INSTALLATION & SERVICING MANUAL FOR 70/90 COMBI BOILER & 70/90 KABIN PAK COMBI LEAVE THESE INSTRUCTIONS WITH THE END USER BS 5750 ISO 9002 PART 2 I ST FI REG RM BSI E R ED NATIONAL ACCREDITATION OF CERTIFICATION BODIES CERT. No.
ISSUE 4 MAR ’03 COMMISSIONING *THIS APPLIANCE MUST BE COMMISSIONED After commissioning ensure that the pre-paid warranty registration card is filled in and returned. SERVICING To ensure continued reliable operation and fuel economy it is recommended that the boiler is serviced annually. Warmflow Engineering Service division provides an excellent back-up service, operating a team of Oftec trained engineers who can meet all the servicing, commissioning and breakdown requirements for your appliance.
BEFORE FITTING THIS BOILER THE INSTALLER MUST CHECK: 1. What the maximum hot water demand is likely to be placed on the boiler. Not every installation is suitable for a Combi boiler. Systems requiring very high hot water flow rates may be better suited with an unvented cylinder. 2. That the mains are capable of supplying up to 24 litre/min with a minimum dynamic pressure of 1.8 bar at the boiler. This is to ensure that the boiler can achieve its maximum output. 3.
Contents Page 1.0 User Instructions ................................................................................................................. 3 1.1 Introduction ................................................................................................................. 4 1.2 General Requirements ................................................................................................ 4 1.3 Components.........................................................................................
1.0 User Instructions 1.0.1 Boiler Control Thermostat The boiler control thermostat is located on the front of the boiler facia panel and may be adjusted from 52°C to 85°C. The recommended minimum thermostat setting is 65°C. Below this ‘cold water corrosion’ is likely to occur thus reducing the life of the heat exchanger and is not covered by the manufacturer’s warranty. When using hot water only it is recommended that the boiler control thermostat is switched to the off position. 1.0.
1.1 Introduction Note: All our domestic appliances have been independently tested and accredited as exceeding the minimum SEDBUK efficiency levels required for its type, in compliance with the Building Regulations Approved Document L1 2001 for England and Wales and the Building Standards (Scotland) Regulations 2001 Part J.
1.3 Components 1.3.1 Combi Assembly 8 9 1 10 11 12 2 13 14 3 4 15 5 16 17 6 18 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Automatic Air Vents Boiler Heat Exchanger Boiler Control and Limit Stat 12 Litre Esxpansion vessel Boiler Data Plate RDB Burner Boiler Drain Valve Pressure Relief Valve Strainer 10. 11. 12. 13. 14. 15. 16. 17. 18. Filling Loop Tank Control and Limit Stat Flow Switch Mixer Valve Plate Heat Exchanger CH Pump Head DHW Pump Head Pump Gate Valves (x3) Tank Drain Valve 1.3.
1.3.3 Kabin Combi Assembly 1 2 3 4 5 6 24 7 23 8 22 21 9 20 19 10 11 1. 2. 3. 4. 5. 6. 7. 8. Flue Terminal Guard Low Level Flue Service Access Hatch Control Panel Cover Controls Pressure Vessel Control Panel Flap Lock Control Panel Flap 9. 10. 11. 12. 13. 14. 15. 16. 12 13 14 16 15 17 Door Panel Burner Reset Burner Reset Button Burner Return Connection DHW Pump CH Pump Cable on Oil Line Grommets 18 17. 18. 19. 20. 21. 22. 23. 24.
2.0 Technical Details 2.
2.2 Baffles FRONT Before firing make sure the baffles have not been dislodged in transit and are correctly positioned. To achieve maximum efficiency push the baffles in the direction of the arrows as shown. 2.3 General Requirements 1. The Warmflow Combi is supplied with all the necessary components for a sealed heating system. However, on some larger systems with a total water content greater than approx 150L, an expansion vessel, in addition to the integral 12L vessel supplied, may be required. 2.
2.4 Dimensions 2.4.1 Combi Dimensions B K J L C H A G F D E MODEL A B C D E F G H J K L 70/90 865 595 595 90 59 554 750 125 127 127 203 2.4.2 Combi Boiler Connections 1620 1310 820 460 1 2 3 4 8130 8000 8045 5 6 REAR VIEW All dimensions are given in mm. 1. 2. 3. Cold Mains (15mm) Heating Flow (22mm) Domestic Hot Water (22mm) 4. 5. 6.
2.4.3 Kabin Pak Combi Dimensions H E J G F D A B 2.5 C MODEL A B C D E F G H J 70/90 892 732 636 373 188 191 376 172 371 Combi Flue Options (not applicable to the Kabin Pak Combi) Note: Low level flue options are rear or left hand outlet only. 2.5.1 ‘Easy Fit’ Telescopic Low Level Balanced Flue (BF-R) The horizontal dimension can be increased up to an additional 1200mm using a combination of long extension pieces (E600 = 600mm) and short extension pieces (E300 = 300mm).
2.5.2 ‘Easy Fit’ High Level Balanced Flue (HLBF) The HLBF is available in 4 fixed horizontal lengths which are: SEE OPTIONS Option 1 – 455mm 160x160 Option 2 – 655mm Option 3 – 585mm Option 4 – 785mm 1128 225 MAX 175 MIN 2.5.3 ‘Easy Fit’ Telescopic Low Level Conventional Flue (LLF-R) 102 Ø125 155 MIN 225 MAX 792 MAX 540 MIN 2.5.4 Standard Low Level Conventional Flue (LLF) The factory supplied elbow may be extended up to 1m horizontally and 1.
AVAILABLE FROM SPRING 2003 2.5.5 Easy Fit Telescopic High Level Balanced Flue (HLBF-R) A EXTENSION KITS AS REQUIRED (PACKS C OR D) PACK E OR F PACK E OR F 175 MIN 225 MAX ALL MODELS DIM A FLUE PACKS MIN MAX 435 610 A+E 560 860 A+F 735 910 A+C+E 1570 MIN 2070 MAX 50/70, 70/90 & 90/120 MODELS ONLY PACK A DIM A FLUE PACKS MIN MAX 860 1160 A+C+F 1035 1210 A+C+C+E 1160 1510 A+C+C+F 1385 1560 A+D+E 1510 1860 A+D+F 2.5.
2.6 Technical Data 70/90 Combi Model Nominal heat Input Nominal heat Output Efficiency at max output (net) KW Btu/hr KW Btu/hr % Burner Head Flue mm 70/90 Kabin Pak Combi 29.3 29.3 100,000 100,000 26.4 26.4 90,000 90,000 90 90 RDB 1 RDB 1 LD3 LD3 100 or 127 Integral Size in 4 or 5 Low Level Max CO2 % 11.5-12.0 11.5-12.0 0-1 0-1 °C 235 235 mbar 12.0 12.0 l/h 3.15 3.15 Flow rate gals/h 0.69 0.69 Nozzle make DANFOSS 60°S DANFOSS 60°S (kerosine) size 0.75 0.
3.0 Electricity Supply 220 - 240V. 1PH, 50 Hz The boiler/burner and other external electrical equipment should be wired via a fused double pole isolating switch which should be fitted with a 5 amp fuse. In order to ensure the safety of the Kabin Pak Combi Warmflow recommends that power to the appliance is supplied through a suitable CE approved RCD trip switch. The appliance must be effectively earthed and all external wiring should comply with current IEE Regulations.
P O Y R W BR BL B G/Y 3.3 3.3.
BREAK INTO THE WHITE WIRE BETWEEN NO 16 ON THE PCB AND THE LIMIT STAT AND CONNECT IN THE PRESSURE SWITCH WITH A WIRING BLOCK AS SHOWN 3.3.
P O Y R W BR BL B G/Y GY 3.4 3.4.
BREAK INTO THE WHITE WIRE BETWEEN NO 16 ON THE PCB AND THE LIMIT STAT AND CONNECT IN THE PRESSURE SWITCH WITH A WIRING BLOCK AS SHOWN 3.4.
3.5 Frost Thermostats 3.5.1 Combi Boilers The switched live from the frost thermostat (the frost thermostat must be supplied by a permanent live) should be connected to number 5 on the boiler terminal block. In order to protect the fabric of the building as well as the boiler and pipework, the thermostat should be located in the coldest part of the house but where it can respond to any temperature rise. FROST THERMOSTAT PERMANENT LIVE 3 4 5 6 3.5.
3.6 Timers for Standard Combi Note: Single channel timers or programmers are not recommended. 3.6.1 Installation of a remote two channel programmer (option 1) Remove the purple wire connecting 5 and 28 and the white wire connecting 3 and 19. Connect the programmer as shown via a fused isolator. E This bypasses the central heating and hot water on/off switch. N L CH HW COM COM OFF ON OFF ON 12 11 If the connection to terminal 12 is not made the mains on lamp is also bypassed.
3.6.3 Installation of Warmflow Optional Programmer (not applicable to the Kabin Pak Combi) 1. Disconnect the electrical supply. 2. Remove top casing (4 studs) and control box cover (1 screw). 3. Remove 2 screws securing blanking plate/programmer bracket. Remove bracket and blanking plate from the control panel. 4. Disconnect the blanking plate from bracket (2 screws). 5. Feed programmer harness through the hole in the bracket. The programmer is secured to the bracket with 2 screws. 6.
3.7 Timers for Kabin Pak Combis Note: Single channel timers or programmers are not recommended. 3.7.
4.0 Oil Supply 1. Oil Tank Steel tanks constructed to BS 799 Part 5 1987 should be painted on the outside only and mounted on piers to prevent corrosion. Plastic oil tanks are also available and can be suitable for installation at ground level. However, oil should never be stored in translucent plastic containers. The tank outlet should be at a height to provide sufficient clearance to allow for proper maintenance of any isolation valve oil filter or water separator fitted. 2.
4.2 Two Pipe System APPROVED SITE GAUGE 20mm PER METRE SLOPE WATER SEPARATOR Total Maximum Pipe Length (m) 4.3 Lift H(m) 0.5 I.D. 8 mm I.D. 10 mm 35 100 1 1.5 2 30 25 20 15 8 6 100 100 90 70 30 20 0.5 3 3.
4.4 One Pipe Lift APPROVED SITE GAUGE Note: The pump vacuum should not exceed a maximum of 0.4 bar. Above this gas is released from the oil thus leading to burner lock out. 20mm PER METRE SLOPE WATER SEPARATOR Total Maximum Pipe Length (m) Lift H(m) 0.5 0.5 1 1.5 2 3 3.
5.0 Flues 5.1 Conventional Flues The flue should be designed in accordance with the local bye-laws and the Clean Air Act. Draught stabilisers are not recommended for oil fired boilers. Sharp bends or horizontal runs should be avoided and the flue should terminate 2 feet (600 mm) above the ridge of the dwelling. Terminals which restrict the discharge or allow ingress of water should be avoided.
Terminal Position A B C D E F G H I J K Min Distance Below gutters, soil pipes or drain pipes From a door, window or air vent Above ground, flat roof or balcony level Below eaves or balconies From an internal or external corner From a terminal facing the terminal From a surface facing the terminal Vertically from a terminal on the same wall Horizontally from the terminal on the same wall Directly below an opening, air brick, window, etc.
6.0 Air Supply for Combustion and Ventilation (see BS 5410) 6.1 Open Flue Boilers When the boiler is sited in a cellar where the only access for combustion and ventilation air is at high level then the combustion air should be ducted to low level. Combustion Air Supply Boiler in Room Boiler in Compartment 6.
6.
6.3.1 Installation of a Balanced Flue (BF-R, HLBF-R & VBF) 1. Make a suitable sized hole in the wall or ceiling for the flue kit. Add the dimensions given on pages 6 (Dimension G) and 8 (Flue Vertical Dimension). The cavities around the opening must be sealed and protected by a non-combustable sleeve. 2. Remove the top panel (kitchen and utility models) and the combustion chamber lid. 3.
6.3.2 Installation of Telescopic Low Level Conventional Flue Installation instructions as per the balanced flue except there is only an inner seal, the burner does not require modification and there is no flexible hose to be fitted. In addition the low level flue should only protrude through the wall by a minimum of 155mm and a maximum of 225mm. 6.3.3 Installation of Standard Low Level Flue (LLF) After cutting a hole in the wall place the flue in the hole.
8.0 Installation The boiler installation must be in compliance with BS 5410 Part 1 1997 and the Building Regulations. 8.1 Hearth The boiler hearth temperature is between 50OC and 85OC and should be stood on a rigid, non-porous, non-combustible base, which is not softened by warmth to comply with the Building Regulations. 8.2 Service Access 8.2.1 Combi 24" (600 mm) Clearance should be provided above and in front of the boiler to allow for routine servicing.
8.3.4 Boiler Connections All connections to the appliance should be made with compression fittings. 8.3.5 Additional Requirements for a Kabin Pak Combi 1. Although the Kabin Pak is manufactured from galvanised sheet it is recommended that after a period of weathering (approx 4-8 weeks) that the Kabin Pak is painted with a suitable primer and finish coat to prevent corrosion. 2.
8.4 Domestic Hot Water The mains water supply pressure must be less than 5 bar. If this pressure is exceeded a pressure reducing valve must be fitted. The final 600 mm of the mains supply pipe to the appliance must be in copper. The flow rate of water from individual taps is dependant on the number of outlets being operated together, as well as the length and size of pipework in the system and the mains supply pressure flow regulators.
8.6 Fitting a Vertical Flue Adaptor 1. Remove the 2 self tappers connecting the flue main body to the Kabin Pak and lift off. It may be necessary to break the seal between the flue main body and the top of the flue pipe. 2. Ensure that the gap between the existing flue pipe and the top of the Kabin Pak is properly sealed with high temperature silicone sealant. 3. Once the flue main body has been removed fit the Kabin Pak adaptor (KPA) into position and secure with the 2 self tapping screws.
9.0 Burners 9.1 RDB Burner The burner is fitted with the correct nozzle and the pressure set. All that is further required before commissioning, is to connect the oil and electricity supply. 1. 2. 3. 4. 9.2 Pump Control box Reset button with lock-out lamp Flange with insulating gasket 5. 6. 7. 8. Air damper adjustment screw Air tube connection (supplied with BF kit) Pump pressure adjustment screw Pressure gauge port Oil Supply The burner is supplied for use with a one pipe system.
9.3 Electrical Connections The boiler control equipment and the burner are provided ex works, it is only necessary to connect a 230V 50Hz supply in accordance with the electrical drawings. 9.4 Electrode Setting Attention Before assembling or removing the nozzle, loosen the screw (A) and move the electrodes away from the nozzle. 9.
10.0 Commissioning and Servicing 10.1 Commissioning Note: IT IS RECOMMENDED THAT AN OFTEC TRAINED AND REGISTERED TECHNICIAN SHOULD BE USED. IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE BOILER IS PROPERLY COMMISSIONED. SEE BS 5410. FAILURE TO DO SO MAY INVALIDATE THE WARRANTY. Combustion tests must be carried out using a Combustion Analyser. The pump pressure can be checked by fitting a manifold and a pressure gauge to the oil pump.
11.0 Horstmann 626 Electronic Programmer (not applicable to Kabin Pak Combi) User Instructions G Note: Ensure selection switch on the rear of the programmer is at the correct setting ‘G’ for HW only or HW and CH. ‘P’ for independent HW and CH. The programmer is factory set at its mid-position. P HORSTMANN TIMERS & CONTROLS Ltd: NEWBRIDGE ROAD, BATH. 626 OEM - WARMFLOW 220-250V 50Hz 5(2)A HEATING 1 2 T.
Setting the Time of Day Press the SET button so that the SET indicator is pointing to the CLOCK position on the front of the programmer. The DAY OF THE WEEK indicator will now flash. Use the PLUS(+) or MINUS(-) buttons to move the DAY OF THE WEEK Indicator to the current day of the week. Numbers relating to the days of the week are printed along the top of the programmer display, i.e. 1 = Monday, 2 = Tuesday, etc. Press the ENTER button. The TIME OF DAY will now flash.
Adjust the flashing time as required by using the (+) AND (-) BUTTONS THEN PRESS ENTER. The display will now show ‘1 OFF’ and the first programmed OFF time for the day will flash. This can be altered in the same way as the ‘1 ON’. Follow the same procedure for the 2nd and 3rd ON/OFF times remembering to press ENTER after each change to the programme. If you do not wish to alter a particular time then simply press ENTER and the display will move on to the next ON/OFF time leaving the previous one unchanged.
1. 2. 3. 4. 5. 6. 7. 8. Hot water ON indicator. Central heating ON indicator. Advance button. Hot water programme select button. Central heating programme select button. Programme positions. Central heating programme indicator. Hot water programme. Programme Selection The following programmes can be selected for either HOT WATER by itself, CENTRAL HEATING by itself or HOT WATER and HEATING together.
Using the Advance The ADVANCE facility allows you to bring forward the next ON or OFF period without having to alter the programmed ON/ OFF times. Press the ADVANCE button once and release. The word ADVANCE will appear in the display. If the programmer was originally ON it will now switch OFF and stay OFF until the next programmed ON time. The opposite will apply if the programmer was originally OFF. In both cases the unit will then revert to the normal programme times.
12.0 Fault Finding 12.1 Central Heating Switch on power, set selectors for CH on and DHW off. Set all controls to call for heat. Does the burner fire? YES Do radiators get hot? YES Is lockout lamp on burner or panel lit? Does boiler cycle on its thermostat? NO Is high limit Press reset YES thermostat lamp button, replace if lit? necessary. NO Check wiring, replace boiler thermostat. NO Is there continuity across the boiler stat connections 17 and 18 on the PCB? YES Check relay and PCB, replace.
12.2 Domestic Hot Water Switch on power, set selectors to CH off and DHW on. NO Is DHW pump working? YES Is there continuity across connection 20 and 21 on the PCB? NO Check wiring, replace tank thermostat. NO Check wiring, replace relay, replace PCB. YES Check plumbing, replace non-return valve. NO Vent all air from system pumps, ensure all valves are open. NO Replace tank stat, replace relay. YES Is there continuity across 25 and 27? YES Check wiring, replace pump.
12.3 Burner START Switch on electricity supply. Set all boiler controls and external controls to call for heat. NO Does burner motor start? NO Check motor wiring fuse, boiler control and limit thermostat. Check power supply. Is burner lockout lamp lit? YES YES Press reset button. Check for pump seizure. Faulty capacitor or faulty motor.
13.0 Spares 13.
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Lisburn Manchester Dublin Lissue Industrial Estate, Moira Road, Lisburn, Co Antrim, N Ireland, BT28 2RF Tel: (028) 9262 1515 Fax: (028) 9262 0869 E-mail: sales@warmflow.co.uk 144 Bradford Road, Manchester, M40 7AS Tel: (0161) 205 4202 Fax: (0161) 205 4818 E-mail: sales@warmflow.co.uk Balbriggan Industrial Estate, Dublin Tel: (01) 841 6158 Fax: (01) 841 6614 FOR PARTS, SERVICE & WARRANTY CONTACT TEL: (028) 9262 1515 FAX: (028) 9262 2827 service@warmflow.co.
