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• INSTALLATION AND COMMISSIONING INSTRUCTIONS• SERVICE AND MAINTENANCE PROCEDURES

• USER MANUALThis document is to be left with the user following installation

Jetstreme 55

Je t s t r emeF l o o r S t a n d i n g O i l B o i l e r

CONTENTS

1.0 General Product Information1.1 Introduction1.2 Compliance Notices1.3 Safety Definitions1.4 Materials Selection1.5 General Product Information1.6 Warranty1.7 Warranty Terms & Conditions

2.0 Pre-Installation Requirements2.1 Compliance Notices2.2 Pre-Installation Checks2.3 Damaged or Missing Parts2.4 Locating and Positioning Boiler2.5 Fuel2.6 Fuel Supply2.7 Storage Tank2.8 Fuel Supply - Single Pipe System2.9 Fuel Supply - Two Pipe System2.10 Single Pipe System with De-Aeration Devices2.11 Pipework and Fittings2.12 Electrical Supply2.13 Balanced Flue Position2.14 Conventional Flue2.15 Ventilation Requirements

3.0 Installation BF and CF Models3.1 Boiler Installation3.2 Balanced Flue

55 & 80 Models only - Standard Flue Installation

3.3 Balanced Flue55 & 80 Models only - LH & RH Flue Installation

3.4 Balanced Flue55 & 80 Models only - Extended Horizontal Flue Installation

3.5 Balanced Flue55 & 80 Models only - Vertical Extension Flue Installation

3.6 Balanced Flue125 Model only - Standard Flue Installation

3.7 Balanced Flue125 Model only - LH & RH Flue Installation

3.8 Balanced Flue125 Model only - Extended Horizontal Flue Installation

3.9 Balanced Flue125 Model only - Vertical Extension Flue Installation

3.10 Conventional Flue - All Models3.11 Connection of Services

4.0 Commissioning4.1 Pre-Commissioning Inspection of the Installation4.2 Pre-Commissioning Inspection of the Boiler4.3 Pre-Commissioning Inspection of the Burner4.4 Pre-Firing Checks4.5 Firing the Boiler4.6 Combustion Checks4.7 Hand Over

5.0 Servicing5.1 Servicing - General Requirements5.2 Servicing - Oil Installation5.3 Servicing - Boiler5.4 Servicing - Burner5.5 Servicing - Re-Commissioning

6.0 Faults Diagnosis

7.0 Wiring Diagrams7.1 With Optional Programmer7.2 No Integral Programmer7.3 Typical ‘S’ Plan7.4 Typical ‘Y’ Plan

8.0 Technical Data for Kerosene Models

9.0 Parts Listing9.1 Parts Identification and Diagram - 55 & 80 Models9.2 Boiler Parts Diagram - 55 & 80 Models9.3 Parts Identification - 125 Model9.4 Parts Diagram - 125 Model9.5 Parts Identification and Diagram - Burner

10.0 User Information10.1 Introduction10.2 Programmable Timer10.3 Boiler Thermostat10.4 Limit Thermostat10.5 Neon lamps and Burner ‘Lockouts’10.6 Burner Problems10.7 Servicing10.8 Routine Cleaning and Maintenance10.9 Useful Information

11.0 Commissioning Report Form

1.2.4The range has been produced with safety and qualityin mind. There are certain basic precautions whichthe installer, commissioning engineer, serviceengineer, and user should be aware of. They arestrongly advised to read the relevant parts of thismanual prior to undertaking installation, adjustment,or use.1.2.5Halstead Boilers supports all new products with acomprehensive information pack which definesmandatory instructions for the safe installation,maintenance, and use of their appliances. Whereproprietary items are incorporated within HalsteadBoilers ’ products, detailed information andinstructions are also provided as part of theinformation pack.1.2.6It is the responsibility of the installer, commissioningengineer, service engineer, and the user, to ensurethat they are familiar with, and understand, therelevant instructions and information contained withinthis manual.

1.0 GENERAL PRODUCT INFORMATION

1.1 INTRODUCTION

1.1.1Halstead Boilers is continuously improving itsproducts and may therefore change specificationswithout prior notice. The statutory rights of theconsumer are not affected.1.1.2Whilst every reasonable care has been taken toensure that the information provided with eachappliance is true, accurate, and up to date, themanufacturer will not accept liability for any claimsarising through inadvertent errors or omissionsrelating to the information detailed herewith.

1.2 COMPLIANCE NOTICES

1.2.1The Jetstreme range of oil fired domestic boilersdetailed herewith is manufactured by HalsteadBoilers within a strictly controlled quality environmentto ISO 9001.1.2.2The Jetstreme range has been subjected to rigorousindependent testing, and has been found to meetThe Essential Requirements of the followingEuropean Directives:-

Machinery Directive (89/392/EEC)

Low Voltage Directive (73/23/EEC & 93/68/EEC)

E.M.C. Directive (89/336/EEC & 91/31/EEC)

Boiler Efficiency Directive (SI 1993 / 3083)

1.2.3In accordance with the terms of the Product LiabilityDirective (65/374/EEC) the manufacturer has takenreasonable and practical steps to ensure that theJetstreme range of domestic boilers are safe andpose no risk when properly used. The appliancesshould therefore only be used in the manner and forthe purpose for which they were intended, and, inaccordance with the recommendations detailedherewith.

1.3 SAFETY DEFINITIONS

1.3.1Contained within the text of the manual, the words‘Caution’ and ‘Warning’ are used to highlight certainpoints.1.3.2Caution is used when failure to follow or implementthe instruction(s) can lead to premature failure ordamage being sustained to the appliance or itscomponent parts.1.3.3Warning is used when failure to heed or implementthe instruction(s) can lead to component damageaccompanied by a possible hazardous situation beingcreated, where there is a risk of personal injury beingsustained.

1.4 MATERIALS SELECTION

1.4.1Neither asbestos nor soft soldered joints are usedin the construction of the Jetstreme range ofdomestic boilers. The materials selected for usecan withstand the mechanical, chemical, andthermal stresses which they will be subject toduring foreseen normal use, and when installedand maintained in accordance with themanufacturers recommendations.

1.5 GENERAL PRODUCT INFORMATION

1.5.1The Jetstreme range of oil fired boilers combine thebenefits of advanced design with well provenconstruction techniques and modern manufacturingprocesses.1.5.2The range offers; a user and maintenance friendlydesign, reliability, efficient and clean combustion, andlow operating noise levels.The controls are enclosed behind a metal hingedpanel on the front of the appliance thus reducingpossible accidental damage to them.The controls comprise of:-(1) ON / OFF Switch.(2) THERMOSTAT Control,(3) OVERHEAT Thermostat manual reset which

will automatically switch off the boiler if itexceeds a set temperature (103 deg)(A DIGITAL PROGRAMMER is available asan optional extra)

1.5.3Insulation is attached on the inside of the case.The case is finished in white powder coat enameland is styled to blend into any kitchen.1.5.4The Jetstreme range can be specified in eitherconventional or balanced flue configuration. Standardunits are designed to fire using kerosene (28 secondclass C2) fuel oil.A combustion test point is located in the top front ofthe boiler shell to enable the commissioning engineerto carry out his commissioning checks at aconvenient point.Commissioning should take place within seven daysof installation. 1.5.5All boilers will operate quite satisfactorily within asystem featuring gravity fed hot water and pumpedcentral heating. It is deemed preferable if both thehot water and central heating systems are pumped,given that the maximum pressure within such aninstallation does not exceed 3 bar (45 psi).

1.6 WARRANTY

1.6.1Each boiler is supplied with a one year peace of mindguarantee against manufacturing or material defects.The warranty is conditional upon the appliance havingbeen installed, commissioned and used in accordancewith the manufacturers recommendations.1.6.2A Commissioning Report and Warranty Registrationform is at the back of this manual. This form must becompleted and returned to Halstead Boilers withinseven days of commissioning having taken place. Itshould be noted that claims under warranty may notbe processed unless the terms and conditions of thewarranty are strictly adhered to.

1.7 WARRANTY TERMS AND CONDITIONS

1.7.1Any part manufactured by Halstead Boilers whichfails due to defective materials or poor workmanshipwithin twelve months from the installation date of theboiler will be repaired or replaced free of chargeinclusive of parts and labour.1.7.2Consumable items are specifically excluded from theterms of the warranty.1.7.3In order that the warranty can be established, theCommissioning Report and Warranty RegistrationForm (at the rear of this manual) must have beencompleted in full and returned to the servicedepartment at Halstead Boilers within seven daysfrom commissioning having been undertaken. Anywarranty claims made without this condition beingfulfilled will not be processed.

1.7.4The Jetstreme must be installed, commissioned, andused, in accordance with the guidelines containedwithin this manual. Failure to comply with thisrequirement will invalidate the warranty.1.7.5Commissioning must take place within seven daysfrom the date of installation. Failure to comply withthis requirement may invalidate the warranty.1.7.6The warranty does not cover claims arising from orassociated with normal wear and tear, neglect,misuse, improper installation, ineffectivecommissioning, or poor maintenance.1.7.7The warranty applies to Halstead Boilers that remainto the manufacturer’s specification. Unauthorizedmodification or deviations will invalidate the warranty.1.7.8The warranty terms and conditions do not affect thestatutory rights of the customer.

1.8 WARRANTY CLAIMS

1.8.1In the first instance any claim under warranty shouldbe addressed to the service department at HalsteadBoilers.1.8.2Subject to the details outlined previously in section1.7 ‘Warranty terms and conditions’, if appropriateHalstead Boilers will bear the cost of necessaryreplacement parts and labour, provided that the faultycomponent is returned on a carriage paid basis toHalstead Boilers.

Prior to installation the site should be surveyed andchecked to ensure that it is suitable for the appliance,and also to ensure that installation, commissioning,and maintenance can be carried out safely andeffectively, and in accordance with the manufacturer’srecommendations.

2.1 COMPLIANCE NOTICES

2.1.1It is a requirement that only competent oil boilerinstallation engineers should commission Jetstremeboilers.2.1.2Under the terms of the current Health and Safety atWork legislation it is a requirement that the installeraffords adequate protection to the person(s) carryingout the installation, and others within the location.2.1.3The installation must comply with any specificinsurance criteria relevant to the site or installation.2.1.4Local, national, and European regulations must alsobe observed, and this must include compliance withbuilding regulations and any appropriate bye laws,as well as compliance with IEE and Europeanelectrical standards and regulations.2.1.5The manufacturer encourages the installer to workwithin recognised standards. Details of certain of theapplicable standards are available from HalsteadBoilers.

2.2 PRE-INSTALLATION CHECKS

2.2.1The installer should ensure that the model is to thespecification agreed with the customer, and that allparts are present. Care should be exercised whenmoving the boiler so as not to damage either the unitor any of its ancillary parts. It is preferable to removethe packaging only when the boiler is ready to beinstalled, thereby reducing the risk of accidentaldamage occurring. When the packaging is removedthe boiler and ancillary parts should be visuallyinspected to ensure that they have not been subjectto transit damage.

2.3 DAMAGED OR MISSING PARTS

2.3.1Any damaged parts or shortages must be noted andthe details provided to the service department atHalstead Boilers immediately. This procedure isnecessary in order to comply with the insurancecriteria, and will ensure that the matter is allocated apriority status

2.0 PRE-INSTALLATION REQUIREMENTS

2.4 LOCATING AND POSITIONING BOILER

2.4.1 THE HEATING INSTALLATION• The installation should be installed in

accordance with the requirements of BS 5449and provisions recommended by the HVCA.

• Water circulation through the boiler may be totallyor appreciably reduced by the application of somemodern controls systems and still allow the boilerto fire. This may result in the boiler controls notbeing able to sense excessive or boilingtemperatures, and switch the boiler off. Shouldthis condition be possible, it is important to seethat the controls are wired so that the power supplyto the burner and circulating pump aresimultaneously switched off.

• With an existing heating installation, if the boileris a replacement, it is important to see that dueconsideration is given to replacing the chimneylining or factory made chimney, and the existingoil supply tank. As these may well not serve thenew installation due to their condition andspecification.

2.4.2 THE HEATING SYSTEM• Prior to replacing an existing oil boiler, please

ensure that the system is chemically cleaned ofscale and debris. Refer to reputable manufacturerfor advice.

• The system must be flushed clean prior to fillingand must contain clean water, it should beinspected and seen to be free of leaks.

• Suitable chemical inhibitors to protect against limescale and corrosion must be added to the systemprior to the first firing of the boiler.

• Kettling and persistent system noises cangenerally be avoided by the application of suitableproprietary pre-treatments from the start.

2.4.3 GENERAL INSTALLATION DETAILS FORBALANCED FLUES

• Flue kits for low level must only be used withKerosene applications.

• A terminal guard must be fitted where the flueterminal can be touched under normalcircumstances.

• Please remove any protective film on the stainlesssteel surfaces, before locating the flue terminalthrough the wall.

Models 55 and 80 can only use the high levelbalanced flue kit for REAR OUTLET ONLY.

2.4.4All Jetstreme boilers should be installed on a level non-combustible surface which is capable of supportingthe weight of the appliance and any ancillary parts. Itis recommended that the installer ensures that thereis adequate clearance to accommodate servicerequirements, this will also serve to provide usefulaccess during installation. The recommendedclearances are detailed below.

RECOMMENDED CLEARANCESAbove the boiler 600mmLeft hand side 25mmRight hand side 25mmIn front 900mm

2.4.5Provision must be made for the connection of thefuel supply, electrical supply, and for flueingarrangements.2.4.6If the unit is specified as a conventional flue modelprovision must be made for adequate ventilation tobe introduced to the area so as to ensure safe andefficient combustion. If the model features a balancedflue then the proposed position should be checkedso as to ensure that it complies with themanufacturers recommendations and with theappropriate building regulations.2.4.7Consideration must also be given to the position ofancillary pipe work for central heating and domestichot water which will have to be connected to theirrespective points on the boiler.

2.5 FUEL

CAUTIONAll Jetstreme boilers are manufactured to be usedwith 28 second fuel oil to class C2 (kerosene).

WARNINGProlonged contact with fuel can result in the naturaloils within the skin being removed. Always wear theappropriate personal protective equipment. Healthand safety data sheets are available from the fuelsupplier.

EXTERNAL OIL STORAGE TANK CLEARANCES FORSINGLE FAMILY DWELLINGSBS 5410 PART 1: 1977. FOR TANKS NOT EXCEEDING 3400 LITRES

FIG 2

2.6 FUEL SUPPLY

2.6.1The fuel supplier should be contacted prior toinstallation so that any concerns regarding delivery,transport, access, and storage can be addressed. Thesupplier will also be able to advise on price/quantitybreaks which can have an influence upon the mostappropriate size of storage tank.2.6.2The constraints of the site will to a large extentdetermine whether the oil feed to the boiler is eitherof the single pipe gravity feed type, or whether it isnecessary to use a twin pipe system.

2.7 STORAGE TANK

2.7.1The oil storage tank must conform to the appropriatestandard; for an externally painted steel vessel this willbe to BS 799 part 5 1987, and, in the case of the moremodern low density polyethylene tank, this must beOFTEC certified to OFS T-100. The use of open lidsas a means of filing is not approved. A 50mm diameterblack iron pipe terminating with a 50mm BSP malethread hose coupling and a non-ferrous screw capwith chain is essential (See OFTEC Book 3)2.7.2Masonry piers should be used to support steel oilstorage tanks with the interface between the pier andthe tank isolated using a damp proof membrane.2.7.3The tank must be positioned so that it slopes awayfrom the outlet by 20mm per 1m thereby ensuringthat impurities do not contaminate the feed. Theseimpurities must be removed during maintenance orservicing to prevent them from building up andentering the feed.

CAUTIONSteel tanks should be painted only on their outsidesurfaces, preferably using a proprietary grade of anti-corrosive paint. Galvanized or open topped tanks arenot suitable and must not be used.2.7.4The oil storage tank should be fitted to include thefollowing; fuel level gauge, a vent pipe (with a diametergreater than the diameter of the filler) and featuring aweather proof termination, a sludge valve, an outlet valvesituated at the opposite end of the tank to the sludgevalve, and, a filler connection placed at the opposite endto the outlet valve.

WARNINGThe site chosen for the storage tank must comply withall the appropriate regulations, it is further suggestedthat BS 5410 parts 1 and 2 are consulted.

EXTERNAL OIL STORAGE TANK PROTECTION FORSINGLE FAMILY DWELLINGSBS 5410 PART 1: 1977. FOR TANKS NOT EXCEEDING 3400 LITRES

FIG 1

Illustrations taken from OFTEC Technical Information Book 3.

DIAMETER X DISTANCE X HEIGHT TABLE

(B) TWO PIPE SYSTEM FUEL FEEDS

Pipe O/D Height X length (m)

12mm 0.0 x 100 0.5 x 100 1.0 x 100 1.5 x 902.0 x 70 3.0 x 30 3.5 x 200.0 x 35 0.5 x 30 1.0 x 25 1.5 x 20

10mm 2.0 x 15 3.0 x 8 3.5 x 6

2.8 FUEL SUPPLY SINGLE PIPE SYSTEM

2.8.1For installations where the oil storage tank is at least300mm above the level of the fuel pump on theburner, the principle of gravity feed may be used.The bore and length of run for the fuel feed to theburner is detailed in Table 1. It should be noted thatall Jetstreme boilers are pre-fired and set up to runusing a single pipe gravity feed system as detailedbelow, in figure 3.

DIAMETER X DISTANCE X HEIGHT TABLE

(A) SINGLE PIPE SYSTEM FUEL FEEDS

Pipe O/D Height X length (m)12mm 0.5 x 20 1.0 x 40 1.5 x 80 2.0 x 10010mm 0.5 x 10 1.0 x 20 1.5 x 40 2.0 x 60

FIG 3

Illustration taken from OFTEC Technical Information Book 3

TABLE 1 TABLE 2

2.9 FUEL SUPPLY TWO PIPE SYSTEM

2.9.1All Jetstreme boilers are fitted with pressure jet burnersas standard, which means that the pump fitted withinthe packaged burner can be used to raise the fuel upto provide a suction feed to the burner if the tank isnot above the level of the burner. This can be facilitatedeither via a two pipe system or by means of a singlepipe system fitted with a de-aeration device. The boreand length of the run for the fuel feed to the burner isdetailed in Table 2.

CAUTIONBefore installation the position of the oil pump by-pass plug and horse shoe shaped washer must bechecked. If the plug and washer is fitted then thepump is set for a single pipe system. It should benoted that this is normally the case. If so, the plugand washer must be removed, and the plug replacedwithout the washer, rendering the unit acceptable fora two pipe system.

2.9.2This system is used when the oil storage tank is atthe same level or lower than the burner (see figure4). Access for the fuel feed to the burner should bevia a suitable tapping made in the top of the tank,through which the feed pipe must extend to not lessthan 100mm from the bottom of the tank. A non-returnvalve with a metal to metal seat should be fitted,especially if the return pipe is terminated above thedraw off tube. The non-return valve must be

removable for service andmaintenance purposes, andthe return pipe from thepump must therefore beextended into the tank to thesame level as the suctionpipe. The presence of atamper proof isolating valvefitted within the line is onlynecessary if there is a riskthat oil will siphon out of thetank if the return pipe isdisconnected at the pumpduring maintenance orservicing, or if the non-returnvalve has been omitted.

2.10 SINGLE PIPESYSTEM WITH DE-AERATION DEVICE

2.10.1Alternatively, where the tankis at the same height or lowerthan the burner a single pipefeed to a de-aeration devicewith twin pipe to/from theburner may be used. SeeFigure 5.

CAUTIONThe pump vacuum must not exceed 0.4 bar otherwisenuisance burner lockouts may occur as a result ofstarvation attributed to gas formation within the oil.2.10.2These are sometimes referred to as ‘Tiger Loops’and their installation must be in accordance with themanufacturer’s recommendations (Fig. 5).

FIGURE 4 - (b) TWO PIPE SYSTEMBOTTOM OF OIL STORAGE TANK BELOW OR LEVEL WITH BURNER

FIGURE 5 - (c) SINGLE PIPE SYSTEM WITH DE AERATION DEVICEBOTTOM OF OIL STORAGE TANK BELOW OR LEVEL WITH BURNER

Illustrations taken from OFTEC Technical Information Book 3

2.11 PIPEWORK AND FITTINGS

CAUTIONGalvanized pipework and fittings must not be used.Any joints must be sealed properly using PTFE orother approved sealing media to prevent both fuelleakage and the ingress of air.2.11.1Normally oil supply pipework consists of annealedcopper tube, which has the advantage of being easilymanipulated to form bends, and enables the line tobe run in continuous lengths without joints. This tubeis available with a durable plastic sheath ready fittedfor added protection.2.11.2Where pipes are buried it is important that they areoffered adequate protection from accidental damage,and that high points (which could cause air locks)are avoided. All pipework must be adequatelysupported.2.11.3It is preferable that all pipework should be run with aslight but continuous rise towards the direction of flow,so that any air can be vented off.

WARNINGIt is a requirement that a fire check valve is presentwithin the system. This may be of either the weightoperated type or the capillary operated type.

CAUTIONIt is a requirement that an oil filter is fitted within thesupply line. Its position should be such that it can beisolated for maintenance and servicing without havingto drain down the system.

2.12 ELECTRICAL SUPPLY

WARNINGAll Jetstreme boilers must be earthed. The electricalsupply must be made via a 6A fused double poleisolation switch with a separation distance of at least3mm between contacts. All conductors must have across sectional area of at least 0.75mm2.2.12.1All wiring and electrical work must be carried out bya competent electrician and must be in compliancewith current IEE regulations.

2.13.2Prior to commencing installation work the proposedposition for the balanced flue terminal must bechecked to ensure that it complies with the relevantregulations.

2.13.3It should also be noted that the terminal should bepositioned so as not to cause a nuisance, and so asto allow unimpaired dispersal of combustionproducts. Where the terminal is within 1m of anyplastic material the plastic must be protected fromthe effects of the flue gases.

Appliance burner type Pressure jet Vaporising

Minimum distances to terminals in millimetres as measured fromtop of the chimney or the rim of a low level discharge opening

A Directly below an opening, airbrick, window etc. 600 Not allowedB Horizontally to an opening, air brick, window etc. 600 Not allowedC Below a gutter, eaves or balcony with protection 75 Not allowedD Below a gutter, or a balcony without protection 600 Not allowedE From vertical sanitary pipework 300 Not allowedF From an internal or external corner 300 Not allowedG Above ground or balcony level 300 Not allowedH From a surface or a boundary facing the terminal 600 Not allowedJ From a terminal facing the terminal 1200 Not allowedK Vertically from a terminal on the same wall 1500 Not allowedL Horizontally from a terminal on the same wall 750 Not allowedM Above the highest point of an intersection with the roof 600 1000N From a vertical structure on the side of the terminal 750 2300O Above a vertical structure less than 750mm from the side of the terminal 600 1000P From a ridge terminal to a vertical structure on the roof 1500 Not allowed

FIG 6

2.13 BALANCED FLUE POSITION

2.13.1 POSITIONS OF BALANCED FLUE TERMINALS SHOULD BE AS ILLUSTRATED IN FIG. 6

Illustration taken from OFTEC Technical Information Book 3

2.14 CONVENTIONAL FLUE

2.14.1The flue should rise as vertically as possible andterminate at a point where it will not be subject todown draughts or eddies as illustrated in Figure 7. Ifan existing traditional chimney is to be used then itmust be lined with a moisture and acid resistant flueliner of the same diameter as the flue spigot on theboiler. The connecting lengths of flue from the boilerspigot to the flue liner should be of twin wall type. Itis recommended that the existing chimney is back-filled around the flue liner with vermiculite so as toretain the heat, maintain boiler efficiency, and prolongthe working life of both the boiler and the flue liner.

CAUTIONIf an existing chimney is to be used it must be cleanedthoroughly, with all soot and scale removed prior tothe liner being installed.2.14.2Where a traditional flue has been lined with a largesection clay flue liner it will be necessary to fit a metalflue liner so as to reduce the bore and improve thethermal insulation. Again, once the flue liner is inposition it should be back-filled with vermiculite.

WARNINGIf an existing flue liner is already fitted its conditionmust be checked to ensure that it is satisfactory.Flexible flue liners usually have an effective workinglife greater than that of the boiler, but it is rare thatthis working life is equal to twice that of the boiler. Itis therefore recommended that when a new boiler isinstalled a replacement flue liner is also fitted.

WINDDIRECTION

FIGURE 7 - TYPICAL PRESSURE ZONES EFFECTINGCONVENTIONAL FLUES

2.14.3When it is not possible to utilise an existing chimneya twin wall stainless steel flue may be used instead.In this case the number of bends must be kept to anabsolute minimum, and the flue must rise vertically.The internal diameter of the twin wall flue must bethe same as that on the boiler flue spigot. It issuggested that the relevant sections of BS 5440 part1, BS 5854 and BS 4543 part 3 are referred to (seefigure 8-internal, figure 8A-external).2.14.4Where single skin flue is to be used considerationmust be given to the possible problems associatedwith the formation and entrapment of condensates.It is therefore strongly recommended that themaximum length of single skin flue is not greater than6m, and an adequate drain facility is included in theflue design.

FIG 8

FIG 8A

C

2.15 VENTILATION REQUIREMENTS

The current requirements detailed within Figures 9and 10 are based upon BS 5410 part 1 for a freearea of non closable ventilation and are based on550mm2 per kW output and multiples thereofdepending upon the application.2.15.1The following information applies to Jetstremeboiler conventional flue models only.

TABLE 3 - VENTILATION REQUIREMENTS FORCONVENTIONAL FLUE BOILERS (BS 5410 PART 1). SEEILLUSTRATIONS IN FIGURE 9 OPPOSITE.

(A) BOILER IN A ROOM (EXTERNAL VENTILATIONREQUIRED IN mm2)

OPEN AREA 55 80 125

in 8855 12870 20130mm2

out 0 0 0

(B) BOILER IN A COMPARTMENT (EXTERNALVENTILATION REQUIRED IN mm2)

OPEN AREA 55 80 125

in 17710 25740 40260mm2

out 8855 12870 20130

(C) BOILER IN A COMPARTMENT WITHIN AROOM (INTERNAL AND EXTERNAL VENTILATIONREQUIRED IN mm2)

OPEN AREA 55 80 125

(e)in 8855 12870 20130

(e)out 0 0 0mm2

(i) in 26565 38610 60390

(i)out 17710 25740 40260

WARNINGThe provision of adequate ventilation is necessaryin order to facilitate safe and efficient operation ofthe boiler. If an extraction unit is fitted within the samearea, the amount of ventilation required will have totake account of this if the extraction unit effectscombustion.

FIGURE 9 - VENTILATION REQUIREMENTS (INTERNALAND EXTERNAL) CONVENTIONAL FLUE MODELS.FIGURES SHOWN ARE NON-CLOSABLE VENTILATION INmm2 PER KW OUTPUT OF BOILER.

(A) BOILER IN ROOM

CONVENTIONAL FLUE

(B) BOILER IN COMPARTMENT

CONVENTIONAL FLUE

(C) BOILER IN COMPARTMENTWITHIN A ROOM

CONVENTIONAL FLUE

(e) (i)

2.15.2The following information applies to Jetstremeboiler balanced flue models only.

WARNINGWhilst it is correct to state that when Jetstremebalanced flue models are installed they do not requireventilation for combustion purposes, it must be notedthat under certain conditions it will be necessary toprovide adequate ventilation for balanced fluemodels. This applies particularly when the boiler isinstalled within a confined space or a compartment,and where the ventilation is provided to prevent theboiler from over heating.

(A) BOILER IN A COMPARTMENT (EXTERNALVENTILATION REQUIRED IN mm2)

Open Area 55 80 125

in 8855 12870 20130mm2

out 8855 12870 20130

(B) BOILER IN A COMPARTMENT WITHIN AROOM (INTERNAL VENTILATION REQUIRED INmm2)

Open Area 55 80 125

in 17710 25740 40260 mm2

out 17710 25740 40260

TABLE 4 - VENTILATION REQUIREMENTS FORJETSTREME BALANCED FLUE MODELS INSTALLED INCOMPARTMENTS. SEE ILLUSTRATIONS IN FIGURE 10OPPOSITE.

FIGURE 10 - VENTILATION REQUIREMENTS (INTERNALAND EXTERNAL) BALANCED FLUE MODELS

BOILER IN ROOM

BALANCED FLUENO COMBUSTION AIR INLET

REQUIRED TO ROOM

(A) BOILER IN COMPARTMENT(EXTERNAL VENTILATION)

(B) BOILER IN COMPARTMENTWITHIN A ROOM

(INTERNAL VENTILATION)

BALANCED FLUECOMPARTMENT VENTILATED

FROM ROOM

BALANCED FLUE

3.1 BOILER INSTALLATION

3.1.1The packaging should be carefully removed fromaround the boiler and the flow and return fittingssecured in their appropriate positions.3.1.2If only one flow and return is to be fitted then it ispreferable that these are positioned so that the flow isabove and diametrically opposite the return.3.1.3The boiler should be placed in position and the topand front panels removed, by lifting upwards andoutwards respectively.

3.2 BALANCED FLUE – 55 & 80 MODELS ONLYSTANDARD FLUE INSTALLATION

CAUTIONBefore commencing with the installation, the installershould be familiar with and ensure compliance with theelectrical supply details contained within section 2.123.2.1Ensure that all the component parts that make upthe balanced flue kit are present, (See Figure 11). Itis also recommended that the figures 11 through to16 are studied in order that the installer might befamiliar with the assembly and installation of thebalanced flue and its options.3.2.2The position of the flue outlet should be marked onthe wall, and the boiler moved and adequatelyprotected, prior to cutting the hole in the wall for theflue outlet. On completion of cutting the hole, the flueoutlet box should extend through the wall so as toallow the air intake slots to project by at least 25mm,(See Figure 12).3.2.3If the boiler is to be installed with either a left hand orright hand balanced flue exit then section 3.3 andfigure 13 should be referred to. If the boiler is to beinstalled with a horizontal or vertical extension thensections 3.4 and figure 14 or 3.5 and figure 15 shouldbe referred to respectively.3.2.4On models featuring a standard balanced fluearrangement, as in figure 11, the installation shouldcontinue as follows. Remove the access plate fromthe inside end of the flue outlet box, together with thefour hexagonal nuts screwed onto the studs aroundthe exhaust outlet on the boiler.

3.0.0 INSTALLATION BF AND CF MODELS3.0 INSTALLATION BALANCED FLUE ANDCONVENTIONAL FLUE MODELS

3.2.5The two gaskets should be offered up so that thefirst is positioned between the boiler and the exteriorof the exhaust box, and the second, between themale end of the flue spigot and the interior of theexhaust box.

FIGURE 11 - BALANCED FLUE INSTALLATION55 & 80 MODELS ONLY (STANDARD KIT -SUPPLIED WITH BOILER)

WARNINGEnsure that the flue spigot, the upper gasket, thebalanced flue exhaust box, and the lower gasket arecorrectly positioned before tightening and securingthe nuts.3.2.6The flue exhaust duct should then be pushedtogether and sealed securely at the correct lengthusing the sealing tape provided.3.2.7The outer case can now be sealed with the tapeprovided.3.2.8The exhaust box access plate can then be refitted,and the flexible air inlet tube secured to both theexhaust box access plate and the burner, using thejubilee clips provided.3.2.9When the hole that was cut in the wall toaccommodate the balanced flue has been madegood, the protective basket should be fitted andscrewed to the wall.3.2.10On satisfactory completion of the flue installation,the connection to other services can be undertakenas detailed in section 4.0

3.3 BALANCED FLUE – 55 & 80 MODELSONLY LH AND RH FLUEIINSTALLATIONS

CAUTIONBefore commencing with the installation the installershould refer to section 3.23.3.1If the balanced flue is to be positioned at right anglesto the boiler, then the blanking plate from theappropriate side panel of the boiler must be removed.

WARNINGThe flue outlet assembly air inlet slots must havea minimum projection from the surface of theoutside wall of 25 mm, (as Figure 12).3.3.2When the hole that was cut in the wall toaccommodate the balanced flue has been madegood, the protective basket should be fitted andscrewed to the wall.3.3.3On satisfactory completion of the flue installation,the connection to other services can beundertaken as detailed in section 4.0.

FIGURE 14 - BALANCED FLUEHORIZONTAL EXTENSION KIT (55 & 80 MODELS ONLY).

FIGURE 13 - BALANCED FLUE INSTALLATION LH ANDRH ORIENTATION LEFT HAND SHOWN. (55 & 80 MODELSONLY).

FIG 12

3.4 BALANCED FLUE – 55 & 80 MODELS -EXTENDED HORIZONTAL FLUEINSTALLATION

CAUTIONBefore commencing with the installation the installershould refer to section 3.2 and Figure 14 coveringstandard flue installations.3.4.1The installation of the balanced flue extension kitshould be treated as though it is an over sizedstandard flue outlet assembly. See section 3.2

WARNINGThe extension cover slides over the terminal and iscemented into the wall, and as there is a larger thanstandard exhaust tube, this requires adjustment tolength to provide an external projection of 200mmon 55 & 80 models.

3.5 BALANCED FLUE – 55 & 80 MODELS ONLYVERTICAL EXTENSION FLUEINSTALLATION

3.5.1On 55 and 80 models only the Vertical extension fluekit may be used for rear outlet only. It may not beused for left hand or right hand outlets, (See Figure15).

The front cover should be removed from the verticalextension kit, and the kit should then be located onthe four studs and secured to the boiler, ensuringthat the gaskets are in place between the exhaustbox and the boiler, and between the spigot and theexhaust box. The assembly should then be fixed inposition using the nuts and studs.3.5.3

3.5.2

The flue exhaust tube should then be inserted intothe flue spigot, and the joint sealed with fire cementand by tightening the clip at the top of the flue box.Now follow 3.2.4 as if fitting directly to the boiler asFigure 11, but as illustrated in figure 15.

3.6 BALANCED FLUE – 125 MODEL ONLYSTANDARD FLUE INSTALLATION

3.6.1Ensure that all the component parts that make up theflue kit are present. It is also recommended that figures16 to 19 are studied in order that the installer may befamiliarised with the assembly and installation of thebalanced flue and its options.

FIGURE 16 - BALANCED FLUE INSTALLATION. (125MODEL ONLY) - STANDARD KIT SUPPLIED WITH BOILER.

FIGURE 15 - BALANCED FLUE INSTALLATION VERTICALEXTENSION. (55 & 80 MODELS ONLY).

3.6.2The position of the flue outlet should be marked onthe wall, and the boiler moved and adequatelyprotected, prior to cutting the hole in the wall for theflue terminal. On completion of cutting the hole, theterminal body should pass through the wall andproject at least 70mm. The exhaust tube must thenproject a further 125mm.3.6.3If the boiler is to be installed with either a left or righthand balanced flue exit, then section 3.7 and figure17 should be referred to. If the boiler is to be installedwith either a horizontal or vertical extension thensection 3.8 with figure 18 or section 3.9 with figure19 should be referred to respectively.3.6.4On models featuring a standard balanced fluearrangement, as in figure 12, the installation shouldcontinue as follows. Remove the access plate fromthe inside of the exhaust box, together with the fourhexagonal nuts screwed onto the studs around theexhaust outlet on the boiler.3.6.5The two gaskets should be offered up, so that thefirst is positioned between the boiler and the exteriorof the terminal body. The second, between the maleend of the spigot adapter and the interior of theterminal body.

WARNINGEnsure that the spigot adapter, the upper gasket, thebalanced flue terminal body, and the lower gasket arecorrectly positioned before securing and tightening nuts.3.6.6The flue exhaust duct should then be pushed togetherand sealed securely at its joint with the flue spigot, usinghigh temperature silicone.3.6.7Attach the wind deflector plate to the outer end of theflue terminal body, using M5 screws.3.6.8The dished extension tube can then be insertedthrought the opening, and pushed home so as to slipover flue exhaust duct. The joint should be sealedusing high temperature silicone.3.6.9The terminal box access plate can then be refitted,and the flexible air inlet tube secured between thisand the burner, using the jubilee clips provided.

3.6.10Make good the wall opening about the flue terminal,and fit the terminal guard.3.6.11On satisfactory completion of the flue installation, theconnection of the remaining services can beundertaken.

3.7 BALANCED FLUE – 125 MODEL ONLYRH & LH FLUE INSTALLATIONS

CAUTIONBefore commencing with the installation the installershould refer to section 3.6.3.7.1See figure 17.3.7.2With the top panel removed, the four top panellocating studs should be removed from the sidepanels and replaced with M5 x10mm screws. Thebrass locating pins should also be removed from theside panels and the control panel. With the sidepanels and control panel in place the top panel cannow be slid into position and held there using theremaining three M5 x 10mm screws.

FIGURE 17 - BALANCED FLUE INSTALLATION LH & RHORIENTATION (125 MODEL ONLY). RIGHT HAND SHOWN.

3.7.3With the top panel removed the installation shouldcontinue as follows: Remove the access plate fromthe end of the exhaust box, together with the fourhexagonal nuts screwed onto the studs around theexhaust outlet on the boiler3.7.4The first gasket should be offered up so that it ispositioned between the boiler and the exterior of thelower part of the transition box. The second gasketshould be placed within the lower part of the transitionbox, which should then be located upon the studsaround the boiler exhaust outlet, ensuring that theair feed spigot is facing forward.3.7.5The flue spigot should be pushed home; through thetop gasket, and through the lower part of the transitionbox and lower gasket, and into the exhaust outlet onthe boiler. This assembly should then be clampedusing the nuts and stud fixings from the boiler.

WARNINGEnsure that the lower transition box assembly and bothgaskets are correctly located prior to clamping intoposition.3.7.6The exhaust extension should then be pushed into theflue spigot, and sealed in place using high temperaturesilicone. This should also be applied to the inner surfaceof the opposite end of the exhaust extension, inpreparation for the joint with the exhaust pipe silencer.3.7.7The top plate from the transition box should then befitted using the self tapping screws.3.7.8The exhaust extension and exhaust pipe silencer shouldbe pushed together firmly, and the joints sealed usinghigh temperature silicone.3.7.9The flue box, with the gasket in position, should beoffered up to the transmission box, and using the fourM6 screws the parts should be clamped. Care must betaken to ensure that the integrity of the gasket ismaintained.3.7.10The flue exhaust duct should then be pushed into andsealed securely at its joint with the flue extension, usinghigh temperature silicone.3.7.11Attach the wind deflector plate to the outer end of theflue terminal using the M5 screws.

3.7.12The dished extension tube can then be insertedthrough the opening, and pushed home so as to slipover the flue exhaust duct. The joint should be sealedusing high temperature silicone.

WARNINGThe exhaust box assembly must have a minimumprojection from the surface of the outside wall of 70mm.The exhaust tube must then project a further 125mm.3.7.13Make good the wall opening about the flue terminal,and fit the terminal guard.3.7.14On satisfactory completion of the flue installation, theconnection to the remaining services can beundertaken.

3.8 BALANCED FLUE – 125 MODEL ONLYEXTENDED HORIZONTAL FLUEINSTALLATION

CAUTIONBefore commencing with the installation the installershould refer to section 3.6, and Figure 16 coveringStandard flue installation.3.8.1See figure 18.3.8.2The installation of the balanced flue extension kitshould be treated as though it is an oversizedstandard flue outlet assembly. See section 3.6.

WARNINGThe extension cover slides over the terminal and iscemented into the wall, and as there is a larger thanstandard exhaust tube, this requires cutting to a lengthto provide an external projection of 125mm for the 125model.

3.9 BALANCED FLUE – 125 MODEL ONLYVERTICAL EXTENSION FLUEINSTALLATION

CAUTIONBefore commencing with the installation the installershould refer to section 3.6.3.9.1See figure 19.3.9.2The front cover should be removed from theextension kit, and the kit should then be located onthe four studs and secured to the boiler, ensuring

FIGURE 18 - BALANCED FLUE INSTALLATIONHORIZONTAL EXTENSION. (125 MODEL).

FIGURE 19 - BALANCED FLUE INSTALLATIONVERTICAL EXTENSION. (125 MODEL).

that the gaskets are in place between the exhaustbox and the boiler, and between the spigot and theexhaust box. The assembly should then be fixed iposition using the nuts and studs.3.9.3The flue exhaust tube should then be inserted intothe flue spigot, and the joint sealed with fire cementand by tightening the clip at the top of the flue box.3.9.4The horizontal section should then be passed throughthe hole in the wall and married up with the verticalextension piece, ensuring that the gasket betweenthe two parts is in place and that the fastenings aresecurely clamped.3.9.5The exhaust silencer should be passed through thehole and positioned into the top of the vertical flueexhaust pipe. The two parts should be pushedtogether and the joint sealed using high temperaturesilicone.3.9.6The dished extension tube can then be insertedthrough the opening, and pushed home so as to slipover the flue exhaust duct. The joint should be sealedusing high temperature silicone.

WARNINGThe flue terminal assembly must have a minimumprojection from the surface of the outside wall of 70mm.The exhaust tube must then project a further 125mm.3.9.7Make good the wall opening about the flue terminal,and fit the terminal guard.3.9.8Refit the front cover to the vertical flue section anddiscard the flue end cover with air pipe adapter, fittingthe plain blanking cover supplied with the horizontalsection of the flue.3.9.9The exhaust box access plate can then be re-fitted,and the flexible air inlet secured to both the exhaustbox access plate and the burner, using the jubilee clipsprovided.3.9.10Make good the wall opening about the flue terminal,and fit the terminal guard.3.9.11On satisfactory completion of the flue installation, theconnection to other services can be undertaken.

installation features a two pipe system it will benecessary for the installer to supply an additionallength of flexible tube to the same specification.3.11.4A suitable remote acting (OFTEC Approved) Firevalve must be installed so that the sensor ispositioned above the burner.3.11.5The electrical connection between the burner andthe control panel should be made by inserting thefour pin plug, on the end of the fly lead from theburner, into the socket located on the underside ofthe control panel.

CAUTIONIf zone controllers are to be installed, the installermust ensure that the information provided with theunits is studied and that their installation is compatiblewith rest of the system.3.11.6Ensure that there is an adequate air supply inaccordance with the ventilation requirements detailedwithin section 2.15

CAUTIONOn balanced flue models the flexible air pipe shouldbe positively connected and secured in place at boththe burner and the air inlet spigot on the balancedflue assembly (figure 20).

FIG 20ENSURE THE FLEXIBLE AIR PIPE IS FIRMLY FIXED ANDSEALED AT BOTH ENDS

3.10 CONVENTIONAL FLUE – ALL MODELS

CAUTIONBefore commencing the installation, the installershould be familiar with the details contained withinsection 2.14 and should check for compliance.3.10.1Ensure that the details outlined within section 3.1 arecomplied with prior to continuing with the installation.3.10.2The position of the flue should be marked on theceiling or wall, and the boiler moved and adequatelyprotected, prior to cutting the hole for the flue.3.10.3The first section of flue should be placed so as to bepositively located within the flue spigot on the boiler,and the joint sealed using high temperature siliconsealant.3.10.4The flue should be supported through the use ofbrackets which should be installed as the flue is beingconstructed.3.10.5When the flue connects into an existing flue linerwithin a chimney the connecting lengths of flue fromthe boiler to the flue liner must be made usingsections of twin wall flue.3.10.6The hole that was cut in the wall or ceiling to accom-modate the flue must be sealed and made good.

3.11 CONNECTION OF SERVICES

3.11.1The pipework for central heating and domestic hotwater to and from the boiler should be completed.3.11.2The mains electrical input should be connected withinthe electrical control panel, ensuring that the wiresare secured and clamped. The cover to the panelmust be replaced and positively secured by its screwand serrated washer.

WARNINGEnsure that the mains supply is isolated beforecarrying out the electrical installation work. Such workshould only be undertaken by a qualified andcompetent electrical engineer.3.11.3The fuel feed from the storage tank should have beenbrought to within 450mm of the oil pump on the burner,and the final connection should then be carried outusing the flexible tube supplied with the boiler. If the

3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS4.0 COMMISSIONING

CAUTIONIt is recommended that an OFTEC approvedengineer is used for commissioning thereby ensuringthat the boiler is set and tested to provide optimumefficiency combined with clean combustion. Checksfor electrical safety must be carried out by anapproved electrical engineer working within IEEguidelines. Not withstanding the above, it should benoted that satisfactory commissioning is arequirement for registration and validation of themanufacturers’ warranty.When the commissioning of the Jetstreme boileris completed, the commissioning report at therear of this manual must be completed in full bythe commissioning engineer and returned toHalstead Boilers Ltd.

4.1 PRE-COMMISSIONING INSPECTION OFTHE INSTALLATION

CAUTION

Ensure that the electrical safety checks have beencarried out, and that the boiler is turned off at theisolator.4.1.1Undertake a physical inspection of the appliance andthe installation to ensure that it is satisfactory4.1.2Ensure that the flueing arrangements are satisfactoryand in compliance with the appropriate regulations4.1.3Ensure the appropriate requirements for ventilationare observed4.1.4Check that the clearances required for servicing arecorrect4.1.5Ensure all gaskets, joints, and fastenings are presentand effective4.1.6Check that the flow and return connections arecorrect and do not leak4.1.7Check that the oil installation has been completedsatisfactorily and that the valves are all in the closedposition4.1.8Check that the electrical connection is satisfactory

4.2 PRE-COMMISSIONING INSPECTION OF THE BOILER

CAUTION

Ensure that the heating and hot water system hasbeen filled before proceeding with the commissioning4.2.1Remove the top panel and front panel from the boiler4.2.2Remove the front plate and check that the bafflesare correctly seated, re-tighten fastenings afterinspection4.2.3On CF models check that flue draught is as detailedwithin section 8 taking the reading through the samplepoint in the front of the boiler4.2.4Check that the burner is set to accept the grade ofoil used4.2.5Connect the oil line to the burner ensuring that priorto connection the valves remain closed4.2.6On completion of the connection of the oil feed tothe burner ensure that the connections are testedfor leaks and that the valves are left open4.2.7Ensure that there are no impurities or air locks withinthe oil feed (gravity feed system only)

4.3 PRE-COMMISSIONING INSPECTION OF THE BURNER

4.3.1Check that the separate information regarding theoperation of the burner is present and within the rearcover of the manual4.3.2Check that the burner head is to specification and inline with the details contained within section 84.3.3Check that the nozzle size is correct4.3.4Read the appropriate section within the separateburner manual

4.4 PRE-FIRING CHECKS

4.4.1Connect the oil pressure gauge to the test point onthe burner oil pump and ensure that the valves onthe oil feed are all open

CautionRunning the oil pump with the valves closed will leadto oil pump failure4.4.2Turn on the electrical supply at the isolator4.4.3Ensure that the controls on the boiler are set todemand heat;(a) Boiler thermostat to highest setting(b) Time clock (if fitted) to an on position for hot waterand central heating.4.4.4Ensure that the external controls are set to demandheat;(a) Room thermostat to highest setting(b) Cylinder thermostat to highest setting4.4.5Check that the boiler starts its ignition sequence asdetailed in section 4.5.1.

4.5 FIRING THE BOILER

4.5.1Ensure that the ignition sequence is as follows;

Firing sequence

Times of operation / action (seconds)

0 (a) Burner motor starts0 - 20 (b) Ignition spark formed12 (c) Solenoid valve opens12 (d) Oil mist is formed20 (e) Ignition occurs20 (f) Flame sensed by photocell20 (g) Spark ceases

CautionThe oil pressure should be adjusted so that it is inaccordance with that specified within section 8

Note(i) It is rare that the burner will ignite on the firstattempt. Usually air will require bleeding from the fuelfeed. If the flame has not been sensed within thesafety time (a+10seconds), the burner willautomatically go to lockout (red neon lit)(ii) If flame detection is within the safety time, andthen the flame subsequently drops out, the burnerwill re-attempt ignition. If this is unsuccessful theburner will then go to lockout (green neon is replacedby orange neon)

4.6 COMBUSTION CHECKS

CAUTIONIt is imperative that combustion checks areundertaken using approved equipment that isregularly tested to ensure its continued accuracy, andthat it remains within calibration.4.6.1With the boiler firing, and having reached thermalequilibrium, check that the oil pressure is as specifiedwithin section 84.6.2Insert the sample tube from the smoke pump throughthe test point and take a smoke reading4.6.3Adjust the air setting on the burner and continue totake samples until the smoke reading is in line withthat detailed within section 84.6.4With the burner air and oil pressure correctly setundertake analysis of the flue gases4.6.5Insert the sample probe through the test point on thefront of the boiler shell and measure CO / CO2 andflue gas temperatures4.6.6Ensure that the readings are within a tolerance of+/- 10% of those stated within section 8 makingadjustments to the burner as appropriate4.6.7Complete the remainder of the commissioning priorto re-checking all readings and entering the data onto the commissioning card4.6.8Ensure that the sample point is sealed after samplinghas been completed4.6.8Ensure that there are no water leaks from the flowand return connections4.6.9Replace and secure the front and top panels

4.7 HAND OVER

4.7.1Using the information contained within section 10 ofthis manual set the programmer to the requirementsof the customer.4.7.2Upon completion of satisfactory commissioning theengineer should provide the customer with sufficientinformation to allow the customer to operate the boilersafely and efficiently. The customer must be madeaware of the appropriate sections within the manual,and be informed that the manufacturer recommendsthat the Jetstreme boiler is serviced by a competentengineer on a regular basis (at least once a year).

FIGURE 21 - ELECTRONIC PROGRAMMER (OPTIONAL).

CONTROL PANEL - ENSURE THE CUSTOMER CANOPERATE THE BOILER SAFELY AND EFFICIENTLY AND ISFULLY CONVERSANT WITH THE CONTROLS

4.7.3The commissioning card must be completed by thecommissioning engineer and returned to themanufacturer within seven days to validate thewarranty.

5.2 SERVICING - OIL INSTALLATION

WARNINGEnsure that the boiler is isolated from the mainselectricity supply before commencing servicing work.5.2.1Check the oil tank for any signs of leakage and forsevere corrosion, ensure that the various fittings arein good condition and operational.5.2.2Inspect the pipework where it is visible and accessible(above ground) to ensure that it remains in goodcondition and has not been damaged.5.2.3If the fuel level is sufficiently low, remove sludge,water and other contaminants from the oil by openingthe sludge cock on the oil tank and draining off thecontaminated fuel. When this operation is completedthe drain cock must be securely closed.

ENVIRONMENTAL WARNINGThe contaminated fuel must be collected in a sealablevessel and disposed of in accordance with therelevant local or national regulations.5.2.4The fuel filter should be removed and cleaned usingclean kerosene, the residual contaminated kerosenemust be put with the contaminants from the oil tankand disposed of correctly

ENVIRONMENTAL WARNINGDo not remove the filter until the fuel supply has beenisolated at the tank.

5.1 SERVICING - GENERAL REQUIREMENTS

5.1.1The manufacturer recommends that the Jetstremeboiler is serviced on a regular basis, at least once ayear, by a registered engineer.

CAUTIONFailure to ensure that adequate servicing is carriedout can invalidate the manufacturers warranty andcan reduce the efficiency of the boiler andcompromise the safety and reliability of the appliance.5.1.2The manufacturer recommends that servicing shouldbe undertaken just before the start of the heatingseason if the boiler is used to provide heating andhot water throughout the year.5.1.3If the boiler is shut down during the summer monthsit is recommended that servicing is carried out assoon as possible after the end of the heating season.This will help to reduce corrosion and in so doingextend the life of the boiler.

3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS5.0 SERVICING

5.3 SERVICING - BOILER

WARNINGEnsure that the boiler is isolated from the mainselectricity supply before commencing servicing work.Also ensure that the oil supply has been shut off atthe appropriate valve(s).5.3.1Remove the top and front panels from the boiler, andplace them to one side so that they will not be proneto inadvertent damage. Disconnect the air tube fromthe burner (BF models only) and disconnect the leadfrom the burner to the control.5.3.2Carefully remove the burner complete with blast tubefrom its flange by removing the retaining screw.5.3.3Unfasten the nuts which clamp the inspection coverand gasket in position, and remove. The gasketshould be inspected to ensure that it is not damaged.5.3.4Remove and inspect the baffles for any signs ofdistortion and serious damage from corrosion. Thefixing points should be inspected to ensure that thereis no apparent damage associated with fretting. Ifnecessary replacements should be fitted.5.3.5With a torch inspect the inside of the boiler for anysigns of distortion, signs of damage associated withflame impingement, and any trace of advancedstages of corrosion. The integrity of the bafflemountings should be carefully inspected to ensurethat they have not been subject to fretting ordistortion.5.3.6The baffles should be taken outside and cleaned toremove any scale, soot, ash, or other residue. Theinside of the boiler should be brushed down andscraped to collect residue, and a vacuum cleanerused to effect its removal.5.3.7Visually inspect the flue to ensure that there is nobuild up of soot and other residue, and that corrosionhas not impaired its operation.5.3.8Check the flow and return connections to ensure thatthey remain tight and leak proof.5.3.9Replace the inspection cover, ensure that the samplepoint remains free for access to allow flue gassampling to occur.

5.4 SERVICING - BURNER

5.4.1Having already removed the burner and draught tube (5.2.1) it is recommended that the major componentparts of the burner are initially subject to a detailed visual inspection.5.4.2The nozzle should be cleaned thoroughly using a soft bristle brush and kerosene. The specification of thenozzle should be checked to ensure that the correct nozzle is fitted.

CAUTIONNever clean the nozzle with sharpinstruments or abrasive materials as thismay damage the orifice and impair theperformance of the boiler. If the nozzleshows signs of wear it must be replaced witha new nozzle to the correct specification.5.4.3The electrodes should be cleaned using a softbristle brush and kerosene. The gap shouldbe checked to ensure that it is in accordancewith the manufacturers recommendations. Ifthe tip of the electrodes shows evidence ofbeing pitted then the electrodes must bereplaced. If the ceramic insulation shows signsof being cracked or crazed then the electrodesmust be replaced.5.4.4The photocell must be removed andthoroughly cleaned to ensure that itcontinues to detect the presence of a flame.

CAUTIONNever clean the photocell with sharpinstruments or abrasive materials as these maycause damage and impair the performance ofthe component. If the photocell shows any signsof damage it must be replaced.5.4.5The blast (no.7) tube must be cleanedthoroughly using a soft bristle brush andkerosene. Ensure that there is no residualmatter that could impair the performance ofthe burner. If there are any signs of damageto the blast tube then the component mustbe replaced with a new unit to the same specification..

1 PHOTORESISTOR2 AIR DAMPER3 IGNITION CABLES4 NOZZLE ASSEMBLY5 NOZZLE6 BRAKE PLATE7 BLAST TUBE8 IGNITION ELECTRODES9 CONNECTING PIPE10 FUEL PUMP11 DRIVE COUPLING

12 INDICATION - AIR DAMPER13 FAN WHEEL14 ADJUSTMENT - AIR DAMPER15 MOTOR16 CONTROL BOX17 CONTROL BOX BASE18 IGNITION TRANSFORMER19 ADJUSTING SCREW20 FIXING FLANGE21 FLANGE GASKET22 FRONT GASKET

5.4.6Electrical connections and leads should all be checkedto ensure that they are secure and in good condition.5.4.7The burner should be reassembled and refitted tothe boiler and on completion of servicing checkedfrom 4.4.0 through to 4.6.9 inclusive.

5.5 SERVICING - RE-COMMISSIONING

5.5.1Prior to firing the boiler a flue draught reading shouldbe taken from the sample point (see 4.2.3).5.5.2Carry out re-commissioning as detailed in sections4.0 to 4.6.

FIGURE 22

6.1 BURNER FAILS TO START

SITUATION POSSIBLE CAUSES REMEDIAL ACTION

CHECK NOZZLEFLAME UNSTABLE BURNER HEAD SPECIFICATION

MOTOR RUNS ELECTRODE POSITIONWRONG HEAD SETTING

CHECK OIL PRESSUREPRE-PURGES OKAY LOW OIL PRESSURE

ADJUST AIR DAMPEREXCESS AIR

FLAME PRESENT CLEAN PHOTO CELLPHOTO CELL PROBLEM REPLACE PHOTO CELL

BURNER LOCKS OUT CONTROL FAULTY CONFIRM WITH NEW CONTROL BOX

6.2 BURNER FAILS TO START

MOTOR RUNS

CHECK FOR DETECTION OFPRE-PURGES OKAY PHOTO CELL PROBLEM AMBIENT LIGHT AT PHOTO CELL

NO FLAME NO SPARK CHECK FOR ELECTRODEARC AT GAP/HT SHORT

BURNER LOCKS OUT NO OIL CHECK OIL FEED TO THE BURNERFOR AIRLOCKS / VALVES AREALL OPEN

CHECK MAGNETIC VALVEOPERATES

6.3 BURNER FAILS TO START AFTER NORMAL OPERATION

NO POWER CHECK ISOLATOR / FUSEBURNER FAILSTO START THERMOSTAT AT RESET THERMOSTAT

OPEN CIRCUIT

OVERHEAT AT RESET OVERHEAT - FIND LOCKOUT LAMP OPEN CIRCUIT REASON FOR OVERHEAT NOT ILLUMINATED

CONTROL / PHOTO CHECK BY REPLACEMENTCELL FAULT

6.4 BURNER FAILS TO START AFTER NORMAL OPERATIONCHECK OIL LEVEL / OILFEED / VALVES

OIL STARVATION PUMP / BURNER NOZZLE

MOTOR RUNS CHECK FOR FUEL CONTAMINATION /AIRLOCKS

INTERMITTENTFLAME DETECTION CHECK PHOTO CELL

EXCESSIVE FLUE DRAW BURNER RUNS TO LOCKOUT NO SPARK CHECK TRANSFORMER / HT

LEAD / ELECTRODE GAP

5.3.0 SERVICING - BURNER3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS6.0 FAULT DIAGNOSIS

6.0.0 FAULT DIAGNOSIS

6.8 FLUE SHOWS SIGNS OF EXCESSIVE SMOKING/SOOTING

CHECK OIL PRESSURE

EXCESSIVE SMOKE AIR:FUEL INCORRECT CHECK NOZZLE AND SOOTING

REQUIRES SERVICE/ CHECK AIR DAMPERRECOMMISSIONING

CHECK SMOKE READING/RECOMMISSION

6.7 BURNER STARTS VIOLENTLY

CHECK ELECTRODES

BURNER STARTS DELAYED IGNITION CHECK HT LEADS VIOLENTLY

CHECK IGNITIONTRANSFORMER

CHECK CONTROL

6.6 DELAYED IGNITION, BURNER STARTS VIOLENTLY IN COLD FLUE CONDITION

NOZZLE BLOCKED CLEAN/REPLACE

NOZZLE DAMAGED CHECK/REPLACE

BURNER PULSATES LOW OIL PRESSURE CHECK/RECOMMISSION ON START - UP

FLUE RESTRICTED CHECK/RECTIFY

FAN SLIP ON SHAFT CHECK/RETIGHTEN

PUMP COUPLING FAULT CHECK/REPLACE

6.5 DELAYED IGNITION, BURNER STARTS VIOLENTLY IN WARM FLUE CONDITION;

BURNER PULSATES EXCESSIVE AIR RECOMMISSION BURNER ON START - UP

SITUATION POSSIBLE CAUSES REMEDIAL ACTION

5.3.0 SERVICING - BURNER3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS7.0 WIRING DIAGRAMS

7.1 WITH OPTIONAL ELECTRONIC PROGRAMMER

7.2 NO INTEGRAL PROGRAMMER

7.3 TYPICAL ‘S’ PLAN

7.4 TYPICAL ‘Y’ PLAN

CONTROL BOXCONNECTION

CONTROL BOXCONNECTION

8.0 TECHNICAL DATA FOR KEROSENE MODELS

Page 34

NOTE:AIR SETTINGS. ALL FIGURES BASED ON ZERO FLUE RESISTANCE* BURNER PRE-SET TO ACCOMMODATE MAXIMUM OUTPUT SETTINGS.TO SET BURNER FOR OTHER OUTPUT SETTINGS PLEASE CONSULT TECHNICALMANUAL SUPPLIED WITH BURNER.

JETSTREMEMODEL 45/55 60/80 90/125

OUTPUT KW 16.1 23.4 36.6BTU / HR 55,000 80,000 125,000

BURNER STERLING STERLING STERLING40 40 50

HEAD SETTING 80mm 80mm 80mm

BLAST TUBE 6-7-21-5-10 6-7-21-5-10 10-8-10-6-19

NOZZLE DANFOSS 0.55 x 80EH 0.75 x 80EH 1.0 x 60ES

OIL PRESSURE PSI 115 120 135

AIR SETTING (APPROX) 8 11.5 22

SMOKE NUMBER 0 0 0

CO2 11%-11.5% 11%-11.5% 11%-11.5%

O2 5.8 5.8 5.8

FLOW/RETURN 1" 1" 1"CONNECTIONS

FUEL CONNECTIONS 3/8" BSP 3/8" BSP 3/8" BSP

MINIMUM FLUE DRAUGHT 8.7 N/M3 8.7 N/M3 8.7 N/M3

0.035" WG. 0.035" WG. 0.035" WG.

MAXIMUM FLUE DRAUGHT 37.4 N/M3 37.4 N/M3 37.4 N/M3

0.15" WG. 0.15" WG. 0.15" WG.

MAXIMUM WORKING 45 PSI 45 PSI 45 PSIPRESSURE 3 BAR 3 BAR 3 BAR

ELECTRICAL SUPPLY 230V/50HZ 230V/50HZ 230V/50HZSINGLE PHASE SINGLE PHASE SINGLE PHASE

7.0.0 WIRING DIAGRAMS5.3.0 SERVICING - BURNER3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS9.0 PARTS LISTINGS

1 Top panel C/F2 Top panel B/F3 LH Side panel4 RH Side panel5 Burner access door6 Control panel door7 Electrical Assembly7A Limit Thermostat7B Boiler Thermostat7C Knob7D Red neon7E Green neon7F Orange neon7G Programmer QE27H Magnetic fastener8 Insulation Kit9 Rear panel10 Rear blanking panel11 Boiler jacket weld assy.12 Service door (boiler)13 Insulation for service door14 Lower baffle assy15 Top baffle Plate16 Flue gasket17 Flue spigot18 CF Air Silencer19 Burner EOGB20 BF Hose21 BF Hose Clip x 222 BF Air Duct23 BF terminal assy.23A Inner cover assy23B Outer cover assy23CElbow weld assy23D Inner cover top23E End plate23F End plate gasket23GExternal basket24 Blanking plug (2)

9.1 PARTS IDENTIFICATION AND DIAGRAM – 55 & 80 MODELS

9.0.0 PARTS LIST

9.2 BOILER PARTS DIAGRAM – 55 & 80 MODELS

9.0.0 PARTS LIST

ITEM DESCRIPTION

1 Top Panel Conventional Flue2 Top Panel Balanced Flue3 Left Hand Side Panel4 Right Hand Side Panel8 Insulation Kit11 Boiler Jacket Weld Assembly14 Lower Baffle Assembly (4)15 Top Baffle Plate (1)18 Conventional Flue Air Silencer19 Oil Burner (EOGB)22 Balanced Flue Air Duct30 Shadow Plate31 Insulation Top Front32 Insulation Top Rear (2)33 D-Gasket

9.3 PARTS IDENTIFICATION – 125 MODEL

9.4 PARTS DIAGRAM – 125 MODEL

9.0.0 PARTS LIST - MOTOR

9.5 PARTS IDENTIFICATION AND DIAGRAM – BURNER

ITEM DESCRIPTION

1 Photoresister2 Air Reg Plate3 Electrode Lead4 Nozzle assy5 Nozzle kerosene6 Brake plate7 Blast Tube8 Electrode9 Oil Pipe10 Pump Danfoss11 Drive Coupling12 Air regulation scale13 Fan Wheel 12014 Air adjusting screw15 Motor 90W / I phase16 Statronic TF830-2B17 Relay base Statronic18 Transformer19 Adj Screw Electrode20 Fixing Flange21 Flange Gasket22 Front Gasket

Flexible Oil Pipe(Not shown)

23 Reset Button

9.0.0 PARTS LIST - MOTOR7.0.0 WIRING DIAGRAMS5.3.0 SERVICING - BURNER3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS10.0 USER INFORMATION

IF YOU WISH TO INSERT YOUR OWNPROGRAMME SEQUENCE, PLEASE FOLLOWINSTRUCTIONS BELOW.

10.2.2PROGRAMMING

SET OWNPROGRAMME

Move slide switch to “ SET OWN PROGRAMME”First ON space is displayed programme as requiredor press HOT WATER button to display first hot waterON space.(1) Day button selects day(s)(2) HOUR +/- MINUTES +/- buttons select time(3) HEATING button stores selection in memory as

heating only programme(4) HOT WATER button stores selection in memory

as hot water only programme(5) COPY button stores selection in memory as

heating and hot water programme(6) First OFF programme space is displayed. repeat

steps 2 - 5 . repeat until all required settings areentered.

10.2.3

RUN OWNPROGRAMME

Move slide switch to next position (RUN OWNPROGRAMME)Clock runs (Flashing colon) Your programme is inoperation.

NBTHE SLIDE SWITCH MUST ALWAYS BE LEFT INRUN PRESET PROGRAMME OR RUN OWNPROGRAMME POSITION OTHERWISE THECLOCK WILL NOT RUN AND NO SWITCHING WILLOCCUR. WITH THE SLIDE SWITCH IN EITHERPOSITION, THE HEATING OR HOT WATERBUTTON CAN BE USED MANUALLY TOOVERRIDE THE TIMED FUNCTION.

10.2 PROGRAMMABLE TIMER

10.2.1 Programming (optional extra) guide.

SLIDE SWITCH POSITION BUTTON FUNCTIONS

set time

SET TIMEAND DAY

(1) Move slide switch to “SET TIME AND DAY(2) Press RESET button(3) Press DAY. HOUR +/- MINUTE +/- to set correct

time

RUN PRESETPROGRAMME

(4) Move slide to next position (RUN PRESETPROGRAMME)

(5) Clock runs (flashing colon)(6) Preset programme in operation.(7) Copy button displays ON/OFF times of presetprogramme

ON OFF ON OFFMonday to Friday 6.30am 8.30am 4.30pm 10.30pmSaturday to Sunday 8.00am 11.00am 4.00pm 11.00pmYOUR QE2 WILL NOW RUN ON THE FACTORYPRESET PROGRAMME.

10.1 INTRODUCTION

The Jetstreme boiler must have been installed andcommissioned by a competent person (OFTECapproved) who is familiar with the appropriate rulesand regulations concerning the siting and use of oilfired domestic appliances. Part of the commissioningprocedure requires that the commissioning engineerinstructs the user on the operation of the boiler. In addi-tion to this it is recommended that the user reads theprevious sections of this manual and becomes familiarwith the general operation of the Jetstreme boiler.

WARNINGThe user must not undertake servicing or makeadjustments to the boiler that take it outside itsdesigned operational scope, to do so cancompromise the safe and efficient running of theboiler and will invalidate the warranty offered by themanufacturer.

10.3 BOILER THERMOSTAT

10.3.1This controls the temperature of the water leavingthe boiler for circulation around the system. For themost efficient use of the system the thermostat shouldbe set towards the upper end of its range to providea flow to the radiators of around 80oC and adifferential on the return to the boiler of approximately11oC lower than the flow.

CAUTIONThe boiler must not be run for prolonged periods withthe boiler thermostat set at the lower end of the range asthis will create condensation within the boiler whichultimately can reduce the life expectancy of the appliance.

FIGURE 23 - CONTROL PANEL

10.4 LIMIT THERMOSTAT

10.4.1This is a safety feature that is fitted to the boiler toprevent overheating in the event that the boilerthermostat should fail. The limit thermostat will shutdown the boiler if the threshold limit temperature of103oC is reached.10.4.2It must be noted that if the limit thermostat is triggeredand the boiler is shut down it will be necessary tomanually reset the limit thermostat prior to attemptingto restart the burner. The reset button is situatedbehind the burner access door, and faces verticallydownwards from the electrical assembly housing(right hand end).

WARNINGIf the limit thermostat repeatedly goes to overheatand shuts down the boiler the cause of the problemmust be found and remedied.

10.6 BURNER PROBLEMS

10.6.1If the burner fails to operate the following checksshould be undertaken;(a) Check that the burner ‘lockout’ neon is notilluminated(b) Ensure that limit thermostat has not gone to‘overheat’ (situated behind the burner access door,and faces vertically downwards from the electricalassembly housing - right hand end).(c) Check that the electrical supply to the boiler isturned on(d) Check that the timer is set to an ‘on’ period(e) Check that the boiler thermostat is correctly setIf the burner continues not to fire reset the boilerthermostat to its highest point. If the boiler fires,reduce the boiler thermostat setting to the desiredlevel. If, however, the boiler does not fire adviseshould be sought from an OFTEC approved engineer.

10.5 NEON LAMPS AND BURNER ‘LOCKOUTS’

10.5.1Each control panel features three coloured neonlamps; the red neon indicates that there is a powersupply to the boiler. The green neon indicates aburner is operating. The orange neon indicates‘lockout’ has occurred, and this warning neon willremain illuminated until the lockout has been clearedby following the lockout re-set procedure as detailedin 10.4.4.10.5.2The ‘lockout’ is an in-built safety feature which comesinto operation when the burner controls register thata fault has developed which could damage theburner.

CAUTIONRepeated burner ‘lockouts’ must be investigated toascertain the cause of the problem.10.5.3Some of the more common causes for ‘lockouts’ aredetailed as follows;(a) Fuel starvation - tank empty, filter blocked,valve(s) closed(b) Fuel contamination - water or air, or wrong fuelgrade(c) Ignition failure - burner problem, or due to (a) or (b)Further details are contained within section 6.0 faultdiagnosis.10.5.4If a burner ‘lockout’ is indicated by the orange neon,the following procedure must be used for cancellingthe ‘lockout’ and for resetting the burner;(a) Turn the boiler thermostat to its lowest setting(b) Remove the lower front panel from the boiler(c) Press and release the illuminated red ‘lockout’button on the front of the burner(d) Check that the lights on the reset button (red)and on the control panel (orange neon) go out(e) Turn boiler thermostat back to desired setting(f) Check that the burner fires(g) Replace lower front panel

10.9 USEFUL INFORMATION

10.9.1

Please record details of your installer, commissioningengineer and service engineer for future reference.

Installation Name:Engineer

Address:

Telephone:

Service Name:Engineer

Address:

Telephone:

Commissioning Name:Engineer

Address:

Telephone:

10.9.2Appliance record; installation, commissioning andservice dates

Installation Date:

Commissioning Date:

10.7 SERVICING

10.7.1It is important that your Jetstreme boiler is servicedregularly and in accordance with the manufacturersinstructions. Only competent engineers (OFTECapproved), are allowed to undertake servicing workon the boiler. The maximum interval betweenservicing should not be greater than twelve months.

10.8 ROUTINE CLEANING AND MAINTENANCE

10.8.1The outer panels on the Jetstreme boiler can becleaned using a mild detergent and soft cloth orsponge. Do not use abrasive or scouring cleanersas these will damage the surface of the panels.

10.8.2The oil storage tank, pipework, and valves must beinspected on a regular basis. Any signs of seriouscorrosion or oil leaks must be attended to immediately

SERVICE HELPLINETelephone 024 7635 1424

ALL SECTIONS TO BE COMPLETED:Please refer to Jetstreme service manual for advice on installation.

Fuel type: 28 sec.

Nozzle size:

Pump pressure:

Flue temperature:

CO2

Smoke number:

Efficiency:

Is this boiler installed in a fully pumped system?

When the boiler is at working temperature, the followingshould be noted:

Temperature of flow:

Temperature of return:

Boiler thermostat setting:

Engineer’s comments:

Engineer’s signature Date:

Print surname:

It is in your interest to ensure that this form is returned to:

The Service DepartmentHalstead Boilers Limited,

Freer Street, Attleborough Village,Nuneaton, Warks CV11 4PR.

Telephone 024 7635 1424

Commissioning ReportFull Warranty Registration

Important:Warranty claims will not be considered unless thiscommissioning form has been completed in full andreturned to the service department of HalsteadBoilers Ltd. within 7 days of commissioning.

Boiler model:

Serial number:

Conventional flue / Balanced flue (Delete)

Date of purchase:

Date of installation:

Name of installer:

Address of installer:

Telephone number:

Name of user:

Address of user:

Telephone number:

Name and address of commissioning company /engineer (If different from installer)

COMMISSIONING REPORT. SEND TO BENSON HEATING9.0.0 PARTS LIST - MOTOR7.0.0 WIRING DIAGRAMS5.3.0 SERVICING - BURNER3.5.0 CONVENTIONAL FLUE MODELS3.0.0 INSTALLATION BF AND CF MODELS11.0 COMMISSIONING REPORT FORM.TO BE SENT TO HALSTEAD BOILERS LTD.

Halstead Boilers Limited, 20/22 First Avenue, Bluebridge Industrial Estate, Halstead, Essex CO9 2EX.Tel: 01787 272800. Sales Direct Line: 01787 475557. Fax: 01787 474588. Service Helpline: 024 7635 1424.

e-mail: [email protected] or [email protected] Website: www.halsteadboilers.co.uk

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