How it Works
WarmFlow
Loading...
COMBI 70

WarmFlow COMBI 70, COMBI 90, KABIN PACK COMBI 90 Installation & Servicing Instructions Manual

INSTALLATION & SERVICING
MANUAL FOR
70/90
COMBI BOILER
&
70/90
KABIN PAK COMBI
LEAVE THESE INSTRUCTIONS WITH THE END USER
CERT. No. FM 29884
BS 5750 PART 2 ISO 9002
ISSUE 4 MAR ’03
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.
Simply telephone
TEL: (028) 9262 0852
FAX: (028) 9262 0869
E-MAIL: service@warmflow.co.uk
COMMISSIONING
*THIS APPLIANCE MUST
BE COMMISSIONED
*Failure to commission this appliance may invalidate warranty
After commissioning ensure that the pre-paid warranty
registration card is filled in and returned.
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. The hardness of the mains water supply. Systems with hard water must be fitted with a suitable chemical scale preventer (eg Fernox Quantomat or Combimate alternatively contact Warmflow for further details).
4. That the flow from any one hot water outlet does not exceed the maximum recommended. This applies particularly to baths which are usually fitted with larger taps and larger bore supply pipes. It may be necessary to restrict the flow to these taps by reducing the bore of the supply pipework or by fitting a restrictor into the pipework.
5. That any outlet when opened does not starve all the other outlets of hot water. If more than one outlet is open at the same time then the total flow from all the outlets should not exceed the maximum flow rate of the boiler.
6. That any showers being supplied hot water by the boiler are compatible with this type of appliance.
It should be noted that the boiler has been factory fitted with an 18 litre/min flow restrictor.
The manufacturers guarantees are void if the appliance is not installed and commissioned in accordance with the recommendations made herein.
Page 1
Contents Page
1.0 User Instructions ................................................................................................................. 3
1.1 Introduction .................................................................................................................4
1.2 General Requirements ................................................................................................ 4
1.3 Components................................................................................................................ 5
2.0 Technical Details.................................................................................................................. 7
2.1 Sequence of Operation Flow Chart............................................................................. 7
2.2 Baffles ......................................................................................................................... 8
2.3 General Requirements ................................................................................................ 8
2.4 Dimensions ................................................................................................................. 9
2.5 Combi Flue Options .................................................................................................. 10
2.6 Technical Data .......................................................................................................... 13
3.0 Electricity Supply............................................................................................................... 14
3.1 RDB Burner Control Box ........................................................................................... 14
3.2 Fitting a Room Thermostat ....................................................................................... 14
3.3 Combi Wiring Details ................................................................................................ 15
3.4 Kabin Pak Combi Wiring Details ............................................................................... 17
3.5 Frost Thermostats ..................................................................................................... 19
3.6 Timers for Standard Combi ....................................................................................... 20
3.7 Timers for Kabin Pak Combis ................................................................................... 22
4.0 Oil Supply ...........................................................................................................................23
4.1 One Pipe System ...................................................................................................... 23
4.2 Two Pipe System ...................................................................................................... 24
4.3 De-aerator System .................................................................................................... 24
4.4 One Pipe Lift ............................................................................................................. 25
5.0 Flues .................................................................................................................................. 26
5.1 Conventional Flues ................................................................................................... 26
5.2 Low Level Discharge/Low Level Balanced Flues Terminal Position ......................... 26
6.0 Air Supply for Combustion and Ventilation.....................................................................28
6.1 Open Flue Boilers ..................................................................................................... 28
6.2 Balanced Flue Boilers ............................................................................................... 28
6.3 Installation of Flues ................................................................................................... 29
7.0 Thermostat Control Knob Peg Setting............................................................................. 31
8.0 Installation .......................................................................................................................... 32
8.1 Hearth .......................................................................................................................32
8.2 Service Access.......................................................................................................... 32
8.3 Heating System......................................................................................................... 32
8.4 Domestic Hot Water .................................................................................................. 34
8.5 Removal of Flow Restrictor ....................................................................................... 34
8.6 Fitting a Vertical Flue Adaptor ................................................................................... 35
8.7 Installation of Air Intake Duct .................................................................................... 35
9.0 Burners ...............................................................................................................................36
9.1 RDB Burner............................................................................................................... 36
9.2 Oil Supply.................................................................................................................. 36
9.3 Electrical Connections .............................................................................................. 37
9.4 Electrode Setting....................................................................................................... 37
9.5 Burner Start-up Cycle ............................................................................................... 37
10.0 Commissioning and Servicing ......................................................................................... 38
10.1 Commissioning ......................................................................................................... 38
10.2 Servicing ...................................................................................................................38
11.0 Horstmann 626 Electronic Programmer ..........................................................................39
12.0 Fault Finding ...................................................................................................................... 44
12.1 Central Heating ......................................................................................................... 44
12.2 Domestic Hot Water .................................................................................................. 45
12.3 Burner ....................................................................................................................... 46
13.0 Spares ................................................................................................................................. 47
13.1 Riello RDB Burner..................................................................................................... 47
13.2 Pipe Spares .............................................................................................................. 48
13.3 Short Parts List ......................................................................................................... 49
Page 2
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.
1.0.2 Mains Indicator
The green mains light will be lit when there is power to the control panel.
1.0.3 H/L Reset
The yellow H/L reset lamp will be lit when the high limit thermostat has tripped at its set temperature of 110°C. This cuts off power to the burner and may indicate that there is a fault in the heating system. The high limit thermostat has a manual reset button located underneath the control panel in line with the control thermostat. Once the temperature has fallen and the reset button has been pressed the boiler should restart. If the high limit thermostat continues to trip contact your service engineer/technician.
1.0.4 Lock Out
The red lock out lamp will be lit when the burner has failed and can be reset by pressing the illuminated red reset button on the burner control box. If there is power and the thermostat is calling for heat and the burner has been reset it will go through its start up cycle. If the burner again fails to fire this would indicate a burner fault or oil supply problem (oil supply problems are not covered by manufacturers warranty).
1.0.5 Tank Control Thermostat
Located on the right hand side of the control panel the tank control thermostat controls the temperature in the thermal store. The temperature is adjustable up to a maximum of 80°C. A peg has been fitted to the rear of the knob to prevent the temperature being set too high. To change the setting see page 31.
1.0.6 Tank Limit Thermostat
Located inside the control panel the tank limit thermostat is a thermal resetting device controlling the on/off operation of the burner in hot water mode.
1.0.7 Hot Water and Central Heating On/Off Switch
Both hot water and central heating operations can be controlled via these switches. However it should be noted that when both switches are in the ‘on’ position hot water will have priority. In addition whenever a timer or programmer is connected to the boiler one or more of these switches may be bypassed.
1.0.8 Pressure Gauge
The pressure gauge fitted to the front of the control panel measures system pressure. The pressure should be set at 1 bar when the boiler is cold. As the boiler heats up, the pressure will rise but should not exceed 3 bar.
1.0.9 Servicing
It is recommended that the boiler is serviced annually by an OFTEC registered engineer.
Page 3
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.
The Warmflow oil fired ‘Combi’ boiler and Kabin Pak Combi are suitable for sealed central heating systems and can provide at mains pressure domestic hot water without the use of a cylinder.
The Warmflow oil fired combis are designed to burn Class C2 (28 sec redwood) kerosine or Class D (35 sec redwood) gas oil. However to comply with building regulations only kerosine may be burned when using the low level balanced flue or low level conventional flue.
As standard the appliance is fitted with a system expansion vessel, circulating pumps, filling loop, pressure gauge and safety valve. An optional 7-day electronic programmer is also available.
The pressure jet oil burner is covered by the manufacturer’s parts and labour warranty valid for one year (from the boiler date stamp). The boiler and heat store are covered by a manufacturer’s warranty of 5 years (from the boiler date stamp) but does not include burner, labour, handling or shipping. Details of any extended warranties are contained within the installation pack.
Optional extended guarantees, for the appliance covering parts and labour of up to 5 years initially are also available (although not applicable to the Republic of Ireland).
The manufacturer’s guarantees are void if the appliance is not installed and commissioned in accordance with the recommendations made herein.
1.2 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. BS5449 : PART 1 : 1997 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 Scotland Part L Northern Ireland
Current IEE Regulations:
BS7074 : PART 1 : Application Selection & Installation of Expansion Vessels
The heating system should be installed by a competent installer in accordance with the recommendations laid down by HVCA, OFTEC 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 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1.3 Components
1.3.1 Combi Assembly
1. Automatic Air Vents
2. Boiler Heat Exchanger
3. Boiler Control and Limit Stat
4. 12 Litre Esxpansion vessel
5. Boiler Data Plate
6. RDB Burner
7. Boiler Drain Valve
8. Pressure Relief Valve
9. Strainer
10. Filling Loop
11.Tank Control and Limit Stat
12. Flow Switch
13. Mixer Valve
14. Plate Heat Exchanger
15. CH Pump Head
16. DHW Pump Head
17. Pump Gate Valves (x3)
18. Tank Drain Valve
1.3.2 Combi Control Panel
BLANKING
PLATE
CH ON/OFF SWITCH
TANK CONTROL
THERMOSTAT
MAINS ON LAMP (GREEN)
HIGH LIMIT TRIPPED LAMP (YELLOW)
BURNER LOCKOUT LAMP (RED)
SYSTEM
PRESSURE
GAUGE
DHW
PUMP
BOILER
CONTROL
THERMOSTAT
CH
PUMP
HIGH LIMIT THERMOSTAT RESET (UNDERNEATH)
Page 5
1
2
3
4
5
6
7
8
9
10
11 12 13 16 17 18
20
19
22
21
24
23
14 15
1.3.3 Kabin Combi Assembly
1. Flue Terminal Guard
2. Low Level Flue
3. Service Access Hatch
4. Control Panel Cover
5. Controls
6. Pressure Vessel
7. Control Panel Flap Lock
8. Control Panel Flap
9. Door Panel
10. Burner Reset
11. Burner Reset Button
12. Burner
13. Return Connection
14. DHW Pump
15. CH Pump
16. Cable on Oil Line Grommets
Note: To convert the Kabin Pak for use with a conventional flue use the Kabin Pak adaptor
(KPA).
1.3.4 Kabin Pak Combi Control Panel
17. Air Intake Grill
18. Pipe Access Hole
19. Plate Heat Exchanger
20. Mixing Valve
21. Side Panel
22. Pipe Entry Grommets
23. Auto Air Vent
24. Pressure Relief Valve
Mains On (Green)
High Limit (Yellow)
Burner Lockout (Red)
CH Pump
DHW Pump
Boiler Control
Thermostat
DHW ON/OFF
Switch
CH ON/OFF
Switch
High Limit
Thermostat Reset
Tank Control
Thermostat
System
Pressure Gauge
Page 6
2.0 Technical Details
2.1 Sequence of Operation Flow Chart
YES
NO
YES
DHW
Tank Stat
Satisfied
Flow
Switch
Closed
Timer
Calling For
Heat
Power
On
DHW
Pump Only
Runs
HW
Limit Stat
Tr ipped
Burner
Fires
Burner
Stops
CH
Selected
Burner
Fires
CH Pump
Only Runs
Boiler
Stat
Satisfied
Boiler
Limit Stat
Tr ipped
YES
NO
YES
YES
NO
NO
YES
NO
YES
NO
NO
NO
YES
YES
HW
Selected
YES
NO
Room
Stat
Satisfied
NO
YES
Press Reset
Button
YES
NO
Boiler
Limit Stat
Tr ipped
Press Reset
Button
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 to be satisfied.
After a draw-off of 120L at 24L/min, with an average temperature rise of 32°C, the thermal store has a recovery time of approximately 7 mins.
Note: If HW has not been selected no hot water can be
produced even if the heat store is up to temperature.
Page 7
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. 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 pipe 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 been seen but cannot cause any injury or damage.
3. 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.
4. The boiler should be stored in a dry environment. No heavy objects should be placed
on top of the boiler. Where possible the boiler should be moved on its pallet or trucked from its rear. Manhandling the boiler by its casings will result in damage and must be avoided.
Page 8
1
8045
8000
8130
1620
1310
460
820
REAR VIEW
2 3 4
5
6
2.4 Dimensions
2.4.1 Combi Dimensions
2.4.2 Combi Boiler Connections
All dimensions are given in mm.
1. Cold Mains (15mm)
2. Heating Flow (22mm)
3. Domestic Hot Water (22mm)
4. Pressure Relief Discharge (15mm)
5. Spare Connection (1” BSP)
6. Central Heating Return (1” BSP)
MODEL
70/90
J
127
A
865B595C595D90E59F554G750H125
K
127L203
J
H
K
C
E
G F
D
B
L
A
Page 9
2.4.3 Kabin Pak Combi Dimensions
MODEL
70/90
J
371
A
892B732C636D373E188F191G376H172
102
712 MAX
225 MAX
175 MIN
490 MIN
Ø125
2.5 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).
E
B C
FGJH
D
A
Page 10
2.5.2 ‘Easy Fit’ High Level Balanced Flue (HLBF)
The HLBF is available in 4 fixed horizontal lengths which are:
Option 1 – 455mm
Option 2 – 655mm
Option 3 – 585mm
Option 4 – 785mm
2.5.4 Standard Low Level Conventional Flue (LLF)
The factory supplied elbow may be extended up to 1m horizontally and 1.5m vertically by welding on additional pipe or by using vitreous enamelled flue pipe.
2.5.3 ‘Easy Fit’ Telescopic Low Level Conventional Flue (LLF-R)
102
792 MAX
155 MIN
540 MIN
Ø125
225 MAX
575
155 MIN
102
155x155
225 MAX
225 MAX
175 MIN
1128
SEE OPTIONS
160x160
Page 11
2.5.5 Easy Fit Telescopic High Level Balanced Flue (HLBF-R)
2.5.6 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
1570 MIN
2070 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.
AVAILABLE FROM SPRING 2003
Page 12
2.6 Technical Data
Model
Nominal heat KW
Input Btu/hr
Nominal heat KW
Output Btu/hr
Efficiency at max output (net) %
Burner
Head
Flue mm
Size in
Max CO
2
%
Smoke
FGT at max output °C
Water resistance at 20°C ∆T mbar
Approx fuel l/h
Flow rate gals/h
Nozzle make
(kerosine) size
Pump bar
Pressure psi
Nozzle make
(gas oil) size
Pump bar
Pressure psi
Dry weight kg
Primary water content L
Min inlet dynamic pressure bar
for max hot water flow psi
Max DHW flow rate achievable
(refer to page 1)
Factory set DHW flow rate
Min DHW flow rate
DHW temp rise °C
Pressure Relief
Heating flow
Heating return
DHW outlet
Cold water mains inlet (refer to page 1)
Ingress Protection
70/90 Combi
29.3
100,000
26.4
90,000
90
RDB 1
LD3
100 or 127
4 or 5
11.5-12.0
0-1
235
12.0
3.15
0.69
DANFOSS 60°S
0.75
8
116
DANFOSS 60°S
0.6
12
175
155
70
1.8
26
Unrestricted
24 l/min (5.3 gals/min) recommended
18 l/min (4.0 gals/min)
2.5 l/min (0.55 gals/min)
32°C @ 24 L/min for 120L draw off
3 bar (43.5 psi)
22 mm
1” BSP
22 mm
Unrestricted 15 mm bore (minimum)
IPX0
70/90 Kabin Pak Combi
29.3
100,000
26.4
90,000
90
RDB 1
LD3
Integral
Low Level
11.5-12.0
0-1
235
12.0
3.15
0.69
DANFOSS 60°S
0.75
8
116
DANFOSS 60°S
0.6
12
175
155
70
1.8
26
Unrestricted
24 l/min (5.3 gals/min) recommended
18 l/min (4.0 gals/min)
2.5 l/min (0.55 gals/min)
32°C @ 24 L/min for 120L draw off
3 bar (43.5 psi)
22 mm
22 mm Comp.
22 mm
Unrestricted 15 mm bore (minimum)
IP45
Page 13
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. It is the responsibility of the installer to ensure that the appliance has been properly earthed.
3.1 RDB Burner Control Box
CONTROL BOX
535SE/LD
M
M
Oil Valve
Photoresistance
Black White Blue
Motor
Capacitor
Lock Out
Live
Neutral
Earth
Fan
Housing
3.2 Fitting a 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.
ROOM THERMOSTAT
282726
PCB
N
5
29 30
Page 14
Loading...
+ 36 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use