 E683 Electrode 2 A6 E689 Photocell 1 A7 E692 Transformer 1 A8 E694 Transformer Cable 1 A9 E697 Control Box 1 A10 E700 Motor 1 11 702 Pump 1 A12 E614 Nozzle Kerosene 2 50 x 80 s 1 A13 C921 Nozzle Gas Oil 1 75 x 80 s 1 SECTION 8 PARTS LIST AND ILLUSTRATIONS HEATER TN SPARES OFS108 A2 Rear 2 Ref Part No Description Qty A1 E714 Cold Inlet Dip Tube 1 A2 C534 Hot Outlet Nipple 1 5 BSP 2 A3 E050 Hydrojet Hot Outlet Cold Inlet Nipple 1 5 BSP 1 A4 C333 Articulated Service Anode 4 A5 E715 Flue Baffle 12 A6 E716 Cleanout Pad Seal 1 A7 C381 Drain Valve 1 A8 C103 Drain Valve Socket 1 A9 C247 Drain Valve Nipple 1 A10 C719 Control High Limit Thermostat 1 A11 C927 Control Thermostat 1 B1 E733 Burner Assembly 1 PARTS LIST AND ILLUSTRATIONS SECTION 8 N BURNER SPARES BTL10 OFS108 Ref Part No Description Qty A1 E677 Blast Tube 1 A2 E687 Fan 1 A3 E681 Brake Plate 1 A4 E685 H T Cable 2 A5 E683
10. Drain Valve Socket 1 A7 C247 Drain Valve Nipple 1 A8 C719 Control High Limit Thermostat 1 B1 E729 Burner Assembly 1 PARTS LIST AND ILLUSTRATIONS SECTION 8 Ref Part No Description Qty A1 E676 Blast Tube 1 A2 E679 Brake Plate 1 A3 E683 Electrode 2 A4 E685 H T Cable 2 A5 E687 Fan 1 A6 E689 Photocell 1 A7 E691 Transformer 1 A8 E694 Transformer Cable 1 A9 E696 Control Box 1 A10 E699 Motor 1 A11 E702 Pump 1 A12 E725 Nozzle Kerosene 0 75 x 80 s 1 A13 E726 Nozzle Gas Oil 0 55 x 80 s 1 BURNER SPARES BTL4 OFS25 SECTION 8 PARTS LIST AND ILLUSTRATIONS HEATER 7 L SPARES OFS 29 Cold Inlet Dip Tube Hot Outlet Nipple Anode Flue Hinged Articulated Service Drain Valve Drain Valve Socket Drain Valve Nipple Control High Limit Thermostat Burner Assembly S PARTS LIST AND ILLUSTRATIONS SECTION 8 A12 13 A3 Ref Part No Description Qty A1 E676 Blast Tube 1 A2 E679 Brake Plate 1 A3 E683 Electrode 2 A4 E685 H T Cable 2 A5 E687 Fan 1 A6 E689 Photocell 1 A7 E691 Transformer 1 A8 E694 Transformer Cable 1 A9 E696 Control Box 1 A10 E699 Motor 1 A11 E702 Pump 1 A12 E703 Nozzle Kerosene 0 85 x 80 s 1 A13 E607 Nozzle Gas Oil 0 60 x 80 s 1 BURNER SPARES BTL 4
11. Electrode 2 A6 E689 Photocell 1 A7 E692 Transformer 1 A8 E694 Transformer Cable 1 A9 E697 Control Box 1 A10 E700 Motor 1 A11 E702 Pump 1 A12 E705 Nozzle Kerosene 3 00 x 80 s 1 A13 E612 Nozzle Gas Oil 2 25 x 80 s 1 SECTION 8 HEATER SPARES OFS163 PARTS LIST AND ILLUSTRATIONS A2 7 Rear 2 Rear lt 0 Ref Part No Description Qty A1 C333 Articulated Service Anode 4 A2 C534 Hot Outlet Cold Inlet Nipple 1 5 BSP 1 A3 E050 Hydrojet Cold Inlet Nipple 1 5 BSP 1 A4 E717 Flue Baffle 20 5 299 Cleanout Pad Seal 1 A6 C381 Drain Valve 1 A7 C103 Drain Valve Socket 1 A8 C247 Drain Valve Nipple 1 A9 C719 Control High Limit Thermostat 1 A10 C927 Control Thermostat 1 A11 E718 Burner Adaptor Flange 1 B1 E734 Burner Assembly 1 PARTS LIST AND ILLUSTRATIONS SECTION 8 Ref Part No Description Qty A1 E678 Blast Tube 1 A2 E688 Fan 1 A3 E682 Brake Plate 1 A4 E686 H T Cable 2 A5 E684 Electrode 2 A6 E690 Photocell 1 A7 E693 Transformer 1 A8 E695 Transformer Cable 1 A9 E698 Control Box 1 A10 701 Motor 1 A11 E702 Pump 1 A12 E706 Nozzle Kerosene 4 50 x 80 s 1 A13 C923 Nozzle Gas Oil 3 50 x 80 s 1 BURNER SPARES BTL20 OFS163 SECTION 8 PARTS LIST ILLUSTRATIONS UNVENTED SYSTEM KIT OFS25 amp OFS29
12. Figs 2 amp 3 Assembly of Draught Stabiliser Approx Height OFS90 1739mm OFS108 2307mm OFS163 2307mm kit 8 i Eea fitted OFS63 1739mm Spigot Adaptor Tee with draught stabiliser To Heater Outlet Spigot Crimped Adaptor Fit the flue tee c w draught stabiliser to the outlet spigot of the water heater see Figs 2 amp 3 SECTION 3 COMMON FLUE HEADER Fig 4 d N Must have vertical flue discharge Draught Stabiliser Draught Stabiliser C It is recommended that individual flues are used for each heater However a common flue header is to be used the following guidelines must be used 1 The cross sectional area of the common flue header must be adequate for the combined output of both heaters Contact the flue manufacturer or flue expert for further information 2 Each heater shall be fitted with draught stabiliser and shall have its own flue pipe to the flue header 3 The entry into the flue header shall be inclined towards the direction of the flue gases See fig 4 4 The common flue header must have a vertical discharge Its is preferable to run the flue inside the building to avoid unnecessary heat losses and minimize the risk of condensation within the flue SECTION 3 The following notes are intended to give general guidance AIR SUPPLY Where the heater is to be installed in a room or interna
13. IMPORTANT Remove Correx 5 if fitted Re fit the Correx anode s when descaling operation is complete SECTION 7 FAULT 1 BURNER WILL NOT START 2 BURNER MOTOR RUNS BURNER GOES TO LOCKOUT 3 FUEL REACHES NOZZLE BUT FAILS TO IGNITE 4 BURNER LIGHTS BUT RUNS TO LOCKOUT 5 BURNER RUNS BUT SMOKE EMITTED FROM FLUE 6 WATER TEMPERATURE TOO LOW 7 NOT ENOUGH HOT WATER 8 WATER DRIPPING FROM BASE OF HEATER 9 RUMBLING NOISE KETTLING ALL MODELS ACTION a Check electrical supply and ON OFF switch is ON b Check thermostat circuit is made and also time clock contacts are closed and limit thermostat is set c Check if locked out Re set d Check continuity of burner motor windings e Check if fuel pump is seized f Replace faulty parts a Check for blocked fuel pipe check filters in filter bowl rear of pump and rear of nozzle are clean and suction pipework for air leaks b Disconnect nozzle output pipe from fuel pump Switch burner on momentarily and check for delivery of fuel c If fuel not delivered from pump check pump motor drive dog d If pump is turning and no fuel is delivered replace pump e Check solenoid valve is opening and trace supply from control box f Check for blocked nozzle g Check fuel in tank a Check electrode adjustment b Check for dirty or cracked electrodes c Check HT leads and connections d Check electric
14. be installed in a room which contains a bath or shower and must not be installed in a bedroom or bedsitting room We recommend that adequate clearance is left around the heater for fitting and servicing purposes with no obstruction at the front of the heater to allow easy access to the burner Service clearance above all the heaters except heater models OFS25 should be 1270mm for removal of the flue baffle Heater model OFS25 flue baffle is hinged for low ceiling removal It is very important that heater models OFS108 amp OFS163 have at least 600mm clearance at the rear for the installation and removal of the T P valve if fitted We will supply magnesium articulated anodes part No C333 as a service replacement for all heater models this will be beneficial where lack of head room is a problem The floor on which the heater is installed must be non combustible level and of sufficient strength to withstand the heater weight when filled with water Any combustible material adjacent to the heater must be placed or shielded as to ensure that its temperature does not exceed 65 150 Every Andrews oil fired water heater is supplied with a purpose matched burner assembly The burner is supplied complete with nozzle factory fitted for use with kerosene class C2 only If the appliance is to be used with gas oil class D the nozzle must be changed before the burner is fitted to the water heater The correct nozzle specified for use with gas oil is suppli
15. rating Typical example for heater model OFS63 Heat input 71 8kW 300kW 0 24kW High level 0 24kW x 0 1m 0 024 Low level 0 24kW x 0 2m 0 048m Some halogen containing compounds can cause rapid corrosion of the Burner and Storage Vessel if drawn into the combustion air Therefore if heaters are to be installed in any of the following locations or in any applications where the above compounds are present they should be sealed off from atmospheres which may contain these compounds and all ventilation air must be taken completely from outside i Hairdressing salons and adjoining rooms or basement ii Establishments where dry cleaning solutions are used iii Industrial use near chemical de greasing processes or where solvents are used or stored iv Installations where refrigerant gases are used or stored v Environments with dust laden atmosphere SECTION 3 QUALITY AND TREATMENT Where extreme conditions of water hardness exist scale can form in any water heating equipment especially when the heater is working under conditions of constant heavy demand and at high temperatures Each water heater is fitted with one or more magnesium anode s which protect the tank from corrosion caused by electrolytic action Magnesium anodes are sacrificial in that they erode as they protect When the anode has eroded to less than 5076 of it s original diameter it may not offer protection The anodes should be inspected
16. using oil and equipment using solid fuel A draught stabiliser is fitted to ensure burner flame stability If a common flue header is to be used see page 10 Notes 1 Draught stabiliser to be fitted to appliance see page 9 2 Male flue spigots to point downwards inside building to keep flue clean 3 Use changeover section going through roof so that male spigots point upwards outside the building to assist weatherproofing 4 The flue should be kept a safe distance from any combustible material especially when going through the roof joists etc T MIH i mmn B IDEAL ACCEPTABLE gt DRAUGHT DRALIGHT MOT ACCEPTABLE BTABWIGEN H ACCEPTABLE STABILISERA ipea Ne This must be at a height at least level with the highest point of the building roof and not subject to down draught Ideally the flue should terminate 1m higher than the highest point of the roof or at least 1m higher than the section of roof through which it projects SECTION 3 4 FLUE Assembly of Draught Stabiliser Approx Height SYSTEMS Flue kit 6 draught stabiliser E013 OFS25 1949mm NIE t Adapt OFS29 2000mm Piper onsen T Heater Outlet Spigot Crimped Adaptor Fig 2 The flue should provide a negative pressure at the base of the flue between 1 1mm 0 03 w g and 2 00mm 0 06 w g The flue route should be as vertical as possible A draught stabiliser is supplied with the heater see
17. Cold Inlet Hot Outlet OFS63 OFS90 T amp P Valve Tapping OFS108 OFS163 Optional Rear Cold Inlet Hot Outlet Drain amp OFS63 Secondary Return OFS90 Tapping OFS108 OFS163 C Fig 5 B 1 0m 40 7 Open em _ Rost F E Open Vent P E wana Crick Overflow EI Hai Wait ian Loic Winer Front Rear Entry Models Supply Waha OFS63 OFS90 OFS108 i OFS163 Top Entry Models OFS25 OFS29 OFS108 aic tonal shan E P Valen Taping T EXC E A s Khas Baum Taping Sanin Taki Fuca Ines Tapping j IJ Tupphy Vatan Fi 6 15 SECTION 3 CONNECTIONS UNVENTED SYSTEMS Unvented Systems should be fitted by an Approved Installer When used in an unvented system the Andrews water Heater will supply hot water at a pressure of 3 5bar 51Ibf in provided that this pressure is available at the mains feed During conditions of no flow system pressure may rise to a maximum of 6bar 87lbf in whilst the burner is operating When testing the system it is recommended that a maximum test pressure of 8 6bar 125 Ibf in is employed The heater can be used on unvented hot water storage systems with the addition of an Unvented Systems Kit these are available from Andrews Water Heaters See Pa
18. SS IN COMBATING LEGIONELLAE SECTION 2 TECHNICAL ANDREWS i OFS25 OFS29 OFS63 t OFS108 i OFS163 Storage Cap 192 146 ro ua tuum UR UD 72 s 20 AN P p a c ou 25 D o SEIN 32 RE C 132 lt n Do Da c p oe CP XE pos 7 s Heat Input Btu Hr 105000 119000 245000 350000 420 000 630 000 Heat Output Btu Hr 86 000 97580 215600 308000 369600 554400 Efficiency Fuel BS2869 Kerosene Class C2 ce sas nas i s ees s Em ew 3 pos E a I j purs Elec Data 220 240 220 240 220 240 220 240 220 240 220 240 pos m sedente edipi 755 n no oe Start Current Run Current 5 n x Nozzle fitted Kero 0 75x80s 0 85x80s 1 65 805 2 50 805 3 00 805 4 50x80s E T erue a t 1 x d P Pressure 78 i 76 86 78 78 78 Nozzle Supplied 0 55x80s 0 60805 1 25 805 1 75 805 2 25805 3 50x80s Pressure Pressure Smoke 2 a n O2 Flue Size Secondary TECHNICAL DATA SECTION 2 ANDREWS i OFS25 OFS29 OFS63 i OFS90 i OFS108 OFS163 Flexible Hose Connection Size 025 025 045 0 25 1 kem E B E ni RE E x 2 7 p
19. This manual must be kept with appliance October 2010 Part No E524 Oil Fired Installation Guide Operation and Service Manual Working towards a cleaner future ANDREWS WATER HEATERS Copyright Andrews Water Heaters 2007 und ANDREWS WATER HEATERS Reproduction of any information in this publication by any method is not permitted unless prior written approval has been obtained from Andrews Water Heaters Andrews Storage Water Heaters have been designed and manufactured to comply with current International standards of safety In the interests of the health and safety of personnel and the continued safe reliable operation of the equipment safe working practices must be employed at all times The attention of U K users is drawn to their responsibilities under the Health and Safety Regulations 1993 All installation and service on the Andrews Water Heater must be carried out by properly qualified personnel and therefore no liability can be accepted for any damage or malfunction caused as a result of intervention by unauthorised personnel The Andrews Water Heaters policy is one of continuous product improvement and therefore the information in this manual whilst completely up to date at the time of publication may be subject to revision without prior notice Further information and assistance can be obtained from Andrews Water Heaters Wood Lane Erdington Birmingham B24 Tel 0845
20. al input to transformer e Replace faulty parts a Carry out checks 2 3 as above b Check that photo cell is correctly located in holder c Check photo cell is clean and not cracked d Replace photo cell e Replace control box a Check fuel quality Fuel should be free from water and dissolved material such as engine oil or anti freeze b Check for blocked fuel filter or pick up pipe c Check nozzle is tight in holder d Check burner settings a Reset the higher temperature b Check pressure at burner a Check pressure at burner b Check amount of water being used against recovery rate given on Data Plate a Check if water stops dripping when water in heater is hot If water stops problem is condensation caused by incorrectly designed flue or by tank cooling excessively i e more hot water being used than recovery rate of the heater b If water continues to drip when heater is hot Problem is a leaking joint or storage vessel a Scale formation in heater consult water treatment specialist Heater must be descaled and suitable water treatment provided to avoid problem re occurring SECTION 8 PARTS LIST AND ILLUSTRATIONS HEATER SPARES OFS25 a Description Ref Part No Qty A1 E707 Cold Inlet Dip Tube 1 A2 E708 Hot Outlet Nipple Anode 1 A3 E709 Flue Baffle Hinged 1 A4 C333 Articulated Service Anode 1 A5 C381 Drain Valve 1 A6 C103
21. annually and replaced as necessary Frequency of anode replacement will vary dependent on water quality Andrews Water Heaters offer Correx UP powered anodes as an alternative to the standard magnesium anodes These anodes do not need maintenance or replacement The potentiostat which regulates the current to the Correx anode features an indicator light which shows green to indicate correct function and red to indicate malfunction An additional Correx BEMS version is available which provides a remote warning signal These anodes are available as an optional extra on all Andrews Water Heaters In hard water areas scale formation can occur in hot water systems and hot water heaters and the higher the temperature and volume of water used the more problematic the scale build up can be Water treatment is normally recommended when the hardness reaches 100 150ppm 7 10 degrees Clark and above This problem can be minimised by reducing the water temperature in the heater and by fitting suitable water pre treatment equipment When installing Andrews Water Heaters in hard water areas we would recommend that a water treatment specialist is consulted The following companies have supplied water treatment equipment in the UK for a number of years to various establishments including those where Andrews water heaters have been installed WATER TECHNOLOGY LTD WATERMATIC Powke Lane Ind Estate Reddicap Trading Estate Blackheath Sutton C
22. ares OFS63 32 Burner Spares BTL6 OFS63 33 Heater Spares OFS90 34 Burner Spares BTL10 OFS90 35 Heater Spares OFS108 36 Burner Spares BTL10 OFS108 37 Heater Spares OFS163 38 Burner Spares BTL20 OFS163 39 Unvented System Kit OFS25 amp OFS29 40 Unvented System Kit OFS63 amp OFS90 41 Unvented System Kit OFS108 amp OFS163 42 SECTION 1 GENERAL AND SAFETY INFORMATION GENERAL INFORMATION BRITISH STANDARDS AND CODES OF PRACTICE The Andrews Water Heater has been designed and manufactured to give an efficient reliable and long service life To ensure the continued trouble free operation of your heater at maximum efficiency it is essential that correct installation commissioning operation and service procedures are carried out strictly in accordance with the instructions given in this manual By law installation and commissioning of the heater must be carried out by properly qualified personnel The heater s must be installed in accordance with the following requirements The current BUILDING REGULATIONS The Water Supply WATER FITTINGS REGULATIONS 1999 Additionally installation should be performed in accordance with all relevant requirements of the Local Authority and recommendations of the British Standards and Codes of Practice detailed below BS 5410 Part 1 Installations up to 44kW output capacity for space heating and hot water supply purposes BS 5410 Part 2 Installations of 44kW and above output capacit
23. city allowed for a feed cistern being 227 litres 50 gallons The actual cistern capacity is the capacity to the normal water line of the cistern All cisterns should be manufactured to the relevant British Standard The distance from the normal water line to the top of the cistern should comply with that specified by the Water Authorities The cold water inlet and hot water outlet connection nipples are identified in Fig 5 Connect the cold water feed and hot water outlet to these nipples with union adaptors for ease of servicing CAUTION DO NOT APPLY HEAT TO THESE NIPPLES IF MAKING CAPILLARY SOLDERED JOINTS AS THEY ARE FITTED WITH PLASTIC INSERTS MAKE THE CAPILLARY JOINTS TO THE PIPES BEFORE CONNECTING TO THE HEATER A DRAIN COCK IS SUPPLIED WITH THE HEATER AND THIS SHOULD BE FITTED TO THE APPROPRIATE BOSS AS SHOWN IN FIG 5 After installation of the water system open the main water supply valve flush the system and fill the heater Open the hot taps to allow air to escape from the system When the water is free of air close the taps and check for leaks at the gas control thermostat drain cock and the pipe connections at the top of the heater Typical water service layout for single heater vented system is shown in Fig 6 SECTION 3 connection sizes are shown on page 5 Cold Inlet Hot Outlet on models OFS25 OFS29 OFS108 CONNECTIONS Front
24. ed for additional guidance Use either Kerosene Class C2 52869 or Gas Oil Class D 652869 NO OTHER FUEL SHOULD BE USED Schematic representations of the fuel supply are shown below It is suggested where possible a gravity feed is used Should a negative head system be employed see typical example below MATERIALS AND JOINTING All materials including the fuel storage tank fuel supply pipe and jointing materials mustcomply fully with the requirements in 55410 SITING OF FUEL STORAGE TANK The siting of the fuel storage tank must fully comply with the requirements in BS5410 TYPICAL GRAVITY FROM THE BOTTOM OF OIL TANK T Oil tank H Total meters Feed line meters i 10mm Filter 1 30 H 4 Burner 2 2 Degasifier i 29 Suction line Return line 9 7 Fire valve _ Non return valve Ap O O N O BI Q N gt 3 1 TYPICAL GRAVITY FEED OVER THE TOP OF TANK 5 il tank x 1 z tan H Total meters 3 Filter meters i 10mm 4 Burner 1 30 1 ee 6 Suction line 2 35 4 3 40 H 7 7 Return line 4 25 p di 8 6 Y 5 9 Non retur
25. ed in the nozzle burner box It is the responsibility of the installer to ensure that the correct nozzle is fitted to suit the fuel to be used with this appliance SECTION 3 The burners are supplied complete with pre wired control thermostat loom to a harness BURNER plug with connects to the harness socket on the burner The burners are supplied with the flange fitted to the burner blast tube in the correct position A gasket is also supplied ASSEMBLY loose in the burner carton See below for correct burner fitting to the heater Heater Models OFS256 OFS63 OFS90 amp OFS108 Locate the burner gasket on the two fixing studs fitted on the heater mounting flange Push the burner into the heater combustion chamber and locate the burner flange on the two fixing studs fitted on the heater mounting flange and tighten the two fixing bolts supplied with the heater Burner Flange LN Heater f _ Mounting Bracket 2 Locating Studs Gasket Heater Model OFS29 Because of the reduced height of the combustion chamber entry position it is necessary to locate the burner onto the heater as the diagram below shows The pump has been rotated thro 180 so that the solenoid is positioned above the vertical to ensure correct operation The burner is fitted to the heater in the same way as heater models shown above Burner Flange 1 Heater Mounting Brack
26. et 7 2 Locating Studs Gasket Heater Model OFS163 The burner used on this heater is considerably bigger and heavier therefore a different fixing method is required See below Locate the burner adaptor flange on the two fixing studs fitted on the heater mounting flange and tighten the two fixing bolts supplied with the heater Next locate both the mating plate and the gasket onto the burner adaptor flange using the four locating studs Finally push the burner into the heater combustion chamber and located the burner flange onto four locating studs and tighten the four fixing bolts supplied Burner Flange Gasket Adaptor ES Flange Heater Mounting 6 n d Bracket 2 2 Locating Studs Mating 4 Locating Plate Studs SECTION 3 FLUE SYSTEMS INSTALLATION OF FLUE Fig 1 TERMINAL LOCATION Detailed recommendations for flue installation are given in BS5410 PT 1 and BS5410 PT 2 The Building Regulations allow the use of stainless steel under the term Deemed to Satisfy but the minimum thickness must be 0 71mm 22swg We recommend that Selkirk SMW Flue System is used to the following specification Twin Wall Insulated Stainless Steel The flue route should be as vertical as possible avoiding sharp bends and horizontal runs It is recommended that each heater should be fitted with its own individual flue It is essential that separate flues are used for equipment
27. hed shuttered socket outlet in conjunction with a fused three pin plug both complying with the requirements of BS 1363 A Alternatively a fused double pole switch of fused spur box serving only the heater may be used The point of connection to the mains should be readily accessible and adjacent to the appliance Connect electrical supply to the harness plug socket see Fig 8 Wiring Diagram Mains input cable should be connected to the mains supply as detailed above 2 E Key to diagram Motor Photocell Ignition transformer Oil Valve LMO LOA 2 control 7 pole connector Remote burner run signal Remote lockout signal N ri 53 B4 a xac CO COT CS ONU i v N T1 T2 53 B4 JE 5 L iN N N 220 240V 50Hz Stat 820 max Limit 93o C 220 240V Time Clock and or 50Hz Switch if fitted a SC thermostat Cr L N 1 UE UO stat TLSC stat SECTION 3 fire valve and filter must be fitted in the fuel supply to the burner Not Supplied Current standards state that the BIO FUEL has a blend of between 7 and 10 FUEL SUPPLY If a higher blend is being used then the burner manufacturer MUST be contact
28. ion valve and secondary return valve 5 Drain down using the drain valve on the heater The burner should be checked every 6 months and if necessary cleaned as follows 1 Inspect fuel tank and drain any water contamination Clean fuel filters replace if necessary Remove the burner from combustion chamber Remove all carbon from burner parts Pay particular attention to electrode and nozzle replace if necessary Remove all dust dirt from burner fan Clean HT leads and check condition Clean photo cell Check condition of control box terminals check security and condition of wiring ON Clean pump filter Check condition of fuel pump drive dog ensure pump is fitted correctly when assembling burner Ensure burner settings are correct 9 Check combustion chamber condition every 6 months The flueway should be checked every 6 months and if necessary cleaned as follows 1 Remove burner assembly complete Disconnect the flue flue stabiliser from heater Inspect and clean the secondary flue installation as necessary Lift out the baffle baffles from inside the central flueway OQ N Clean the flueway with a brush and clean any deposit from the underside of the storage vessel bottom and from the flue baffle Re assemble in the reverse order 7 Re light and carry out commissioning check SECTION 6 Magnesium sacrificial anode s is are fitted to the top of the storage vesse
29. l The anode s MAGNESIUM will prevent corrosion of the storage vessel Anode condition should be checked annually ANODE S and replaced if excessive wear is present We recommend that the anode s are replaced annually 1 Withdraw each anode using 1 1 16in AF socket spanner A new anode measures 21 mm diameter 2 An anode should be replaced if at any point it s length the diameter is reduced to half or less of original Particular attention should be paid to the ends 3 If the anode is encrusted with limescale it should be either wire brushed to reveal bright metal or replaced 4 For models OFS25 amp OFS29 withdraw the hot water outlet nipple anode and replace See Fig 9 Refer to parts list pages 32 amp 32 5 Replace all anodes with service anode articulated part no C333 OFS25 8 OFS29 Disconnect pipe fittings and turn nipple anti clockwise to remove z J Fig 9 Where Correx anodes are fitted no maintenance is necessary SECTION 6 CLEANING THE STORAGE VESSEL ALL MODELS The storage vessel should be checked and cleaned annually Scale formation in the base of the vessel may occur particularly in hard water areas and is normally associated with high usage and high water temperatures It is characterised by a rumbling noise when the main burner is lit Scale formation in the base of the vessel will affect the efficiency of the water heater and reduce the life of the storage vessel
30. l space the heater requires the AND room or internal space containing it to have a permanent air vent The vent must be either direct to outside air or to an adjacent room or internal space which must itself have VENTILATION a permanent vent of at least the same size direct to outside air The minimum effective area of the permanent air vent s required is as follows Air supply requirements for appliances up to 44kW Where the appliance is to be installed in a room High level 550mm per kW of appliance rating over 5kW Where the appliance is to be installed in a compartment Air supply direct to outside High level 550mm per kW of appliance rating over 5kW Low level 1100mm per kW of appliance rating over 5kW Where the appliance is to be installed in a compartment Air supply into a room High level 1100mm per kW of appliance rating over 5kW Low level 1650mm per kW of appliance rating over 5kW The room itself must have permanent ventilation direct to outside High level 550mm per kW of appliance rating over 5kW Draught Stabilisers When an appliance with draught stabiliser is fitted in a room add 550mm per kW to the free air of the combustion air inlet When an appliance with a draught stabiliser is fitted in a compartment which is vented as above no additional allowance is required Air supply requirements for appliances of 44kW and above High level 0 1m per 300kW of appliance rating Low level 0 2m per 300kW of appliance
31. n valve o 10 9 s 8 3 4 TYPICAL SUCTION FEED m 1 a tank H Total meters 3 Filter meters 10mm Qi 12mm A 4 Burner 0 5 26 54 6 Suction line i z 6 7 Return line 5 14 30 Z 10 Foot valve 25 10 23 1 3 6 15 H 3 35 n 7 Measurement between minimum oil level and pump axis L Max length of suction line including vertical lifts For each bend of valve deduct 0 25m V Internal diameter of pipe a SECTION 4 IMPORTANT These oil fired water heaters must be commissioned by a competent engineer CAUTION IMPORTANT PRESSURE WITHIN COMBUSTION CHAMBER SHOULD READ BETWEEN 0 2 MBAR AND 0 5 MBAR ADJUST THE DRAUGHT STABILIZER TO ENSURE A READING OF 0 1 TO 0 4 15 ACHIEVED TO ENSURE SAFE AND CORRECT OPERATION CAUTION DO NOT OPERATE THE WATER HEATER UNTIL THE STORAGE VESSEL IS COMPLETELY FILLED WITH WATER WITH WATER RUNNING FROM ALL HOT TAPS CAUTION ENSURE THE CORRECT NOZZLE IS FITTED TO SUIT THE FUEL TYPE BEING USED SEE TECHNICAL DATA SECTION 2 OR PAGE 21 A To light the burner 1 Turn on the fuel supply to heater 2 Switch on power supply to burner 3 Rotate the thermostat adjustment knob to the desired water temperature at which the burner will begin its prepurge At about 15 secs the burner will light The thermostat should be set at a temperature to suit the system it controls 4 The two control thermostats should be set to the same tempe
32. nd listed in the current Water Research Centre Materials and Fittings Directory Installation of unvented hot storage water systems must comply with Part G of Schedule 1 of the Building Regulations 1991 Typical water service layout for single heater unvented system is shown in Fig 7 p aie cr TE apara Thar mias Pipa na pr ry into ihe bandage Top Entry Models OFS25 OFS29 Hot Water Senara 5108 Front Rear Entry Models OFS63 4 OFS90 OFS108 OFS163 Cold Wai Coid Wars Take CHE Hai Wa u i Berane i n Cold ualet inet hook E E m 1 i vim Tina Fig 7 T Depan Disia T a Return Tee J Note On heater models OFS108 amp OFS163 the 2 T P is located at the rear via a 2 Sq Tee SECTION 3 ELECTRICAL SUPPLY Wiring external to the water heater must be installed in accordance with the I E E Regulations for the wiring of buildings and to any local regulations that may apply The heaters are designed to run off 220 240V 1 Ph 50 Hz supply and the fuse rating is 5 Amp See pages 4 amp 5 The method of connection to the mains electricity supply should facilitate complete electrical isolation of the appliance preferably by use of an unswitc
33. nd the position of the deflector disk adjustable via screw 2 The burner is in fact fitted with a special screw to adjust the position of the deflector disk this device allows for optimisation of combustion by reducing or increasing the air flow between deflector disk and head It is normally necessary to reduce undo screw 2 the air flow between deflector disk and head when there is reduced fuel delivery this passage must be proportionately more open screw in screw 2 when the burner is working with a higher fuel delivery rate After modifying the position of the deflector 20 disk it is usually necessary to correct the air damper positions and afterwards check for proper ignition See diagrams on page 21 SECTION 4 1 Air register opening adjustment Reference index in position register closed Reference index in position 9 register open Flame disc position Asse Air register opening adjuster reference index Air damper in open position 9 Air damper in closed position Air Damper Fixing Screw OY OQ UJ When the combustion adjustment is complete the following combustion analysis readings will be achieved ADJUSTMENT Andrews Model No OFS25 OFS29 OFS63 OFS90 OFS108 OFS163 Smoke No 0 0 0 0 0 0 Gas Temp 380 380 260 260 260 260 CO 11 5 11 5 11 5 11 5 11 5 11 5 5 5 5 5 5 5 5 5 5 5
34. oldfield Birmingham West Midlands B65 OAH B75 7BY Contact Contact Gareth Morris Mike Potter Tel 0121 561 3144 Tel 08000 838496 Fax 0121 561 4184 Fax 0121 311 1427 SECTION 3 E WATER CONNECTIONS Hydrojet System Top Cold Inlet Connection The upper jet ports direct the flow outward to begin the dynamic mixing action The lower jet ports direct the flow inward to increase the turbulence p All models now incorporate the new Mini Hydrojet system cold inlet side connections This system ensures water is directed onto the tank base Mini which minimises sediment build Hydrojet Inlet Nipple up from day one of installation Side Cold Inlet V E Connection The heater is fitted with the Hydrojet Total Performance System incorporated in the cold inlet dip tube The tube is designed to increase turbulence and reduce sediment build up reduce thermal stacking and increase delivery SECTION 3 CONNECTIONS VENTED SYSTEMS The water heater must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644 The Water Supply Water Fittings Regulations 1999 must be observed when installing the system The cold water feed cistern must have an actual capacity greater than the hourly recovery rate of the heater or heaters to which it is fitted the minimum actual capa
35. ratures OFS108 amp OFS 163 only B To shut off the burner 1 Rotate the thermostat adjustment knob to the off position 2 Forlong periods only eg holidays or periods of 7 days switch the burner power supply OFF and turn off the fuel service cock For shorter periods eg less than 7 days leave the heater under control of the thermostat C Burner Adjustment The burner comes factory pre set The correct burner head settings are shown below Refer to the table if the nozzle or electrodes are replaced 1 A B C D BTL 4 3 0 6 25 BTL6 10 20 3 2 6 3 gt COMBUSTION The burner is factory pre set to an average value that must then be adjusted to the water ADJUSTMENT heater in question To adjust the combustion device start by increasing the air volume When the burner starts it is burning with excess air and smoke number Reduce the air volume until soot occurs and increase again to reach a combustion free of soot By this procedure an optimum adjustment is obtained See Below Loosen the fixing screw 6 and bring the air damper into the position thought to be necessary as a midway point for fuel to be burnt Turn the main switch to ON to power the burner and ignite it Correct if necessary combustion air delivery by adjusting the intake damper a
36. rts List Pages 40 42 The Wall mounting assembly is available as an optional extra Temperature Pressure Relief Valve C5 PARTS Expansion Vessel Cold Water Inlet of C2 Check Valve C3 Expansion Valve Cold Water Inlet C1 Pressure Reducing Valve Strainer Balance Cold Water Take off if required NB Tees elbows stop valves and pipework not supplied C7 Tundish C5 must be fitted into C6 and fitted on the hot water outlet nipple located at the rear of heater models OFS108 amp OFS163 When assembling items C1 and C2 ensure that the flow arrows marked on the components are pointing in the direction of flow i e towards the water heater The cold water for services may be drawn from the 22mm compression port on item C1 a The water pressure at this point will be similar to that available at the hot water outlet of the water heater If port a is not used it should be sealed with the blanking plug supplied SECTION 3 If higher flow rates are required for the cold water services a suitable tee fitting should WATER be fitted to the pipework upstream of item C1 CONNECTIONS The pipework fitted to the tundish outlet should be one size larger than the outlet pipe of the safety device and should be terminated at a suitable drain see Building Regulations 1991 Approved Document G3 All fittings and materials must be suitable for use with drinking water a
37. the design and operation of water systems with reference to avoidance of factors that favour colonisation by Legionellae bacteria These factors include stagnation lukewarm conditions 20 to 45 and the accumulation of debris scale and corrosion in the base of tanks and calorifiers Andrews Water Heaters has commissioned an independent evaluation of their products to investigate their resistance to build up of legionellae bacteria Experiments were conducted to determine whether following a substantial challenge by legionellae pneumophilia after overnight and stagnation conditions the system was rendered free from viable recoverable legionellae It was found that at 61 following a challenge of approximately 107 organisms per litre within one hour more than 99 999 of organisms had been killed After a subsequent stagnation period sampling did not reveal any residual contamination The design of the base of the water heater precludes legionellae colonisation even after build up of debris The burner positioning ensures that the water at the bottom of the heater reaches the same or higher temperature as in the rest of the heater Based on data obtained through experiment the Andrews Water Heater can be described as legionellae resistant as it is considered unlikely that at the temperature tested the organism would colonise the water heater and present a possible health risk HEALTH AND SAFETY REGULATIONS 1993 EFFECTIVENE
38. tions Advise the user or purchaser that for continued efficient and safe operation of the heater it is important that magnesium anodes are inspected annually and that adequate servicing is carried out at regular intervals by the installer For your safety read before lighting the appliance WARNING 1 Always follow manufacturers instructions when lighting the appliance Failure to do so may result in damage to property personal injury or loss of life WARNING Hotter water increases the risk of scalding Before changing the temperature refer to instruction manual or data label Hot water can produce third degree burns in 6 seconds at 140 F 60 30 seconds at 130 F 54 C OPERATION SECTION 5 When properly installed and adjusted the heater will require minimal attention Should it become necessary to completely drain the heater close the cold water inlet valve and open a hot water tap to allow air to enter the system Fit a suitable hose to the drain cock and open Whenever the heater is filled with cold water condensation may form on the storage vessel surfaces when the burner is lit This is normal and will disappear when the heater warms up The thermostats fitted to heater models OFS25 OFS29 OFS63 amp OFS90 have a built in high limit thermostats In the case of dangerous water temperatures the fuel supply will be automatically shut off The reason for such high temperature must be corrected before the heater is relit
39. y for space heating and hot water supply purposes GENERAL AND SAFETY INFORMATION SECTION 1 It is the duty of manufacturers and suppliers of products for use at work to ensure so far as is practicable that such products are safe and without risk to health when properly used and to make available to users adequate information about their safe and proper operation Andrews Water Heaters should only be used in the manner and purpose for which they were intended and in accordance with the instructions in this manual Although the heaters have been manufactured with paramount consideration to safety certain basic precautions specified in this manual must be taken by the user It is imperative that all users of the heater must be provided with all the information and instruction necessary to ensure correct and safe operation Water systems in buildings have been associated with outbreaks of Legionnaires Disease particularly in health care facilities where occupants are significantly more susceptible to infection In recognition of the risks in hospitals a Code of Practice for the Control of Legionellae in Health Care premises has been issued by the Department of Health 1991 Codes of Practice applicable to other premises have been published by other organisations principally the Health and Safety Executive HS G70 and the Chartered Institute of Building Services Engineers CIBSE TM13 All Codes of Practice draw attention to
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