Boiler Manual Incorporating: Guarantee Registration User Instructions Installation Instructions Service Instructions Service Record High Efficiency Condensing Boilers For use with kerosene only Models covered by this manual: U-Series Utility Utility Pumped Utility System Utility Combi K-Series Kabin Pak Kabin Pak Pumped Kabin Pak System Kabin Pak Combi U70HE UP70HE US70HE UC70HE U90HE UP90HE US90HE UC90HE U120HE UP120HE US120HE U150HE UP150HE K70HE KP70HE KS70HE KC70HE K90HE KP90HE KS90HE KC90HE
ISSUE 3 AUG 08 Commissioning This appliance must be commissioned. Failure to commission the boiler will invalidate the warranty. After commissioning ensure that the attached guarantee registration card is completed and returned. Alternatively, you can register your guarantee online at www.warmflow.co.uk Servicing To ensure continued reliable operation and fuel economy it is recommended that the boiler is serviced annually by a Warmflow or an OFTEC registered technician.
Contents Page User Instructions......................................................................................................................................................................2 Condensing Boiler Installation Requirements.......................................................................................................................4 Condensing Combi Boiler Pre-Installation Requirements..............................................................................................
USER INSTRUCTIONS Dual Thermostat The radiator temperature is regulated via the boiler control thermostat. The thermostat is user adjustable from 55°C at its minimum setting (dial ‘0’) to 85°C at its maximum setting (dial ‘5’). In order to provide an additional level of safety there is a high limit thermostat which has a cut off point of 110°C; this is factory set and is not adjustable. If thermostat trips it needs to be reset manually.
Filling Loop If the system pressure falls below the minimum (eg, removal of radiator for decorating purposes) then the system should be topped up using the filling loop valve. After the system has been topped up the pressure gauge should read 1 bar when the system is cold. The valve must be fully closed and the filling loop flexible removed from the valve, expect a small water loss from the pipe.
CONDENSING BOILER INSTALLATION REQUIREMENTS The Warmflow condensing boiler can be fitted to most installations using standard practices and techniques. There are however a number of considerations that must be taken into account. 1. All existing systems must be properly flushed to remove any sediment/ sludge in order to prevent any blockage or reduction in efficiency of the boiler. 2. The system must be fully pumped. 3.
BEFORE FITTING A COMBI BOILER THE INSTALLER MUST CHECK: 1. What the maximum hot water demand placed on the boiler is likely to be. 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.
1.0 General Information 1.1 Introduction Note: All our domestic appliances have been independently tested and accredited as exceeding the minimum SEDBUK efficiency levels required for their type, in compliance with the Building Regulations Approved Document L1A, L1B for England and Wales, the Building Standards (Scotland) Regulations Section 6, Part F Northern Ireland and Part L Republic of Ireland.
1.3 Combi General Requirements The boiler will have a DHW priority when both domestic hot water (DHW) and central heating (CH) are selected. So if the flow switch is closed or the heat store has not been satisfied the entire output of the boiler is directed to DHW before the boiler will switch over to CH. When fully cold it can take up to 20 minutes for the heat store of a 90,000 Btu/h combi to be satisfied, and slightly longer for a 70,000 Btu/h combi.
Page 1.4 150 HE Models The primary heat exchanger baffles consist of two half-width baffle stacks at the bottom, 3 full-width baffle stacks in the middle and 1 baffle plate at the top. Upon installation or after servicing, ensure the baffles are in the correct order and correctly stacked. To achieve maximum efficiency, push the primary heat exchanger baffles in the direction of the arrows as shown.
Page Components 5 Boiler Assembly Top Casing (removable) Rear Casing Side Casing Front Casing (removable) Models up to 120 HE 1. 2. 3. 4. 5. 1 2 1.5.1 U-Series Utility – Casing Components 1.5 3 4 7 1 2 3 Boiler Assembly Top Front Casing (removable) Top Rear Casing (removable) Rear Flue Casing Rear Casing (removable) Side Casing Front Casing (removable) 150 HE Models 1. 2. 3. 4. 5. 6. 7.
Page 10 9 Models up to 120 HE 10 6 1. Heat Exchanger 2. Condensing Unit 3. Auto Air Vent 4. Service Door 5. ‘Dual-Safe’ Thermostat 6. Heat Exchanger Baffles 7. Service Door 8. Service Door Cover 9. Condensate Trap 10. Riello RDB 2.2 Burner 11. Heating Flow Connection 12. Heating Return Connection 8 5 3 7 4 12 1 2 11 1.5.2 U-Series Utility – Pre-Wired (UHE) – Key Components 9 150 HE Models 6 10 1. Heat Exchanger 2. Condensing Unit 3. Auto Air Vent 4. Service Door 5.
Page 11 Models up to 120 HE 14 10 1. Heat Exchanger 2. Condensing Unit 3. Pipework Assembly 4. Pressure Relief Valve 5. Auto Air Vent 6. Circulating Pump 7. Auto Air Vent 8. Service Door 9. ‘Dual-Safe’ Thermostat 10. Heat Exchanger Baffles 11. Service Door 12. Service Door Cover 13. Condensate Trap 14. Riello RDB 2.2 Burner 15. Heating Flow Connection 16. Heating Return Connection 13 12 9 7 6 5 11 8 15 16 4 1 2 3 1.5.
1.5.4 U-Series Utility – System (USHE) – Key Components 1. 2. 3. 4. 5. 6. 7. Pumped (UPHE) Boiler Assembly System Kit (SK1) Pressure Gauge Expansion Vessel Filling Loop Heating Flow Connection Heating Return Connection 1 6 7 2 3 4 5 1.5.5 U-Series Utility – Combi (UCHE) – Key Components 1. Heat Exchanger 2. Heat Store 3. Condensing Unit 4. Service Door 5. Pipework Assembly 6. Plate Heat Exchanger 7. Twin Head Pump 8. Condensate Trap 9. Service Door 10. Service Door Cover 11. Control Panel 12.
Page 13 8 Models up to 120 HE 1 2 6 4 1. 2. 3. 4. 5. 6. 7. 8. 3 5 7 Boiler Assembly Top Casing (removable) Flue Assembly (removable) Rear Flue Casing Blanking Plug (removable) Rear Casing (removable) Side Casing Front Casing (removable) 1.5.6 K-Series Kabin Pak – Casing Components 8 1 2 Boiler Assembly Top Casing (removable) Flue Assembly (removable) Rear Flue Casing Blanking Plug (removable) Rear Casing (removable) Side Casing Front Casing (removable) 150 HE Models 1. 2. 3. 4. 5. 6. 7. 8.
Page 14 10 9 8 Models up to 120 HE 6 5 3 7 4 2 1 11 1. Heat Exchanger 2. Condensing Unit 3. Auto Air Vent 4. Service Door 5. ‘Dual-Safe’ Thermostat 6. Heat Exchanger Baffles 7. Service Door 8. Service Door Cover 9. Condensate Trap 10. Riello RDB 2.2 Burner 11. Heating Flow Connection 12. Heating Return Connection 12 1.5.7 K-Series Kabin Pak – Pre-Wired (KHE) – Key Components 9 150 HE Models 6 10 1. Heat Exchanger 2. Condensing Unit 3. Auto Air Vent 4. Service Door 5.
Page 15 Models up to 120 HE 14 10 1. Heat Exchanger 2. Condensing Unit 3. Pipework Assembly 4. Pressure Relief Valve 5. Auto Air Vent 6. Circulating Pump 7. Auto Air Vent 8. Service Door 9. ‘Dual-Safe’ Thermostat 10. Heat Exchanger Baffles 11. Service Door 12. Service Door Cover 13. Condensate Trap 14. Riello RDB 2.2 Burner 15. Heating Flow Connection 16. Heating Return Connection 13 12 9 7 6 5 11 8 15 16 4 2 1 3 1.5.
1.5.9 K-Series Kabin Pak – System (KSHE) – Key Components 1. 2. 3. 4. 5. 6. 7. Pumped (KPHE) Boiler Assembly System Kit (SK1) Pressure Gauge Expansion Vessel Filling Loop Heating Flow Connection Heating Return Connection 1 6 7 2 3 4 5 1.5.10 K-Series Kabin Pak – Combi (KCHE) – Key Components 1. Heat Exchanger 2. Heat Store 3. Condensing Unit 4. Service Door 5. Pipework Assembly 6. Plate Heat Exchanger 7. Twin Head Pump 8. Condensate Trap 9. Service Door 10. Service Door Cover 11. Control Panel 12.
1.5.11 Combi Control Panel Layout Control Thermostat Mains On Lamp (Green) High Limit Tripped Lamp (Yellow) High Limit Thermostat Reset (Underneath) HW On/Off Switch 1.5.
2.0 Technical Details 2.
2.2 Dimensions 2.2.
2.2.
2.2.
2.2.
2.2.8 K-Series Kabin Pak (KCHE Models) KCHE DIMS MODEL KC~ A 700 B 600 R S T U V 700 705 117 67 C 600 D 900 E 770 F 210 G 396H 209J 92 K 161 L 52 M 50 N50 P R S A B 40 T 90 U 40 V 67 W 415 X 65 900 90 40 67 770 C D 210 E 396 209 F G 92 161 H J 52 K 50 L 50 M 705 N 117 P 67 40 2.2.
2.3 Flue Options, Components & Dimensions The use of any flue system other than that supplied or recommended by the manufacturer will invalidate the warranty. 2.3.1 HE Low Level Balanced Flue Kit (FBF) Comprising the following four main components. 2.3.2 Plume Management Kit 4 Plume Management Kits are available for our range of appliances. Please refer to the Installation Instructions supplied with the kits. 3 5 2 1. 2. 3. 4. 5.
2.3.3 Warmflow HE Boiler Flue Components: 80/125 Ø Note: 1. Flue fitting kit required. 2. If terminal is less than 2 metres above ground level terminal guard must be fitted. 3. Extension pipes and flue adaptor lengths quoted are effective lengths and not the actual length of the piece. 4. All dimensions in mm unless otherwise stated.
2.3.4 Vertical & High Level Terminal Options BOILER OUTPUT (kW) TOTAL EQUIVALENT FLUE LENGTH (m) Vertical Balanced Flue High/Low Level Balanced Flue 15 8.0 5.0 21 8.0 5.0 26 8.0 5.0 30 6.0 3.5 33 4.0 2.5 44 4.0 2.5 Note: 1. All flues can utilise any combination of bends, straights, adaptors and terminals. 2. Ensure flue is arranged such that it falls continuously towards the boiler. 3.
2.4 Condensate Disposal The Warmflow high efficiency condensing boiler is supplied with a factory fitted, self sealing condensate trap. The trap has been fitted inside the boiler casing to the right hand side. The condensate drainage pipe within the boiler is a flexible plastic hose which can be trimmed to length. 3/4” or 22mm pipe should be connected to the flexible hose. The pipe should not be made from steel or copper.
2.5 Technical Data 2.5.1 U-Series Utility – Pre-Wired (UHE) MODEL U70HE Nominal kW 14.7 U90HE 17.6 21 U120HE 23.5 21 27.1 29 27.1 U150HE 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22 24.4 22 28 30 28 34 40 33 46.8 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 112,629 136,139 159,681 Heat Input Burner RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.
2.5.2 U-Series Utility – Pumped (UPHE) MODEL UP70HE Nominal kW 14.7 21 23.5 21 27.1 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 Heat Output Nominal kW 15.3 18.4 22 24.4 22 28 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 Heat Input UP150HE UP120HE UP90HE 17.6 29 27.1 32.7 38.5 33 44 92,380 99,050 111,600 112,629 131,362 150,128 30 28 34 40 33 46.8 95,550 102,400 116,000 112,629 136,139 159,681 Burner RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.2 26-33 RDB 3.
2.5.3 U-Series Utility – System (USHE) MODEL US70HE Nominal kW 14.7 US90HE 17.6 21 23.5 21 US120HE 27.1 27.1 29 32.7 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 92,380 99,050 111,600 Heat Output Nominal kW 15.3 18.4 22 24.4 22 28 30 28 34 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 Heat Input Burner RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.
2.5.4 U-Series Utility – Combi (UCHE) MODEL Nominal Heat Output UC70HE UC90HE kW 14.7 17.6 21 21 23.5 27.1 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 Nominal Heat Input kW 15.3 18.4 22 22 24.4 28 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 Burner Head Secondary Air Damper Flue Diameter Flue Gas Temp Smoke Kerosene Settings Nozzle Oil Pump Pressure Water Content RDB 2.2 21-26 T2SH N/A 100 or 125 4 or 5 100 or 125 4 or 5 mm in °C Bacarach 88 0 86 90 90 Danfoss 60°ES 0.5 0.6 0.
2.5.5 K-Series Kabin Pak – Pre-Wired (KHE) MODEL K70HE Nominal kW 14.7 K90HE 17.6 21 K150HE K120HE 23.5 21 27.1 29 27.1 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22 24.4 22 28 30 28 34 40 33 46.8 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 112,629 136,139 159,681 Heat Input Burner RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.2 26-33 RDB 3.
2.5.6 K-Series Kabin Pak – Pumped (KPHE) MODEL KP70HE Nominal kW 14.7 KP90HE 17.6 21 KP150HE KP120HE 23.5 21 27.1 29 27.1 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22 24.4 22 28 30 28 34 40 33 46.8 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 112,629 136,139 159,681 Heat Input Burner RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.2 26-33 RDB 3.
2.5.7 K-Series Kabin Pak – System (KSHE) MODEL KS70HE Nominal kW 14.7 KS90HE 17.6 21 23.5 21 KS120HE 27.1 27.1 29 32.7 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 92,380 99,050 111,600 Heat Output Nominal kW 15.3 18.4 22 24.4 22 28 30 28 34 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 Heat Input Burner RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.
2.5.8 K-Series Kabin Pak – Combi (KCHE) MODEL KC70HE KC90HE Nominal Heat Output kW 14.7 17.6 21 21 23.5 27.1 Btu/hr 50,000 60,000 71,650 71,650 80,000 92,380 Nominal Heat Input kW 15.3 18.4 22 22 24.4 28 Btu/hr 52,150 62,600 75,000 75,000 83,175 95,550 Burner Head Secondary Air Damper Flue Diameter Flue Gas Temp Smoke Kerosene Settings Nozzle Oil Pump Pressure Water Content RDB 2.2 21-26 T2SH N/A 100 or 125 4 or 5 100 or 125 4 or 5 mm in °C Bacarach 88 0 86 90 90 Danfoss 60°ES 0.5 0.6 0.
3.0 Electricity Supply & Wiring Details 220 – 240V. 1PH, 50 Hz The boiler/burner and other external electrical equipment should be wired with heat resistant cable via a fused double pole isolating switch which should be fitted with a 5 amp fuse. The appliance must be effectively earthed and all external wiring should comply with current IEE Regulations. 3.
The 3 pin mains plug must be supplied with a permanent live to allow the pump overrun stat and relay to operate correctly. 3.3 Combi Wiring Details 3.3.
Page 38 N L1 MAINS PLUG 16 N E L1 1 13 14 1 2 4 6 N BOILER LIMIT STAT H/L RESET LAMP (YELLOW) 7 C.H. H.W. MAINS ON LAMP (GREEN) 15 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 5 3 19 20 25 N 26 TANK STAT 21 24 28 TANK LIMIT STAT FLOW SWITCH 23 22 C N.C. N.O. C COIL LOW PRESSURE SWITCH N.C. N.O. C N.C. N.O.
3.3.3 Fitting a Room Thermostat to a Combi PCB 26 27 28 29 30 N 5 ROOM THERMOSTAT Remove the purple wire from no 5 and no 28 on the PCB and wire the thermostat as shown. The room thermostat should be located where it is not subjected to extraneous heat gains, direct sunlight or draughts. 3.3.
3.4 Installation of a Warmflow Combi Optional Programmer (PC1) 1. Disconnect the electrical supply. 2. Drop down control box front (2 screws). 3. Disconnect the 6 pin plug from the CH/HW on/off switched. 4. With a sharp knife cut out the outline of the panel knockout through the facia label from the front of the panel. 5. With a hacksaw blade or snips remove the knockout piece ensuring that all metal tags or burrs have been removed from the hole. 6.
3.5 Remote Timers for Combis 3.5.1 Installation of a remote two channel programmer (option 1) Connecting the programmer in this manner will bypass the CH and HW on/ off switches on the boiler control panel. A separate connection to the boiler 3 pin mains plug is NOT required. Inside the boiler control panel, remove the purple and white wires connecting terminals 5 and 3 on the terminal block with terminals 19 and 28 on the PCB.
3.6 Optional Programmer (PU1) for Non-Combi Models 3.6.1 Programmer Control Box Wiring Diagram 3.6.2 General Requirements 1. The optional programmer as supplied will supply power to the pump and burner via the central heating channel. 2. When connecting to external controls, eg ‘Y’ plan or ‘S’ plan it will be necessary to remove the loop between 3 and 12 on the programmer terminal block. 3. The programmer is not suitable for gravity hot water systems.
3.6.3 Programmer Installation 1. Disconnect electrical supply. 2. Drop down control box front (2 screws). 3. Secure control box to the horizontal casing bracket (2 screws) and right hand side (1 screw). 4. Connect the thermostat, circulating pump and the mains supply to the leads on the rear of the control box. 5. Two examples of system wiring are shown in the following sections. 6.
3.6.4 Honeywell ‘Y’ Plan – Independent CH & DHW (Fully Pumped Only) Note: Before fitting programmer remove loop between 3 and 12 on the terminal block.
3.6.5 Honeywell ‘S’ Plan – Independent CH & DHW (Fully Pumped Only) Note: Before fitting programmer remove loop between 3 and 12 on the terminal block.
4.0 Oil Supply 1. Oil Tank Steel tanks constructed to BS799 : PART 5 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 Total Maximum Pipe Length (m) Head H(m) 0.5 0.5 1 1.5 2 3 ID 8mm 35 30 25 20 15 8 ID 10mm 100 100 100 90 70 30 4.3 3.5 6 20 De-aerator System For maximum pipe length and lift contact de-aerator manufacturer.
4.4 One Pipe Lift System 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. Total Maximum Pipe Length (m) Head H(m) 0.5 0.5 1 1.5 2 3 ID 8mm 35 30 25 20 15 8 ID 10mm 100 100 100 90 70 30 Page 48 3.
5.0 Flues 5.
5.1.1 Installation of a Balanced Flue (FBF) 1. Make a suitable sized hole in the wall or ceiling for the flue. For the dimensions of the boiler, see the Dimensions Section of this manual. For the dimensions of the flue system, see the Flue Kits & Dimensions Section of this manual. Note: The cavities around the opening must be sealed and protected by a noncombustible sleeve. 2. Remove the top casing panel.
5.2 Conventional Flues The flue system should be designed in accordance with local bye-laws and the Building Regulations. Draught stabilisers are not recommended for oil fired boilers. Sharp bends or horizontal runs should be avoided and the flue should terminate 2 feet (600mm) above the ridge of the dwelling. Terminals which restrict the discharge or allow ingress of water should be avoided.
MINIMUM DISTANCES TO TERMINALS IN MILLIMETRES AS MEASURED FROM THE TOP OF THE CHIMNEY OR THE RIM OF A LOW LEVEL DISCHARGE OPENING A Directly below an opening, air brick, opening window etc. 600 B Horizontally to an opening, air brick, opening window etc. 600 C Below a gutter, eaves or balcony with protection. 75 D Below a gutter or a balcony without protection. 600 E From vertical sanitary pipework. 300 F From an internal or external corner or surface or boundary alongside the terminal.
6.0 Air Supply for Combustion & Ventilation (see BS5410) 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.
7.0 Installation Requirements The boiler installation must be in compliance with BS5410 : PART 1 and the Building Regulations. 7.1 General Requirements 7.1.1 Hearth The boiler has a hearth temperature of between 50°C and 85°C and should be stood on a rigid, non-porous, non-combustible base, which is not softened by warmth, to comply with the Building Regulations. 7.1.2 Service Access 24” (600mm) Clearance should be provided above and in front of the boiler to allow for routine servicing.
7.2 Sealed Systems 7.2.1 Expansion Vessel Refer to BS7074: PART 1 and BS5449 for details of expansion vessel sizing. The values given in the table below are for total system volumes which include the primary water capacity of the boiler which can be found in the Technical Data section of this manual. System and Combi models up to 120HE are supplied with a 12 litre expansion vessel charged to 1.0 bar. This can accommodate a maximum combined boiler and system volume of 110 litres.
7.3 Combi Domestic Hot Water 7.3.1 Mains Water Pressure To protect the appliance and to prevent excessive flow rates, a pressure reducing valve must be fitted to limit the maximum supply pressure to 3 bar. We strongly advise that all installation pipework is run in copper. However, if plastic pipe is used, it must be recommended by the pipe manufacturer for use with oil fired appliances and, in any case, the last 1000mm of pipework connected directly to the appliance must be of copper.
8.0 Burners 8.1 RDB Burner 1. 2. 3. 4. 8.2 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 Pump The burner is supplied for use with a one pipe system. For use on a two pipe system, it is necessary to remove the return port plug and fit a small by-pass plug as shown. 1. 2. 3. 4. 5. 6. 7. 8.
8.3 Electrode Setting When removing or replacing the nozzle, move the electrodes forward to avoid the risk of damage. The electrodes are slackened by unscrewing the brass post that passes from the electrode holder out of the side of the burner. When work is complete, ensure the electrodes are reset as shown and secured by tightening the brass post. 8.4 Burner Start-Up Cycle Normal Lock-out due to failure to light Thermostat Motor Ignition Transformer Valve Flame Lock-Out Lamp ~ 12s 8.
9.0 Commissioning & Servicing 9.1 Commissioning Note: It is the responsibility of the installer to ensure that the boiler is properly commissioned by an OFTEC trained and registered technician. Failure to do so WILL invalidate ALL warranties. Before firing ensure that all the baffles are in place, as they may have been displaced during transit; Refer to the General Information section. Switch the boiler on, ensuring all controls are calling for heat.
Check Boiler Controls NO Check L & N to Control Box NO Burner Motor Runs YES YES Replace Motor Capacitor NO Motor or Pump Seized Lock Out within 1 second YES NO Page 60 Replace Burner Motor NO Motor gives 50 Volts to White Wire Repair/Replace Motor/Pump NO Lock Out after 12 second purge YES YES Replace Solenoid Coil NO Coil of Solenoid Functional Replace the Control Box NO Check and Set the Electrodes NO Ignition Spark Proved YES YES Replace Photo Cell NO Photo Cell Functio
11.0 Combi Fault Finding 11.1 Central Heating Switch on power, set selectors for CH on and DHW off. Set all controls to call for heat. YES Does the burner fire? NO Refer to burner fault finding. YES Do radiators get hot? YES Is lockout lamp on burner or panel lit? Does boiler cycle on its thermostat? Is high limit thermostat lamp lit? NO Check wiring, replace boiler thermostat.
11.2 Domestic Hot Water Switch on power, set selectors to CH off and DHW on. NO Is DHW pump working? Is there continuity across connection 20 and 21 on the PCB? YES 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.
12.0 Optional Boiler Mounted Digital Timer 12.1 Operating Instructions 12.1.1 After Installation When you first install the Cr2032 battery (by removing the clear plastic strip from the rear of the timer) you must press the ‘RESET’ button, the LCD display will display fully for 3 seconds. Then LCD display will change to ‘5:2d’. You can press DAY button to select ‘7d’, ‘24H’ programme mode.
12.1.2 Built in Programme For convenience, the timer module has a built in programme, however, it can be easily adjusted (see section 12.5 To Change the Programmes). The timer offers 3 options for both CH and HW programme period. OFF: Off all the time. AUTO: To run your time schedule for period one or two or three each day. ON: Turn on all the time.
12.1.5 To Set Programme Period Press and hold DAY button and press MIN until the correct programme period is displayed.
12.1.8 Manual Select 1. Press SELECT to toggle through ON / AUTO / OFF modes as indicated by the timer status. 2. ON mode turns on the timer. 3. OFF mode turns off the timer. 4. AUTO mode runs the set programme. 12.1.9 Manual Select This function is only applicable when your timer is set on AUTO mode. You can temporarily override the normal switching times by pressing the ADV key. The temporarily override won’t affect the normal programme after execution of the override. 1.
13.0 Spares 13.1 RDB 2.2 Spares 2908126 (5) - 05/2008 8 2 3 30 30 7 26 27 30 COD. 3514157 COD. 3514257 COD.
13.2 RDB 3.
13.
13.
13.
14.0 Your Guarantee, Terms & Conditions 1. Warmflow Guarantees 2. Conditions of Guarantee The boiler, including all controls, plate heat exchangers and associated equipment contained within the boiler casing, the burner and flue system if supplied by Warmflow against defective parts and faulty workmanship, for period of 12 months from the date of installation, providing the boiler is installed and commissioned in accordance with the installation instructions supplied with the boiler.
Commission/Service Record Boiler Serial No |__|__|__|__|__|__|__|__| In order that your boiler gives you many years of economical trouble free use and to validate the warranty, this boiler must be commissioned upon installation and serviced annually. Contact Warmflow for an approved engineer within your area.
Notes Page 74
Notes Page 75
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Licence No BEL 1609 BUSINESS REPLY SERVICE TEAR ALONG PERFORATION Warmflow Engineering Ltd Appliance Registration Dept Lissue Industrial Estate Moira Road Lisburn Co Antrim BT28 2RF 2 CUSTOMERS FROM ROI PLEASE AFFIX STAMP
