GAH OS90/120 - User Manual

1
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

Operator Controls

2-1 Control Panel Overview

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

2-1.1 Boiler Thermostat Control

Controls the boiler water temperature within the chamber.

2-1.4 Lockout Indicator Lamp

Illuminates when a burner lockout has occurred, indicating the boiler is not operational.

2-1.5 Limit Indicator Lamp

Indicates overheating; the high limit thermostat has tripped.

2-1.6 Manual Limit Reset

Resets the high limit thermostat manually after overheating.

2-1.8 Hot Water High Limit Reset

Manual reset for the hot water high limit thermostat.

2-2 Option Control Panel

Details the control panel for Option models.

2-2.1 Option Boiler Thermostat

Controls boiler water temperature for Option models.

2-2.2 Option High Limit Thermostat

Manual reset high limit thermostat for Option boilers.

Boiler Operation

3-1 Switching Boiler ON

Step-by-step guide to turning the boiler on.

3-1.1 Boiler Operation Modes

3-2 Switching Boiler OFF

Procedures for turning the boiler off.

3-3 Burner Lockout Explained

Information on burner lockout and its causes.

3-3.1 Restarting After Lockout

Procedure to restart the burner after a lockout event.

3-4.3 Boiler Servicing Requirements

Installation General Guidance

4-1 Installation Compliance

4-2 Boiler Siting and Positioning

Guidelines for selecting the boiler's location and placement.

4-2.3 Frost Protection Measures

Boiler Installation Procedures

5-1 Floor Standing Installation

Steps for installing Select and Option internal floor-standing boilers.

5-1.2 Heating Connections

5-1.3 Control Panel Connection

5-1.4 Floor Standing Oil Connection

5-2 Internal Wall Mounted Installation

Steps for installing Select internal wall-mounted boilers.

5-2.2 Wall Mounted Heating Connections

5-2.3 Fixing Boiler to Wall

Suggested procedure for fixing wall-mounted boilers.

5-2.4 Wall Mounted Control Panel Connection

5-2.5 Wall Mounted Oil Connections

5-3 External Wall Mounted Installation

Steps for installing external wall-mounted boilers.

5-3.2 External Heating Connections

5-3.4 Fixing External Boiler

Suggested procedure for fixing external wall-mounted boilers.

5-3.5 External Control Panel Connection

5-3.6 External Oil Connections

5-4 Free Standing External Installation

Steps for installing free-standing external boilers.

5-4.2 Free Standing Heating Connections

5-4.4 Free Standing Oil Connection

5-4.5 Fitting the Flue

5-5 Floor Standing System Boiler Installation

Steps for installing Option floor-standing system boilers.

5-5.5 Pressure Relief Valve Function

5-5.7 Expansion Vessel Details

5-5.8 Filling Loop Procedure

5-5.9 System Boiler Wiring

5-5.10 Cold Fill Pressure Setting

Procedure for setting the initial cold fill pressure.

5-5.11 Expansion Vessel Pressure Check

5-5.12 Filling the System Steps

Comprehensive steps for filling and venting the heating system.

Combistream and Combi 65 Systems

6-1 Combistream and Combi 65 Overview

Introduction to Combistream and Combi 65 systems.

6-1.1 Combi Boiler Design Principles

6-1.2 Combistream System Features

Highlights key features and benefits of the Combistream system.

6-1.3 Combistream System Design

Detailed explanation of the Combistream system's design and layout.

6-2 Combistream;Combi 65 Components

6-2.1 Accumulator Function

6-2.4 Heating TPR Valve

6-2.6 Heating Expansion Vessel

6-2.7 Hot Water Expansion Vessel

6-2.9 Filling Loop Installation

6-2.10 Pressure Regulating Valve

6-2.11 Cleanstream Scale Prevention

6-3 Boiler Connections

Connecting the combi system to the boiler.

6-3.1 Heating Connections

6-3.2 Thermostatic Mixing Valve

6-3.4 Control Panel Connection

Oil Supply System

7-1 Oil Storage Tanks

Requirements and considerations for oil storage tanks.

7-1.1 Tank Size and Siting

7-2 Oil System Overview

Introduction to different oil supply system options.

7-2.1 Oil System Selection Guide

How to select the appropriate oil supply system.

7-2.2 Oil Supply Pipe Requirements

7-3 Oil Supply System Types

Detailed descriptions of various oil supply systems.

7-3.1 Single Pipe Tank Above Burner

7-3.2 Single Pipe Tank Below Burner

7-3.3 Single Pipe Deaerator (Tigerloop)

7-3.4 Two Pipe System Requirements

Conventional Flue Systems

8-1 Conventional Flue Overview

General information and compliance for conventional flues.

8-1 c Combustion Air Supply

Balanced Flue Systems

9-1 Balanced Flue Selection Guide

How to select the correct balanced flue kit for various boiler models.

9-2 Suggested Flue Siting

Recommended clearances and positioning for balanced flues.

9-2.1 Flue Positioning Clearances

9-3 Burner Air Supply

9-3.2 Burner Air Duct Connection

Commissioning Procedures

10-1 General Commissioning Checks

Essential checks to perform before commissioning the boiler.

10-1.1 Oil Tank and Supply Line Checks

Verifying the oil tank and supply line installation.

10-1.2 Two Pipe Oil Supply Checks

10-1.3 Boiler Checks

Verifying the boiler's internal components and seals.

10-1.4 Burner Checks

Verifying the burner, nozzle, and air supply.

10-1.5 Conventional Flue Checks

10-1.6 Balanced Flue Checks

10-1.7 Electrical System Checks

10-2 System Boiler Extra Procedures

Additional steps for commissioning system boilers.

10-2.1 System Expansion Vessel Pressure

10-2.2 System Pressure Relief Valve Check

10-3 Combi Boiler Extra Procedures

Additional steps for commissioning combi boilers.

10-3.1 Combi Expansion Vessel Pressure

10-3.2 Combi Pressure Relief Valve Check

10-4 Combustion Tests

Performing and recording combustion test results.

10-5 Handing Over Procedures

Steps for handing over the boiler and documentation to the homeowner.

Routine Servicing

11-1 Routine Service Steps

Standard procedure for annual boiler servicing.

11-1.1 Boiler Internal Servicing

Cleaning internal components like baffles and heat exchanger.

11-1.2 Service Combustion Test

11-2 System Boiler Service Additions

11-3 Combi Boiler Service Additions

11-4 Baffle Position Importance

Fault Finding Guide

12-1 Householder Fault Finding

Basic troubleshooting steps for homeowners.

12-2 System Boiler User Faults

User troubleshooting for common system boiler issues.

12-3 Combi Boiler User Faults

User troubleshooting for common combi boiler issues.

12-4 Engineer Fault Finding

Troubleshooting guide for engineers covering burner and system faults.

12-5 Engineer Fault Finding - System Boilers

Engineer troubleshooting for system boiler specific faults.

12-6 Engineer Fault Finding - Combi Boilers

Engineer troubleshooting for combi boiler specific faults.

Technical Specifications

13-1 Boiler Specifications Summary

Comprehensive technical specifications for all boiler models.

13-2 Boiler Output Options

13-3 Burner Setting Data (Kerosene)

Burner setting data for Kerosene fuel.

13-3.1 Wall Mounted Burner Settings

13-3.2 Floor Standing Burner Settings

13-4 Burner Settings Overview

General guidance on burner settings.

13-4.1 Minor Burner Air Setting

13-4.2 Minor Burner Head Setting

13-4.5 Max Burner Air Setting

13-4.6 Burner Oil Pressure Adjustment

Procedure for measuring and adjusting burner oil pressure.

13-4.7 Burner Oil Pump Details

13-5 Panel Wiring Diagrams

Electrical wiring diagrams for various boiler panels.

13-5.1 Floor Standing;Wall Mounted Internal Wiring

13-5.2 Floor Standing Option Wiring

13-5.3 Wall Mounted External Wiring

13-5.4 Combistream;Combi 65 Internal Wiring

13-5.4 Combistream;Combi 65 External Wiring

13-7 Boiler Dimensions (Select;Option)

13-8 Balanced Flue Dimensions

Health and Safety Information

Fuel Safety Precautions

Safety advice when handling kerosene and oil fuels.

Seals and Insulation Safety

Safety measures when working with seals and insulation materials.

Electrical Safety Precautions

Essential electrical safety measures during work.

External Boiler Safety

Specific safety advice for external boiler installations.

GAH OS90/120 Specifications

General

Brand	GAH
Model	OS90/120
Category	Boiler
Language	English