GAH OS80/95 - User Manual

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CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
1 USER INFORMA1 USER INFORMA
1 USER INFORMA1 USER INFORMA
1 USER INFORMA
TIONTION
TIONTION
TION
2 OPERA2 OPERA
2 OPERA2 OPERA
2 OPERA
TOR CONTROLSTOR CONTROLS
TOR CONTROLSTOR CONTROLS
TOR CONTROLS
3 BOILER OPERA3 BOILER OPERA
3 BOILER OPERA3 BOILER OPERA
3 BOILER OPERA
TIONTION
TIONTION
TION
4 INST4 INST
4 INST4 INST
4 INST
ALLAALLA
ALLAALLA
ALLA
TION GENERALTION GENERAL
TION GENERALTION GENERAL
TION GENERAL
5 INST5 INST
5 INST5 INST
5 INST
ALLAALLA
ALLAALLA
ALLA
TIONTION
TIONTION
TION
6 INST6 INST
6 INST6 INST
6 INST
ALLAALLA
ALLAALLA
ALLA
TIONTION
TIONTION
TION
7 OIL SUPPL7 OIL SUPPL
7 OIL SUPPL7 OIL SUPPL
7 OIL SUPPL
YY
YY
Y
8 CONVENTIONAL FL8 CONVENTIONAL FL
8 CONVENTIONAL FL8 CONVENTIONAL FL
8 CONVENTIONAL FL
UEUE
UEUE
UE
9 BALANCED FL9 BALANCED FL
9 BALANCED FL9 BALANCED FL
9 BALANCED FL
UEUE
UEUE
UE
10 COMMISSIONING10 COMMISSIONING
10 COMMISSIONING10 COMMISSIONING
10 COMMISSIONING
11 SERVICING11 SERVICING
11 SERVICING11 SERVICING
11 SERVICING
12 F12 F
12 F12 F
12 F
AULAUL
AULAUL
AUL
T FINDINGT FINDING
T FINDINGT FINDING
T FINDING
13 TECHNICAL13 TECHNICAL
13 TECHNICAL13 TECHNICAL
13 TECHNICAL
INFORMAINFORMA
INFORMAINFORMA
INFORMA
TIONTION
TIONTION
TION
APPENDIXAPPENDIX
APPENDIXAPPENDIX
APPENDIX
CONTENTSCONTENTS
CONTENTSCONTENTS
CONTENTS
Section 1 User InformationSection 1 User Information
Section 1 User InformationSection 1 User Information
Section 1 User Information
1-1 Installer ---------------------------------------------------------- 2
1-2 Householders Information --------------------------------------- 2
1-3 Service History -------------------------------------------------- 2
1-4 Boilers covered by this manual ---------------------------------- 3
Section 2 Operator ContrSection 2 Operator Contr
Section 2 Operator ContrSection 2 Operator Contr
Section 2 Operator Contr
olsols
olsols
ols
2-1 Control Panel - Select and Combistream ------------------------ 4
2-2 Control Panel - Option ------------------------------------------- 6
2-3 Combi Thermostatic Mixing valve ------------------------------- 7
2-4 Combi &Expansion Relief --------------------------------------- 7
Section 3 Boiler OperationSection 3 Boiler Operation
Section 3 Boiler OperationSection 3 Boiler Operation
Section 3 Boiler Operation
3-1 Switching the Boiler ON ----------------------------------------- 8
3-2 Switching the Boiler OFF ---------------------------------------- 8
3-3 Burner ‘Lockout’ ------------------------------------------------- 8
3-4 Care of the Boiler ------------------------------------------------ 9
Section 4 Installation GeneralSection 4 Installation General
Section 4 Installation GeneralSection 4 Installation General
Section 4 Installation General
4-1 Compliance --------------------------------------------------- 10
4-2 Siting and Positioning the Boiler ------------------------------ 10
Section 5 InstallationSection 5 Installation
Section 5 InstallationSection 5 Installation
Section 5 Installation
5-1 Select and Option Internal Floor Standing --------------------- 11
5-2 Select Internal Wall Mounted ---------------------------------- 12
5-3 Select External Wall Mounted --------------------------------- 14
5-4 Select Free Standing External ---------------------------------- 16
5-5 Option Floor Standing System Boiler ------------------------- 18
Section 6 Installation CombistrSection 6 Installation Combistr
Section 6 Installation CombistrSection 6 Installation Combistr
Section 6 Installation Combistr
eam and Combi 65eam and Combi 65
eam and Combi 65eam and Combi 65
eam and Combi 65
6-1 Combistream System and Combi 65 -------------------------- 21
6-2 Combistream System and Combi 65 Components ------------ 23
6-3 Combistream and Cobi 65 Connections to the Boiler ---------- 26
Section 7 Oil SupplySection 7 Oil Supply
Section 7 Oil SupplySection 7 Oil Supply
Section 7 Oil Supply
7-1 Oil Storage Tanks ---------------------------------------------- 28
7-2 Oil System----------------------------------------------------- 28
7-3 Oil Supply System --------------------------------------------- 29
Section 8 Conventional FlueSection 8 Conventional Flue
Section 8 Conventional FlueSection 8 Conventional Flue
Section 8 Conventional Flue
8-1 Conventional Flue --------------------------------------------- 31
Section 9 Balanced FlueSection 9 Balanced Flue
Section 9 Balanced FlueSection 9 Balanced Flue
Section 9 Balanced Flue
9-1 Balanced Flue Selection --------------------------------------- 32
9-2 Suggested Flue Siting ----------------------------------------- 33
9-3 Burner Air Supply---------------------------------------------- 34
Section 10 CommissioningSection 10 Commissioning
Section 10 CommissioningSection 10 Commissioning
Section 10 Commissioning
10-1 Commissioning Checks --------------------------------------- 35
10-2 Extra Procedures for System Boilers --------------------------- 36
10-3 Extra Procedures for Combi Boilers ---------------------------- 36
10-4 Combustion Tests --------------------------------------------- 37
10-5 Handing Over -------------------------------------------------- 37
Section 11 ServicingSection 11 Servicing
Section 11 ServicingSection 11 Servicing
Section 11 Servicing
11-1 Routine Service ------------------------------------------------ 38
11-2 Extra Procedure for System Boilers ---------------------------- 38
11-3 Extra Procedure for Combi Boilers ----------------------------- 39
11-4 Baffle Positions ------------------------------------------------ 39
Section 12 Fault FindingSection 12 Fault Finding
Section 12 Fault FindingSection 12 Fault Finding
Section 12 Fault Finding
12-1 Householders Fault Finding ----------------------------------- 41
12-2 Householders Fault Finding - System Boilers ----------------- 41
12-3 Householders Fault Finding - Combi Boilers ------------------ 41
12-4 Engineers Fault Finding --------------------------------------- 42
12-5 Engineers Fault Finding - System Boilers --------------------- 43
12-6 Engineers Fault Finding - Combistream Boilers --------------- 43
Section 13
TT
TT
T
echnical Informationechnical Information
echnical Informationechnical Information
echnical Information
13-1 Boiler Specifications ------------------------------------------ 44
13-2 Boiler Output Options ------------------------------------------ 45
13-3 Burner Setting Data -------------------------------------------- 45
13-4 Burner Settings ------------------------------------------------ 47
13-5 Panel Wiring Diagrams ---------------------------------------- 49
13-6 Parts Supplied with Boiler ------------------------------------- 52
13-7 Boiler Dimensions --------------------------------------------- 54
13-8 Balanced Flue Dimensions ------------------------------------ 59
AppendixAppendix
AppendixAppendix
Appendix
AP1 Regulations ---------------------------------------------------- BC
COMBISTREAMCOMBISTREAM
COMBISTREAMCOMBISTREAM
COMBISTREAM
COMBI 65COMBI 65
COMBI 65COMBI 65
COMBI 65

Summary

Section 1 User Information

1-1 Installer

Details about the boiler installer and contact information.

Section 2 Operator Controls

2-1 Control Panel - Select, Combistream and Combi 65

Overview of control panel features for Select, Combistream, and Combi 65 models.

Hot Water High Limit Thermostat

Control Panel - Option

Description of the control panel for Option boilers.

Thermostatic Mixing Valve

Section 3 Boiler Operation

Switching the Boiler ON

Step-by-step guide to switching the boiler on for different models.

Switching the Boiler OFF

Methods for safely switching the boiler off.

Burner Lockout

Understanding and resolving burner lockout conditions.

Section 5 Installation

Select and Option Internal Floor Standing

Installation details for internal floor standing Select and Option boilers.

Connecting Control Panel

Oil Connections

Select External Wall Mounted

Installation overview for external wall mounted Select boilers.

Select Free Standing External

Overview of installation for free standing external boilers.

Fixing the Boiler - Suggested Procedure

Connecting Control Panel

Option Floor Standing System Boiler

Wiring Instructions

Filling the System Procedure

Section 6 Installation Combistream & Combi 65

Combistream System and Combi 65

Overview of Combistream and Combi 65 system design and features.

Combi Boiler Design

Combistream System Features

Combistream System Components

Cleanstream Scale Prevention Unit

Hot Water TPR Discharge Tundish

Connections to the Boiler

Connecting the Combistream and Combi 65 boilers to the pipework.

Thermostatic Mixing Valve Installation

Connecting the Control Panel

Section 7 Oil Supply

Oil Storage Tanks

Oil System Overview

Overview of oil system configurations and selection criteria.

Oil Supply Pipe Specifications

Oil Supply System Types

Description of different oil supply system types.

Single Pipe System - Deaerator (Tigerloop)

Two Pipe System Installation

Section 8 Conventional Flue

Conventional Flue Installation

Installation guidelines for conventional flue connections.

Section 9 Balanced Flue

Balanced Flue Selection

Choosing the correct balanced flue components for different boiler models.

Suggested Flue Siting

Burner Air Supply

Section 10 Commissioning

Commissioning Checks

Essential checks to be performed during boiler commissioning.

Oil Tank and Supply Line Checks

Boiler Checks

The Burner Checks

Extra Procedures for System Boilers

Additional steps for commissioning system boilers.

Check Pressure Relief Valve (Combi)

Combustion Tests

Performing combustion tests using approved equipment for accurate readings.

Handing Over Procedure

Ensuring satisfactory handover to the householder with documentation.

Section 11 Servicing

Routine Service Procedure

Procedure for routine boiler servicing, including safety and checks.

Combustion Test During Service

Performing combustion tests as part of the routine service.

Extra Procedure for Combi Boilers

Baffle Positions

Section 12 Fault Finding

Householders Fault Finding

Troubleshooting guide for common boiler issues encountered by householders.

System Boilers - Householder Faults

Combi Boilers - Householder Faults

Engineers Fault Finding

Burner Motor Start Issues

Diagnosing and resolving issues when the burner motor fails to start.

Flame Establishment Faults

Troubleshooting flame establishment issues with the burner.

Burner Lockout Issues

Identifying causes when the burner locks out after flame establishment.

Lockout When Starting from Cold

System Boilers - Engineer Fault Finding

Specific fault finding for system boilers by engineers.

Combi Boilers - Engineer Fault Finding

Specific fault finding for Combi boilers by engineers.

Section 13 Technical Information

Boiler Specifications

Table detailing technical specifications for all boiler models.

Boiler Output Options

Burner Setting Data

Guidelines for setting the burner, including fuel type and adjustments.

Wall Mounted Burner Settings

Floor Standing Burner Settings

Burner Settings - Minor Series

Combustion Air Setting

How to adjust combustion air for minor series burners.

Combustion Head Setting

How to adjust the combustion head for minor series burners.

Nozzle Electrode Settings

Correct settings for nozzle and electrodes on minor series burners.

Combustion Air Setting - Max Series Burners

Burner Oil Pressure Adjustment

Burner Oil Pump Details

Panel Wiring Diagrams

Floor Standing Select;Wall Mounted Internal Wiring

Wiring diagram for floor standing Select and internal wall mounted boilers.

Floor Standing Option Range Wiring

Wall Mounted;Free Standing External Wiring

Combistream;Combi 65 Internal Wiring

Combistream;Combi 65 External Wiring

Boiler Dimensions - Select;Option

Select and Option Range Dimensions

Boiler Dimensions - W40;501 & W50;801 Internal

Boiler Dimensions - W40;50 E & W50;80 E External

Free Standing External Boiler Dimensions

Combistream;Combi 65 Internal Dimensions

Combi 65 External Boiler Dimensions

Balanced Flue Dimensions

Floor Standing High Level Flue Dimensions

Floor Standing Rear Flue Dimensions

Floor Standing Side Flue Dimensions

Floor Standing Vertical Flue Dimensions

Wall Mounted Internal Rear Flue Dimensions

Wall Mounted Internal High Level Flue Dimensions

Wall Mounted Internal Vertical Flue Dimensions

Combistream;Combi 65 Rear Side Flue Dimensions

Health and Safety Information

Mineral Oil Handling Precautions

Seals and Insulation Safety

GAH OS80/95 Specifications

General

Brand	GAH
Model	OS80/95
Category	Boiler
Language	English