WarmFlow 50/70, 70/90, 90/120, 120/150, 150/200 Installation & Servicing

50/70 – 70/90 – 90/120 – 120/150 – 150/200
BLUEBIRD BOILERHOUSE MODELS,
GOLDBIRD KITCHEN MODELS
& WHITEBIRD UTILITY ROOM MODELS
50/90
FRONT SERVICING BOILERS
GOLDBIRD KITCHEN MODEL
200/250
BLUEBIRD BOILERHOUSE MODEL
50/70 – 70/90
WHITEBIRD UTILITY ROOM SYSTEM BOILER
50/70 – 70/90 – 90/120 – 120/150 – 150/200
KABIN PAK EXTERNAL BOILERHOUSE MODULES
50/90
SLIMLINE KABIN PAK
EXTERNAL BOILERHOUSE MODULE
50/70 – 70/90
KABIN PAK BACK OUTLET
EXTERNAL BOILERHOUSE MODULES
300 – 400 – 500
CONVENTIONAL FLUED
INDUSTRIAL BLUEBIRD BOILERHOUSE MODELS
LEAVE THESE INSTRUCTIONS WITH THE END USER
INSTALLATION & SERVICING
MANUAL FOR
ISSUE 6.2 JAN ’04
COMMISSIONING
*THIS APPLIANCE MUST
BE COMMISSIONED
*Failure to commission the boiler will invalidate the warranty.
After commissioning ensure that the pre-paid
warranty registration card is completed
and returned.
SERVICING
To ensure continued reliable operation and fuel
economy it is recommended that the boiler is
serviced annually by an OFTEC registered
technician.
NI CUSTOMERS ONLY
Warmflow Engineering Service division (NI)
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.
Telephone
0870 240 6532
Fax: 028 9262 2827
E-mail: service@warmflow .co.uk
Contents Page
1.0 User Instructions ............................................................................................................................................................ 2
1.1 Goldbird Models ................................................................................................................................................. 2
1.2 Bluebird, Kabin Pak and Whitebird Models ........................................................................................................ 2
1.3 Servicing ............................................................................................................................................................ 2
1.4 Components 50/70, 70/90, 90/120, 120/150, 150/200, 200/250 ........................................................................ 2
1.5 System Boiler ..................................................................................................................................................... 3
1.6 Components 50/90 Front Servicing Boiler
1.7 Components 300, 400 & 500 Industrial Boilers .................................................................................................. 4
1.8 Baffles ................................................................................................................................................................ 5
2.0 Introduction..................................................................................................................................................................... 6
2.1 General Requirements ....................................................................................................................................... 6
3.0 Dimensions ..................................................................................................................................................................... 7
3.1 Goldbird & Whitebird Models ............................................................................................................................. 7
3.2 Bluebird Models ................................................................................................................................................. 7
3.3 Industrial Bluebird Models .................................................................................................................................. 8
3.4 Kabin Pak ........................................................................................................................................................... 8
3.5 Kabin Pak Back Outlet ....................................................................................................................................... 9
3.6 Slimline Kabin Pak ............................................................................................................................................. 9
3.7 Flue Options ..................................................................................................................................................... 10
4.0 Installation..................................................................................................................................................................... 12
4.1 Service Access ................................................................................................................................................. 12
4.2 Hearth .............................................................................................................................................................. 12
4.3 Heating System ................................................................................................................................................ 12
4.4 Sealed System ................................................................................................................................................. 12
4.5 Air Vents........................................................................................................................................................... 13
4.6 Drain Cock ....................................................................................................................................................... 13
4.7 Expansion Vessels ........................................................................................................................................... 13
4.8 System Filling ................................................................................................................................................... 13
4.9 System Pressure .............................................................................................................................................. 13
5.0 Electricity Supply ......................................................................................................................................................... 14
5.1 Dual Thermostat............................................................................................................................................... 14
5.2 RDB Control Box .............................................................................................................................................. 14
5.3 Control Panel Wiring (Goldbirds) ..................................................................................................................... 15
5.4 R40 Control Box ............................................................................................................................................... 16
5.5 Installation of Optional Programmer................................................................................................................. 16
5.6 System Wiring Diagrams (Goldbirds) ............................................................................................................... 17
6.0 Technical Data............................................................................................................................................................... 19
6.1 Goldbird, Whitebird & Bluebird ......................................................................................................................... 19
6.2 Industrial Bluebirds........................................................................................................................................... 21
7.0 Air Supply...................................................................................................................................................................... 22
7.1 Open Flue Boilers ............................................................................................................................................ 22
7.2 Balanced Flue Boilers ...................................................................................................................................... 22
8.0 Flues ......................................................................................................................................................................... 23
8.1 Conventional Flues .......................................................................................................................................... 23
8.2 Low Level Flues ............................................................................................................................................... 23
8.3 Installation of Flues .......................................................................................................................................... 25
9.0 Installation of Boilers ................................................................................................................................................... 27
9.1 120/150 & 150/200 White Casings................................................................................................................... 27
9.2 Industrial Bluebird Casings .............................................................................................................................. 27
9.3 Industrial Firebrick ............................................................................................................................................ 27
9.4 Kabin Pak Installations ..................................................................................................................................... 29
9.5 Standard Kabin Paks ....................................................................................................................................... 30
9.6 Kabin Pak Vertical Flue Adaptor....................................................................................................................... 30
9.7 Slimline Kabin Pak ........................................................................................................................................... 31
9.8 Slimline Kabin Pak Vertical Flue Adaptor ......................................................................................................... 31
10.0 Oil Supply ...................................................................................................................................................................... 32
10.1 One Pipe System ............................................................................................................................................. 32
10.2 Two Pipe System ............................................................................................................................................. 33
10.3 Deaerator System ............................................................................................................................................ 33
10.4 One Pipe Lift .................................................................................................................................................... 34
11.0 Burners ......................................................................................................................................................................... 35
11.1 RDB Burner ...................................................................................................................................................... 35
11.2 G10 Burner....................................................................................................................................................... 35
11.3 G20S Burner .................................................................................................................................................... 36
11.4 Oil Supply ......................................................................................................................................................... 36
11.5 Air Damper Adjustment .................................................................................................................................... 37
11.6 Electrode Setting .............................................................................................................................................. 37
11.7 Burner Start-up Cycle....................................................................................................................................... 37
12.0 Servicing & Commissioning ........................................................................................................................................ 38
12.1 Commissioning................................................................................................................................................. 38
12.2 Servicing .......................................................................................................................................................... 38
13.0 User Instructions – Horstmann 626 Internal Programmer........................................................................................ 39
14.0 Fault Finding ................................................................................................................................................................. 44
15.0 Spares ......................................................................................................................................................................... 45
15.1 RDB Burners 1 & 2........................................................................................................................................... 45
15.2 RDB 3 & 4 Burners........................................................................................................................................... 46
15.3 R40 G10 Burner ............................................................................................................................................... 47
15.4 R40 G20S Burner............................................................................................................................................. 48
15.5 Boiler Parts List ................................................................................................................................................ 49
Page 1
1.0 User Instructions
1.1 Goldbird Models Thermostat Control
The recommended minimum thermostat setting is 65°C. Below this ‘cold water corrosion’ is likely to occur which can reduce the life of the heat exchanger and is not covered by the boiler warranty. The boiler thermostat is adjustable from 52°C to 88°C.
Mains Indicator
The green mains lamp will be lit when there is power to the control box.
H/L Reset
The yellow H/L reset lamp will be lit when the boiler has overheated and tripped the high limit thermostat, which then needs to be manually reset. If the high limit thermostat continues to trip, contact Warmflow or your service engineer/technician. The manual reset thermostat has a cut out point of 110°C.
Lock-Out
The red lock out lamp will be lit when the burner has failed to fire and can be reset by pressing the illuminated red reset button on the burner control box.
1.2 Bluebird, Kabin Pak and Whitebird Models
The recommended minimum thermostat setting is 65°C (thermostat setting 1). If the high limit thermostat operates it may be reset by removing the reset cover and pressing the reset button. If the burner goes to lockout it can be reset by pressing the illuminated red reset button on the burner control box. Combustible material must not be placed on top of the boilerhouse models or on top of the burner cover as the temperature of certain exposed components can occasionally reach 70°C. The boiler thermostat is adjustable from 60°C to 90°C and the manual reset limit thermostat has a set point of 110°C.
1.3 Servicing
It is recommended that the boiler is serviced annually by an OFTEC registered engineer. WARNING: No adjustments to externally situated boilers should be made where wet
weather conditions prevail. In such conditions there may be a risk of ingress of water into the appliance, which could lead to component failure or electrocution.
1.4 Components – 50/70, 70/90, 90/120, 120/150, 150/200, 200/250
LIMIT THERMOSTAT RESET BUTTON COVER
BOILER THERMOSTAT CONTROL
TOP LID
FLUE
BURNER LOCKOUT LAMP & RESET BUTTON
BAFFLES
BOILER CASING
BURNER COVER
BASE INSULATION
TOP LID
FLUE
BURNER LOCKOUT LAMP & RESET BUTTON
BURNER COVER BASE INSULATION
BAFFLES
LIMIT THERMOSTAT MANUAL RESET BUTTON COVER
BOILER THERMOSTAT CONTROL
THERMOSTAT
POCKET
BOILER CASING
Bluebird Goldbird/Whitebird
Page 2
1 Flue 2 System Pressure Gauge 3 Spare BSP Connection (x2) 4 Boiler Limit Thermostat 5 Thermostat Pocket 6 12L Expansion Vessel 7 Heating Return (x2) 1” BSP 8 Drain Cock 9 Heating Flow 10 Automatic Air Vent 11 Pressure Relief Discharge 12 Isolation Gate Valve (x2) 13 Grundfoss Pump 14 Pressure Relief Valve 15 Filling Loop Connection 16 Data label 17 Optional Air Intake Spigot 18 RDB Burner 19 Burner Reset Button/Lock Out Lamp
1.5.2 Pipe Layout
1.5.3 Mains Water Supply
The mains water connection for the filling loop has been left free for the installer to fit a 15mm copper pipe. The pipe can be routed over the top of the boiler, down one of the side channels or through the cable entry grommets towards the front of the base tray.
Note: Also 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.
1.5 System Boiler
1.5.1 Components
18
17
16
15
14
13
12
11
10
9
8
7
6
4
3
2
1
19
5
Page 3
1.6 Components 50/90 Front Servicing Boiler
INSULATION
RETAINER
BOILER TEST POINT
EXTERNAL DOOR
INSULATION
BURNER RESET BUTTON/
LOCK OUT LAMP
RDB
BURNER
OPTIONAL AIR
INTAKE SPIGOT
SIDE
CASING
FLUE RING
TOP CASING
THERMOSTAT
POCKET
WHITEBIRD
THERMOSTAT
GOLDBIRD
CONTROL PANEL
BAFFLES
INSULATION SHIELD
DOOR INSULATION
DOOR GASKET
SERVICE DOOR
BOILER CONTROL THERMOSTAT
LIMIT THERMOST AT RESET BUTTON COVER
SERVICING DOOR
1" BSP DRAIN VALVE CONNECTION
BAFFLES
4 No 3" BSP CONNECTIONS
FIREBRICK REAR
AND BOTTOM
BOILER CASING
2 No 1/2" BSP CONNECTIONS
FLUE TOP LID
1.7 Components – 300, 400 and 500 BB Industrial Boilers (x 1000 Btu/hr)
Page 4
1.8 Baffles
1.8.1 Top Servicing Boilers
50/70
(3 in number)
70/90 & 120/150 (8 in number)
90/120, 150/200, 300, 400 & 500
have a similar arrangement
(12, 12, 12, 16 and 16
baffles respectively)
FRONT FRONT
50/90
(4 in number)
heavy baffle to the bottom
Note: Before firing make sure the baffles have not been dislodged in transit and are correctly positioned. T o achieve maximum efficiency push the baffles in the direction of the arrows as shown.
1.8.2 Components 50/90 Front Servicing Boiler
50/90
(5 in number)
heavy baffle to the bottom
Page 5
2.0 Introduction
The boilers are fired by a pressure jet oil burner which is covered by the manufacturer’s parts and labour warranty valid for one year (from boiler date stamp). Optional extended guarantees covering parts and labour are also available (although not applicable to the Republic of Ireland).
Warmflow oil fired boilers are designed to burn 28 second redwood No 1 (Kerosene Class C2) fuel or with some adjustment 35 second redwood No 1 (Gas Oil Class D). In order to comply with current building regulations only kerosene must be burned when used with low level flue or low level balanced flue. The 400 and 500 Bluebirds are only suitable for use with 35 second redwood No 1 (Gas Oil Class D).
The boiler shells are fabricated from the best quality mild steel plate electrically welded and pressure tested to 4.5 bar (65 PSI) making them suitable for either open or pressurised systems (max working pressure 1.5 bar). Note that all industrial boilers are tested to 6 bar (90 PSI). They incorporate two flow and return connections on each side of the boiler for connection to the central heating and domestic hot water systems. Each shell is covered by the manufacturer’s warranty of 5 years (effective from date stamped on warranty label) but does not include burner, labour, handling or shipping.
The manufacturers guarantees are void if the appliance is not installed and commissioned and serviced in accordance with the recommendations made herein.
2.1 General Requirements
The installation of the boiler must be in accordance with the following regulations.
BS5410 : PART 1 : 1997 Code of Practice for oil firing. BS5410 : PART 2 : 1977 BS5449 : PART 1 : 1977 Forced Circulation Hot Water Systems. BS7593 : 1992 Treatment of water in domestic hot water central heating systems.
Current Building Regulations: Part J England and Wales
Part F Section III Scotland Part L Northern Ireland
Current IEE Wiring Regulations: The heating system should be installed by a competent installer in accordance with the recommendations laid down by HVCA and a sound engineering practice.
In order to comply with GB building regulations OFTEC forms CD10 for installations and CD11 for commissioning should be left with the customer.
Page 6
H
A
B
J
F
D
E
C
= =
G
K
3.0 Dimensions
3.1 Goldbird Kitchen, Whitebird and Whitebird System Utility Room Models (including front servicing boilers)
J
127 127 127 127 127
OUTPUT (kW)
14.6-20.5
20.5-26.4
26.4-35.2
35.2-44.0
44.0-58.6
A
865 865
865 1168 1168
B
413 413 595 495 495
C
599 599 599 785 785
D
90 90
90 102 102
E
59 59 59 72 72
F
554 554 541 809 809
G
664 664 664 956 956
H
128 128 128 128 128
MODEL
50-70 70-90
90-120 120-150 150-200
K
4x1” 4x1”
4x1
1
/2”
4x1
1
/2”
4x1
1
/2”
3.2 Bluebird Boilerhouse Models
B E
K
= = J
H
C
A
F G
D
L
J
127 127 127 127 127 152
A
688 688 688 965 965 965
B
405 405 585 490 490 490
C
387 387 392 530 530 530
D
88 88
88 102 102 102
E
62 62 67 72 72 72
F
554 554 541 809 809 809
G
662 662 662 956 956 956
H
130 130 138 119 119 139
MODEL
50-70 70-90
90-120 120-150 150-200 200-250
OUTPUT (kW)
14.6-20.5
20.5-26.4
26.4-35.2
35.2-44.0
44.0-58.6
58.6-73.3
K
188 188 188 188 246 246
L
4x1” 4x1”
4x1
1
/2”
4x1
1
/2”
4x1
1
/2”
4x1
1
/2”
Page 7
B
M
E
L
N Q
P
A
D
C
K
FG
H
J
R
3.3 Industrial Bluebird Models
3.4 Kabin Pak
The Kabin Pak comes factory fitted with a Warmflow Bluebird Boiler and insulated low level flue kit complete with a terminal guard.
An adaptor is available to allow the low level flue to be extended using standard twin wall round flue. Only the outer flue and flue end cap need be removed.
D
G
J
A
E
F
N
B
K
L
MH
C
MODEL
50-70 70-90
90-120 120-150 150-200
J
554 554 541 809 809
A
892 892
892 1089 1089
B
732 732 942 902 902
C
636 636 636 836 836
D
373 373 373 373 373
E
188 188 188 188 188
F
191 191 191 191 191
G
390 390 390 602 602
H
137 137 137 151 151
K
84 84 84 96 96
L
86 86 86 86 86
M
137 137 137 191 191
N
554 554 554
— —
P
50 50 50
— —
Q
— —
— 729 729
MODEL
300 400 500
J
412 446 461
A
814 934
1062
B
824 934
1072
C
864 974
1085
D
864 974
1085
E
432 407 464
F
1313 1313 1570
G
263 263 297
H
272 306 321
K
166 166 170
L
1032 1032 1466
M
111 111 102
N
203 203 203
Page 8
P
K
A
F
D
E
G
I
H
B
L
C
J
M
N
Q
J
B
H
C
== D
K
L
M
A
G
F
E x N
3.5 Kabin Pak Back Outlet
MODEL
50-70 70-90
J
85 85
A
892 892
B
732 732
C
636 636
D
156 156
E
191 191
F
554 554
G
138 138
H
85 85
K
137 137
L
554 554
M
50 50
N
188 188
3.6 Slimline Kabin Pak
When installing a Slimline Kabin Pak against a wall allow 600mm to the front and rear of the appliance for servicing.
MODEL
50-90
I
190
A
784B925C398D109E86F65G440H50
J
272K61L188M134N554P48
Page 9
3.7 Flue Options
3.7.1 Easy Fit Low Level Balanced Flue
The horizontal dimension can be increased up to an additional 1200mm using a combination of long extension pieces (600mm) and short extension pieces (300mm).
102
712 MAX
225 MAX
175 MIN
490 MIN
Ø125
3.7.2 ‘Easy Fit’ High Level Balanced Flue
The HLBF is available in 4 fixed horizontal lengths which are:
Option 1 – 455mm
Option 2 – 655mm
Option 3 – 585mm
Option 4 – 785mm
225 MAX
175 MIN
1128
SEE OPTIONS
160x160
Page 10
3.7.4 Easy Fit Vertical Balanced Flue (VBF)
EXTENSION KITS
AS REQUIRED
(PACKS C OR D)
PACK E OR F PACK E OR F
A
175 MIN
225 MAX
900 MIN
1400 MAX
PACK A
PACK H PITCHED ROOF FLASHING (22" – 45" ADJUSTABLE)
PACK B VBF TERMINAL SECTION
EXTENSION KITS (PACK C OR D) AS REQUIRED MAX 2 NO PACK D
PACK A
675mm MIN
675mm MIN
PACK G FLAT ROOF FLASHING
PACK B VBF TERMINAL SECTION
MIN
435 560 735
MAX
610 860 910
A + E A + F A + C + E
FLUE PACKS
DIM A
ALL MODELS
MIN
860 1035 1160 1385 1510
MAX 1160 1210 1510 1560 1860
A + C + F A + C + C + E A + C + C + F A + D + E A + D + F
FLUE PACKS
DIM A
50/70, 70/90 & 90/120 MODELS ONLY
MIN 1340 1640 1940 2290 2590 2890 3240
MAX 1840 2140 2440 2740 3040 3340 3740
A + B A + B + C A + B + C + C A + B + D A + B + D + C A + B + D + C + C A + B + D + D
FLUE PACKS
FLUE HEIGHT
ALL MODELS
Note: When using a VBF or HLBF-R on a 120/150 or 150/200 model ensure that the boiler is
fitted with a RDB3 burner.
3.7.3 Easy Fit Telescopic High Level Balanced Flue (HLBF-R)
Page 11
4.0 Installation
The boiler installation must be in compliance with BS 5410 and the Building Regulations.
Failure to install and commission in accordance with the instructions contained within this booklet will invalidate the warranty.
4.1 Service Access
24” (600mm) clearance should be provided above and in front of the boiler (and the rear for Slimline Kabin Paks) to allow for routine servicing. When top servicing boilers are placed under a worktop ensure that the worktop is easily removed.
4.2 Hearth
The boiler hearth temperature is between 50°C and 85°C to comply with the Building Regulations. The boiler should be stood on a rigid, non-porous, non-combustible base, which is not softened by warmth. For the heavier industrial boilers it would be advisable to have a level concrete base raised 50mm above floor level.
4.3 Heating System
The heating system should be installed to HVCA current codes of practice and the recommendations made in the relevant British Standards.
The use of inappropriate pipe sizes and incorrect plumbing leading to system and boiler noise is not covered under the boiler warranty.
It is recommended that the flow and return pipes are connected on opposite sides of the boiler.
It is recommended that new and existing systems are commissioned in accordance with BS7593 : 1992 ‘Treatment of water in central heating systems’. It is recommended that a non-corrosive commissioning cleanser is used when flushing the system.
We would also recommend that the system is further treated with a corrosion inhibitor .
These products should be used strictly in accordance with the manufacturers instructions.
In areas of hard water a suitable water softener would also be recommended.
4.4 Sealed Systems
All Warmflow boilers are suitable for use on a sealed heating system. It is recommended that a CE approved pressure relief valve (PRV) set at 3 bar is fitted to the system. The industrial bluebirds can be fitted with a 4 bar PRV. On the system boiler a 3 bar PRV has been factory fitted.
Page 12
4.5 Air Vents
On the system boiler an automatic air vent complete with its own check valve is fitted to the top of the boiler heat exchanger. It is recommended that an air vent is fitted at the highest point in the system. However where the pipework comes off the boiler and drops down an automatic airvent should be fitted to the top of the boiler.
4.6 Drain Cock
Drain cock(s) should be fitted to the lowest points in the system to enable the system to be fully drained. On the system boiler a drain cock has been fitted to the system boiler heat exchanger.
4.7 Expansion Vessels
Refer to BS 7074: part 1 or BS 5449 for details of the pressure vessel sizing. The values given in the table are for a total system values which includes the primary water capacity . On the system boiler a 12 litre expansion vessel charged to 0.5 bar is supplied. This can accommodate a maximum system volume of approximately 150 litres. If this volume is exceeded an additional vessel will be required.
0.5 2.1 4.2 6.3 8.3 10.5 12.5 14.6 16.7 18.7 20.8 22.9 25.0
1.0 2.7 5.4 8.2 10.9 13.6 16.3 19.1 21.8 24.5 27.2 30.0 32.7
1.5 3.9 7.8 11.7 15.6 19.5 23.4 27.3 31.2 35.1 39.0 42.9 46.8 25 50 75 100 125 150 175 200 225 250 275 300
INITIAL CHARGE
TOTAL
SYSTEM
VOLUME
VESSEL VOLUMES
4.8 System Filling
Water loss from a sealed system, as indicated by a reduction in pressure on the pressure gauge, may be made up through a filling loop, however the cause of the water loss should be fully investigated and corrected.
After filling, vent all air from the system. Ensure the caps on the automatic air vents are loose, bleed the circulating pump and disconnect the temporary filling loop.
As standard, a filling point complete with a filling loop has been included within the system boiler. A system pressure, when cold, of 1 bar is recommended.
4.9 System Pressure
The pressure relief discharge shall be positioned away from any electrical components. No other valves should be positioned between the relief valve and the discharge, and the discharge pipes should not be used for any other purposes. The discharge pipe must be plumbed to an external drain in a position where the discharge can be seen but cannot cause any injury or damage.
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 thermostats.
Page 13
TO BURNER
FROM POWER SUPPLY (SWITCHED LIVE)
5.0 Electricity Supply
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.
5.1 Dual Immersion Thermostat (Bluebird and Whitebird Boilers)
CONTROL BOX
535SE/LD
M
M
Oil Valve
Photoresistance
Black White Blue
Motor
Capacitor
Remote
Lock Out
(Goldbirds only)
Live
Neutral
Earth
Fan
Housing
Note: A remote lock out lamp is only factory fitted wired on Goldbird models.
Warning: Do not fit any other wires or loop wires to this stat as this will bypass the
thermostats.
5.2 RDB Burner Control Box
Page 14
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