Boiler Manual Incorporating: User Instructions Installation Instructions Service Instructions Guarantee Terms & Conditions High Efficiency Condensing Boilers For use with Kerosene only Models covered by this manual: B-Series Boilerhouse B70HE B90HE B120HE Utility U70HE U90HE U120HE U150HE Utility Pumped UP70HE UP90HE UP120HE UP150HE Utility System US70HE US90HE US120HE Utility Combi UC70HE UC90HE UC120HE Kabin Pak K70HE K90HE K120HE K150HE Kabin Pak Pumped KP70HE KP90HE KP12
COMMISSIONING This appliance must be commissioned. Failure to commission the boiler will invalidate the warranty. After commissioning, ensure that the Boiler Passport is completed and returned. SERVICING To ensure continued reliable operation, fuel economy and to validate the guarantee, it is recommended that the boiler is serviced annually by a Warmflow or an OFTEC registered technician.
CONTENTS 1 USER INSTRUCTIONS......................................................................................................... 3 1.1 1.2 1.3 1.4 1.5 1.6 Dual Thermostat .........................................................................................................................3 High Limit Thermostat Reset ......................................................................................................3 Burner Lockout ................................................................
10 10.1 10.2 10.3 11 11.1 11.2 11.3 11.4 11.5 12 12.1 12.2 13 13.1 14 14.1 14.2 15 15.1 16 16.1 16.2 16.3 16.3 16.4 17 INSTALLATION REQUIREMENTS ................................................................................. 70 General Requirements ............................................................................................................. 70 Sealed Systems .......................................................................................................................
1 USER INSTRUCTIONS 1.1 Dual Thermostat The radiator temperature is regulated via the boiler control thermostat. The thermostat is user adjustable from 45°C at its minimum setting (dial „0‟) to 75°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. Control dial Reset button 1.
1.4 System Pressure – System & Combi Boilers System Pressure When the boiler is connected to a sealed system the system pressure should be periodically checked. The minimum pressure, as indicated by the black needle, is 0.5 bar when the boiler is cold and 2.5 bar when the boiler is at normal operating temperature. If the pressure is outside this range contact Warmflow or your installer. 1.5 Filling Loop If the system pressure falls below the minimum (e.g.
2 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.
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 a Warmflow 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.
4 GENERAL INFORMATION 4.1 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.
The heating system should be installed by a competent installer in accordance with the recommendations laid down by the building services compliance guide, OFTEC and sound engineering practice. In order to comply with building regulations, the boiler passport and or OFTEC forms CD10 for installations and CD11 for commissioning should be left with the customer. Alternatively the installation can be inspected and approved by a building control officer. 4.
4.4 Baffle Positioning Page 9 Models up to 120 HE The primary heat exchanger baffles consist of one heavy baffle stack (4mm thick) at the bottom, 3 lighter baffle stacks (3mm thick) in the middle and 1 baffle plate (3mm thick) 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.
4.5 Components 4.5.1 B-Series Boilerhouse – Casing Components & Key Components 3 2 4 Page 10 1 5 6 1. 2. 3. 4. 5. 6. Boiler Assembly Top Front Casing (removable) Top Rear Casing (removable) Sides & Rear Casing Front Casing (removable) Bottom Front Casing 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.
4.5.
4.5.
4.5.
4.5.5 U-Series Utility – System (USHE) - Key Components 4.5.
4.5.
4.5.
4.5.
4.5.10 K-Series Kabin Pak – System (KSHE) - Key Components 4.5.
4.5.12 Combi Control Panel Layout 5 6 1 7 8 2 3 4 (underneath) 1) Heating Temperature Control The heating temperature control adjusts the temperature of the central heating water flowing from the boiler to the radiators. Turn the dial clockwise towards red to increase the temperature and anticlockwise towards blue to reduce. 2) High Limit Reset The high limit thermostat protects the boiler against overheating and is factory set to 110°C (not adjustable).
4.5.
5 TECHNICAL DETAILS 5.
5.2 Dimensions 5.2.1 B-Series Boilerhouse (B70HE, B90HE & B120HE Models) A 395 B 600 C 685 D 332 E 118 F 34 G 664 H 97 J 77 K 197 L 371 M 85 N 35 P 30 Q 50 R 80 5.2.
5.2.3 U-Series Utility (150HE Models) 5.2.
5.2.5 K-Series Kabin Pak (KHE, KPHE & KSHE Models up to 120HE) 5.2.
5.2.7 K-Series Kabin Pak (150HE Models) 5.2.
5.2.9 K-Series Kabin Pak (KCHE Models) 5.2.
5.3 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.
5.4 Technical Data 5.4.1 B-Series Boilerhouse (BHE) MODEL Nominal Heat Output Nominal Heat Input B70HE kW Btu/hr kW Btu/hr 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 15.3 18.4 22.0 22.0 24.4 28.0 28.0 30.0 34.0 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 Head Secondary Air Damper Flue Diameter Flue Gas Temp. Smoke mm in 0 C B120HE 14.7 Burner Conventional B90HE 86 Bacarach RDB 2.
5.4.2 U-Series Utility – Pre-Wired (UHE) MODEL U70HE Nominal kW 14.7 21.0 21.0 U120HE 23.5 27.1 29.0 27.1 U150HE 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22.0 22.0 24.4 28.0 30.0 28.0 34.0 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.
5.4.3 U-Series Utility – Pumped (UPHE) MODEL UP70HE Nominal kW 14.7 21.0 21.0 UP120HE 23.5 27.1 29.0 27.1 UP150HE 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22.0 22.0 24.4 28.0 30.0 28.0 34.0 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.
5.4.4 U-Series Utility – System (USHE) MODEL Nominal Heat Output Nominal Heat Input US70HE kW Btu/hr kW Btu/hr 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 15.3 18.4 22.0 22.0 24.4 28.0 28.0 30.0 34.0 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 Head Secondary Air Damper Flue Diameter Flue Gas Temp. Smoke mm in 0 C US120HE 14.7 Burner Conventional US90HE 86 Bacarach RDB 2.
5.4.5 U-Series Utility – Combi (UCHE) MODEL UC70HE UC120HE UC90HE Nominal Heat Output kW Btu/hr 14.7 50,000 17.6 60,000 21.0 71,650 21.0 71,560 23.5 80,000 27.1 92,380 27.1 92,380 29.0 99,050 32.7 111,600 Nominal Heat Input kW Btu/hr 15.3 52,150 18.4 62,600 22.0 75,000 22.0 75,000 24.4 83,175 28.0 95,550 28.0 95,550 30.0 102,400 34.0 116,000 Burner Head Secondary Air Damper Conventional Flue Diameter mm in 0 Flue Gas Temp. Smoke C 86 Bacarach RDB 2.2 15-21 RDB 2.
5.4.6 K-Series Kabin Pak – Pre-Wired (KHE) MODEL K70HE Nominal kW 14.7 21.0 21.0 K120HE 23.5 27.1 29.0 27.1 K150HE 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22.0 22.0 24.4 28.0 30.0 28.0 34.0 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.
5.4.7 K-Series Kabin Pak – Pumped (KPHE) MODEL KP70HE Nominal kW 14.7 21.0 21.0 KP120HE 23.5 27.1 29.0 27.1 KP150HE 32.7 38.5 33 44 Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Heat Output Nominal kW 15.3 18.4 22.0 22.0 24.4 28.0 30.0 28.0 34.0 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.
5.4.8 K-Series Kabin Pak – System (KSHE) MODEL Nominal Heat Output Nominal Heat Input KS70HE kW Btu/hr kW Btu/hr 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 15.3 18.4 22.0 22.0 24.4 28.0 28.0 30.0 34.0 52,150 62,600 75,000 75,000 83,175 95,550 95,550 102,400 116,000 Head Secondary Air Damper Flue Diameter Flue Gas Temp. Smoke mm in 0 C KS120HE 14.7 Burner Conventional KS90HE 86 Bacarach RDB 2.
5.4.9 K-Series Kabin Pak – Combi (KCHE) MODEL KC70HE KC90HE KC120HE Nominal Heat Output kW Btu/hr 14.7 50,000 17.6 60,000 21.0 71,650 21.0 71,560 23.5 80,000 27.1 92,380 27.1 92,380 29.0 99,050 32.7 111,600 Nominal Heat Input kW Btu/hr 15.3 52,150 18.4 62,600 22.0 75,000 22.0 75,000 24.4 83,175 28.0 95,550 28.0 95,550 30.0 102,400 34.0 116,000 Burner Head Secondary Air Damper Conventional Flue Diameter mm in 0 Flue Gas Temp. Smoke C 86 Bacarach RDB 2.2 15-21 RDB 2.
6 ELECTRICITY SUPPLY & WIRING DETAILS 220 – 240V. 1PH, 50Hz 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. 6.1 Dual-Safe Thermostat (Non-Combi Boilers) Warning: Do not fit any other wires or loop wires to this stat as this will bypass the thermostats. 6.
The 3 pin mains plug must be supplied with a permanent live to allow the pump overrun stat and relay to operate. 6.3 Combi Wiring Details 6.3.
6.3.
6.3.3 Fitting a Room Thermostat to a Combi 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. 6.3.4 Fitting Frost Protection to a Combi In order to provide frost protection for the fabric of the building a frost thermostat should be fitted in the coldest room in the house.
6.4 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.
6.5 Remote Timers for Combis 6.5.1 Installation of a remote two channel programmer (option 1) Permanent Live Supply The boiler must be supplied with a permanent live mains supply via a fused isolator connected to the boiler 3 pin mains plug into the control panel. Failure to connect a permanent live to the boiler will prevent the programmer, boiler mains lamp and pump overrun thermostat from operating. It will also disable the built-in frost protection of a Kabin Pak Combi.
6.6 Optional Programmer (PC1) for Non-Combi Models 6.6.1 Programmer Control Box Wiring Diagram 6.6.2 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.
6.6.3 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.
6.6.4 Honeywell ‘Y’ Plan – Independent CH & DHW (Fully Pumped Only) Note: Before fitting programmer, remove loop between 3 and 12 on the terminal block.
6.6.5 Honeywell ‘S’ Plan – Independent CH & DHW (Fully Pumped Only) Note: Before fitting programmer, remove loop between 3 and 12 on the terminal block.
7 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.
7.2 Two Pipe System Head H(m) ID 8mm ID 10mm Total Maximum Pipe Length (m) 0.0 0.5 1.0 1.5 2.0 3.0 35 30 25 20 15 8 100 100 100 90 70 30 3.5 6 20 7.3 De-aerator System For maximum pipe length and lift contact de-aerator manufacturer.
7.4 One Pipe Lift System Head H(m) ID 8mm ID 10mm Total Maximum Pipe Length (m) 0.0 0.5 1.0 1.5 2.0 3.0 35 30 25 20 15 8 100 100 100 90 70 30 3.5 6 20 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 lockout.
7.5 Instructions for the use of Bio Fuel To ensure consistency, the fuel supplier must be able to demonstrate compliance with a recognised Quality Control and management system to ensure high standards are maintained within the storage, blending and delivery processes. The installation oil storage tank and its ancillaries must also be prepared BEFORE liquid Bio fuel is introduced. Checks and preparation should include; 1.
INSTALLER/SERVICER NOTES 1. During the burner installation, check that the gasoil and bio fuel blends are in accordance with Riello recommendations (please refer to the chapters “Technical Data” and “Guidance for the use of bio fuel blends within the burner technical manual). 2. If a Bio blend is in use the installer must seek information from the end user that their fuel supplier can evidence that the blends of fuel conform to the relevant EN standards. 3.
8 FLUES 8.1 Flue Options, Components & Dimensions The use of any flue system other than that supplied or recommended by the manufacturer will invalidate the warranty. The following flue options are available from Warmflow: FBF HBF VBF HFL VFL UPMK KPMK Low Level Balanced Flue Kit High Level Balanced Flue Kit Vertical Balanced Flue Kit Horizontal Entry Flue Liner Kit Vertical Entry Flue Liner Kit Utility Plume Management Kit Kabin Pak Plume Management Kit 8.1.
8.1.2 Condensing Boiler Flue Kits FIRE SAFETY As with a metal flue system, where a plastic flue system is used within a building which is „compartmentalised‟ as defined by the Building Regulations, care must be taken to ensure that the installation of the flue does not contravene the Regulations and create a safety risk.
8.1.3 HE Low Level Balanced Flue Kit (FBF) The kit comprises: FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue kit. FIT STARTER PIECE 2. Remove the appropriate casing panel cut-out using snips. Fit the boiler adapter (A). 3. Lubricate the seals then insert the starter assembly (B).
MEASURE AND CUT FLUE TERMINAL 4. Cut a hole through the wall and fit a non-combustible sleeve. 5. Lubricate then fit the flue terminal (C) and measure the excess length, X. 6. Cut X mm from the outer pipe of the terminal then X mm from the inner pipe. CONNECT TERMINAL AND AIR HOSE 7. Lubricate then refit the terminal then secure with the locking band. 8. Fit the air inlet spigot and gasket to the burner. Attach the flexible air hose to the burner and starter assembly and secure with the jubilee clips.
8.1.4 HE High Level Balanced Flue Kit (HBF) The kit comprises: FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue kit. FIT STARTER PIECE 2. Remove the top panel casing cut-out using snips. Fit the boiler adapter (A). 3. Lubricate the seals, then insert the starter assembly (B).
4. Lubricate and fit the extension (C) and bend (D) then secure with the locking bands. 5. Fit the air inlet spigot and gasket to the burner. Attach the flexible air hose to the burner and starter assembly and secure with the jubilee clips. MEASURE AND CUT FLUE TERMINAL i. Cut a hole through the wall and fit a non-combustible sleeve. ii. Fit the flue terminal (E) and measure the excess length, X. iii. Cut X mm from the outer pipe of the terminal then X mm from the inner pipe.
8.1.5 HE Vertical Balanced Flue Kit (VBF) The kit comprises: FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue kit. FIT STARTER PIECE 2. Remove the top panel casing cut-out using snips. Fit the boiler adapter (A). 3. Lubricate the seals, then insert the starter assembly (B).
CONNECT 1ST EXTENSION AND AIR HOSE 4. Lubricate then fit the 1st extension and secure with the locking band. 5. Fit the air inlet spigot and gasket to the burner. Attach the flexible air hose to the burner and starter assembly and secure with the jubilee clips. MEASURE AND CUT TERMINAL 6. Fit the flashing and assemble the flue up through the roof, lubricating all seals. Measure the excess length, X, noting carefully the correct measurement locations. 7.
8.1.6 Warmflow HE Boiler Flue Components: 80/125 Ø Note: 1. Flue fitting kit required. 2. If the terminal is less than 2 metres above ground level, a terminal guard must be fitted. 3. Extension pipes and flue adapter lengths quoted are effective lengths and not the actual length of the piece. 4. All dimensions in mm unless otherwise stated.
8.1.7 Flue Length Calculation Note: 1. All flues can utilise any combination of bends, straights, adapters and terminals. 2. Ensure flue is arranged such that it falls continuously towards the boiler. 3. The Low Level, High Level and Vertical Balanced Flue Systems can use any combination of flue extension pieces up to the maximum equivalent length depending upon boiler output as illustrated in the above table. Example Calculation: Boiler Output: 20kW Length of Flue (distance from boiler to terminal): 8.
8.1.8 Plume Management Kits Plume Management Kits are available for our range of appliances. 8.1.
REMOVE TERMINAL END 1. Hold the Terminal Assembly (A) in place and extract the Terminal End (B) by gripping and pulling firmly. CUT OFF EXCESS MATERIAL 2. Using a suitable saw, cut off the highlighted portion of the end of the Terminal Assembly (A) then de-burr the cut edge. FIT DIVERTER ELBOW 3. Lubricate and insert one of the Elbows (C) into the end of the Terminal Assembly (A). Elbow (C) can be pointed at any angle up to +/- 87° from the vertical.
8.1.
1. FIT DIVERTER ASSEMBLY SEALS Apply suitable lubricant to the two Diverter Assembly Seals (supplied loose) then fit to the end of the boiler flue pipe noting the correct orientation. The seals MUST be fitted as shown with the outer surface sloping away from the end of the pipe to allow the Diverter Assembly to push over the seals. 2. FIT SPLIT RING-NUT Fit the Split Ring-nut by pulling open the split and pushing the nut over the pipe. Ensure the threaded end is facing towards the seals. 3.
8.1.11 Flexible Flue Liner Kit (HFL & VFL) These boiler connection kits (F16 or F18) contain: Installation instructions FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue. FIT STARTER PIECE 2. Remove the top casing panel cut-out using snips. Fit the boiler adapter (A). 3. Lubricate the seals then insert the starter assembly (B).
CONNECT 1ST EXTENSION AND AIR HOSE 4. Lubricate then fit the 1st extension and secure with the locking band. 5. Fit the air inlet spigot and gasket to the burner. Attach the flexible air hose to the burner and starter assembly and secure with the jubilee clips. CONNECT TO CLOSURE PLATE Install the chimney components and closure plate as instructed in the separate instruction leaflet. Run the flue from the boiler to the chimney closure plate. If necessary, the extension(s) can be cut to length.
8.2 Flue Terminal Locations 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.
9 AIR SUPPLY FOR COMBUSTION & VENTILATION (see BS5410) 9.1 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 OPEN FLUE Boiler in Compartment OPEN FLUE VENTILATED FROM OUTSIDE OPEN FLUE VENTILATED FROM ROOM 9.
10 INSTALLATION REQUIREMENTS The boiler installation must be in compliance with BS5410 : PART 1 and the Building Regulations. 10.1 General Requirements 10.1.1 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. 10.1.2 Service Access 24” (600mm) Clearance should be provided above and in front of the boiler to allow for routine servicing.
10.2 Sealed Systems 10.2.1 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.
10.2.5 Low Pressure Switch Where there is a catastrophic loss of water from the system the boiler thermostats may fail to operate which would result in serious damage to the appliance. To prevent this it is recommended that a low pressure cut out switch set at 0.2 bar is fitted to the system and wired in series with the boiler limit thermostat. 10.3 Combi Domestic Hot Water 10.3.
11 BURNERS 11.1 RDB Burner 11.2 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.
11.3 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. 11.4 Burner Start-Up Cycle 11.5 Air Damper Adjustment The air damper is set in factory. This regulation is purely indicative.
12 COMMISSIONING & SERVICING 12.1 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.
13 BURNER FAULT FINDING 13.
14 COMBI FAULT FINDING 14.
14.
15 OPTIONAL BOILER MOUNTED DIGITAL TIMER 15.1 Operating Instructions 15.1.1 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.
15.1.2 Built in Programme For convenience, the timer module has a built in programme, however, it can be easily adjusted (see section 15.1.5 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.
15.1.5 To Set Programme Period Press and hold DAY button and press MIN until the correct programme period is displayed.
15.1.8 Mode 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. 15.1.9 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.
16 SPARES 16.1 RDB 2.
16.2 RDB 3.
16.
16.
16.
17 YOUR GUARANTEES, TERMS & CONDITIONS 1. Warmflow Guarantees The boiler, including all controls, plate heat exchangers, pipework and unions, and associated equipment contained within the boiler casing, and the burner and flue system, if supplied by Warmflow, are guaranteed against defective parts and workmanship, providing the boiler is installed and commissioned in accordance with the instructions supplied with the boiler.
This manual is accurate at the date of printing (E&OE) but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.
