TECHNICAL BOOK 5: DOMESTIC SERVICING & COMMISSIONING

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Herbert Wilkerson
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1 Semi Automatic Controls Fully Automatic Controls Initial Test (CD/11 Schedule Item 9.8) Analyser Test (CD/11 Schedule Item 9.9) Wall Flame Type Burner - Additional (CD/11 Schedule Item 10) Rim and Flame Grills (CD/11 Schedule Item 10.1) Rotor and Stator Assemblies (CD/11 Schedule Item 10.2) Ignitors and Rim Heaters (CD/11 Schedule Item 10.3) Appliance Safety Controls (Schedule Item 11) Safety Valve (CD/11 Schedule Item 11.1) High Temperature Limit Thermostat (CD/11 Schedule Item 11.2) Frost Thermostat (CD/11 Schedule Item 11.3) Controls Check (Schedule Item 12) Temperature Controls Central heating and DHW (CD/11 S. Item 12.1) Frost Thermostats (CD/11 Schedule Item 12.2) Motorised Valves (CD/11 Schedule Item 12.3) Programmers and Time Controls (CD/11 Schedule Item 12.4) Appliance Short Cycling Check (CD/11 Schedule Item 12.5) Thermostatic radiator Valves (CD/11 Schedule Item 12.6) Non Electrical Domestic Hot Water Controls (CD/11 Schedule Item 12.7) System Check Hot Water Type (CD/11 Schedule Item 13) System Check Warm Air Type (CD/11 Schedule Item 14) Identification of Safety/Environmental Risks SECTION 7 OFTEC PROCEDURES 7.1 OFTEC Warning Stickers General CD/10 & CD/10T (Installation Completion Report) General CD/11 (Service and Commissioning Report) General Filling in the Report CD/12 (Landlord Oil Installation Check) General Filling in the Report Edition Contents Page XI

2 7.5 CD/14 (Warning & Advice Notice) General Filling in the Report Work Notification Introduction SECTION 8 FAULT FINDING 8.1 General Approach to Fault Finding Introduction Avoidance of Pre-conceptions On-site Interrogation Initial Procedure Electrical Faults Installation Safety Oil Availability Inspection Oil Check T61Q Questionnaires Relating to Combustion Problems Storage Tank Valves Filter(s) Oil line Oil Lifter Fire Valves Oil Control Valves Oil Pressure and Vacuum Oil Leakage and Pressure Testing Combustion Fault Checks Oil Fired Appliance Basic Fault Identification Procedure for PJ Burners/App Natural Draught Pot Burner Natural Draught Multi-Stage Burners Manually Lit Semi-Automatic Vaporising Burners Fan Assisted Vaporising Burners Fully Automatic Vaporising Burners Flame Failure After Start Up SECTION 9 HISTORICAL VAPORISING BURNERS 9.1 Rotary Vaporising Burners Description Operation... 1 Page XII Contents 2010 Edition

3 9.1.3 Standards Application Fuel Burner Component Data Landon Kingsway Rotary Vaporising-Wallflame-Burners Models Ignition Motor Rotor Oil Strike Height Cold Oil Depth Soleniod Operated Control Top Flame Rim Fan Shut Down Draught Stabiliser Torridheat Rotary Vaporising-Wallflame-Burners Models Iginition Rotor Oil Strike Height Cold Oil Depth Flame Rim Grilles Fan Assembly Draught Stabiliser Commissioning and Servicing for Rotary Vaporising Burners Commissioning Procedure Servicing Procedure Fan Pressurised Pot Burners Description Operation Standards Application Fuel Burner Component Data Powell Duffryn 0.45 (Smiths Burner) Redfyre Centramatic Series II Gyro-Pac YO-1/YO Natural Draught Multi Stage Burners Description Operation Applications Lighting Procedure Commissioning and Servicing Procedure Oil Lifters BM Oil Lifter SECTION 10 ACKNOWLEDGEMENTS SECTION 11 BLANK PAGES 2010 Edition Contents Page XIII

4 SECTION 2 Diagram 1 Main Areas where Petroleum can be found... 1 Diagram 2 Global Oil Consumption Diagram 3 Schematic of an Oil Refinery Process... 4 Diagram 4a Comparative Domestic Fuels Costs... 5 Diagram 4b Comparative Domestic Fuels Costs... 6 Diagram 4c Comparative Domestic Fuels Costs... 6 Table 1 Approximate conversions between Viscosity in Centistokes to Viscosity in Redwood Seconds... 8 Table 2 Characteristics of Distillate Oil Fuels... 9 SECTION 3 Diagram 5 Conventional Flue... 2 Diagram 6 Flue Draught... 3 Diagram 7 The Operation of a Counter Balanced Stabilizer... 4 Diagram 8 The Oil Fired Heat Storage Cooker... 6 Diagram 9 A Typical Cooker Installation... 7 Diagram 10 The Oil Fired Roomheater (Principles applicable to both Vaporising Sleeve and Vaporising Pot Burners)... 8 SECTION 4 Diagram 11 Typical Perforated Sleeve Burners... 2 Diagram 12 Deep Well Perforated Burner... 3 Diagram 13 Cross Section Schematic of Deep Well Perforated Sleeve Burner... 4 Diagram 14 Circular Multi-Sleeve Perforated Sleeve Burner...,... 5 Diagram 15 Rectangular Perforated Sleeve Burner... 5 Diagram 16 Bi-Directional Levelling and Cold Oil Depth Measurement... 7 Diagram 17 A Typical Vaporising Pot Burner... 8 Diagram 17 (a) Natural Draught Pot Burners... 8 Diagram 17 (b) Natural Draught Pot Burners... 8 Diagram 18 Manual and Electrical Ignition Principles... 9 Diagram 19 Lighting Sequence with Automatic (Electric) Ignition Diagram 20 Sections through the Centres of two Types of Multi-Stage Burners Diagram 21 Schematic of Fan Pressurised Pot Principles Diagram 22 Pressure Measurement with an Inclined Manometer Diagram 23 Waterless Manometer Diagram 24 Cold Oil Depth Measurement with a Dip Stick Diagram 25 BM Valve Diagram 26 CI Valve Diagram 27 CI Twin Control Valve Diagram 28 Toby Valve Diagram 29 Oil Control Valve - Single Float Type Diagram 30 Oil Control Valve - Double Float Type Diagram 31 Oil Control Valve Manual Type Diagram 32 Oil Control Valve Constant Level Type Diagram 33 Oil Control Valve with Thermostatic Control Diagram 34 Metering Stem Diagram 35 Servicing a Toby Oil Control Valve Diagram 36 BM Oil Control Valve Page XIV Contents 2010 Edition

5 Diagram 37 Thermostatic Control Diagram 38 Manual Flow Rate Control Diagram 39 Vapour Pressure Type Thermostatic Flow Rate Control Diagram 40 Electrical Bi-Metal Flow Rate Control Diagram 41 BM Tempomat (Electric Head) Diagram 42 ZR31 (Electric Top) Diagram 43 Pressure Reducing Valves Diagram 44 Pressure Regulating Valve Diagram 45 Taisan Pump Diagram 46 BM Oil Lifter Diagram 47 Taisan Oil Lifter SECTION 5 Diagram 48 A Hydrocarbon Molecule... 1 Diagram 49 Combustion Reaction Diagram 50 Combustion Reaction Properties... 4 Diagram 51 Combustion of Hydrocarbons in Oxygen... 5 Diagram 52 Heating Oil Combustion in Air... 6 Diagram 53 Effect of Increased Excess Air on the Carbon Dioxide and Oxygen Contents of Diagram 54 Flue Gases of Oil Fired Appliances Excess Air - Relationship with Smoke Production and Efficiency for Vaporising Burners Diagram 55 Efficiency Lost Diagram 56 Gross Flue Loss as a Percentage of Heat Input for Kerosene Diagram 57 Smoke Tester Diagram 58 Draught Gauge Diagram 59 Flue Gas Analyser with Probe and Remote Printer Diagram 60 Carbon Dioxide Indicator Diagram 61 Flue Gas Thermometers Table 3 Typical Combustion Readings Table 4 Gross Flue Loss Chart Corrected for an Ambient Temperature of 15.6 o C (60 o F) SECTION 6 Diagram 62 Completed Flue and Hearth Data Plate SECTION 7 Diagram 63 OFTEC Oil Warning Sticker... 1 Diagram 64 CD/10 Form... 3 Diagram 65 CD/10T Form... 4 Diagram 66 CD/11 Form (Front)... 6 Diagram 67 CD/11 Form (Back)... 7 Diagram 68a CD/12 Form... 9 Diagram 68b CD/14 Form SECTION 8 Table 5 Probable Causes of Combustion Faults with Oil Fired Appliances... 8 Table 6 General Fault Finding Chart for Vaporising Sleeve Oil Burners Edition Contents Page XV

6 Table 7 Fault Finding - Cause Chart SECTION 9 Diagram 69 Landon Kingsway Rotary Vaporising Burner... 2 Diagram 70 Electrode Settings for Landon Kingsway Rotary Vap. Wallflame-Burner... 4 Diagram 71 Torridheat Type Rotary Vaporising Burner... 8 Diagram 72 Burner Details for Torridheat Rotary Vaporising Burner Diagram 73 Oil Distribution Tube Types for Torridheat Rotary Vaporising Burner Diagram 74 Electrode Setting for Torridheat Rotary Vaporising Burner Diagram 75 Smiths Burner and Igniter Diagram 76 Redfyre Centramatic Burner and Igniter Diagram 77 Gyro-Pac Burner and Igniter Diagram 78 Negema Burner Diagram 79 BM Oil Lifter Page XVI Contents 2010 Edition

TECHNICAL BOOK 4: OIL FIRED APPLIANCE & SYSTEM INSTALLATION REQUIREMENTS

TECHNICAL BOOK 4: OIL FIRED APPLIANCE & SYSTEM INSTALLATION REQUIREMENTS 3.18.6 Independent Control of Two Space and One Water Heating Circulation Zones in a Fully Pumped System with Three Motorised Valves... 64 3.19 Non Domestic Systems and Processes... 64 SECTION 4 FUEL CONSERVATION