WarmFlow Boilerhouse B90HE, Utility U150HE, Utility U120HE, Boilerhouse B120HEU, Utility Pumped UP70HE User Manual

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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

U-Series

Utility U70HE U90HE U120HE U150HE Utility Pumped UP70HE UP90HE UP120HE UP150HE Utility System US70HE US90HE US120HE Utility Combi UC70HE UC90HE UC120HE

K-Series

Kabin Pak K70HE K90HE K120HE K150HE Kabin Pak Pumped KP70HE KP90HE KP120HE KP150HE Kabin Pak System KS70HE KS90HE KS120HE Kabin Pak Combi KC70HE KC90HE KC120 HE

LEAVE THIS MANUAL WITH THE END USER

Cert. no. FM29884

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.

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.

Tel: 028 9262 1515

Fax: 028 9262 2827

E-mail: service@warmflow.co.uk

Web: www.warmflow.co.uk

For Parts, Service Technical & Warranty Contact

Great Britain & N. Ireland, Tel: 028 9262 1515 Republic of Ireland, Tel: 048 9262 1515

LISBURN TELFORD

Lissue Industrial Estate, Moira Road, Unit 13, 32 Hortonwood, Lisburn, Co. Antrim, N. Ireland, BT28 2RF Telford, TF1 7EU

Tel: (028) 9262 1515 Tel: (01952) 607 750 Fax: (028) 9262 0869 Fax: (01952) 603 983 E-mail: sales@warmflow.co.uk E-mail: salesgb@warmflow.co.uk

technical@warmflow.co.uk technical@warmflow.co.uk service@warmflow.co.uk service@warmflow.co.uk

Page 1

CONTENTS

1 USER INSTRUCTIONS ......................................................................................................... 3

1.1 Dual Thermostat ......................................................................................................................... 3

1.2 High Limit Thermostat Reset ...................................................................................................... 3

1.3 Burner Lockout ........................................................................................................................... 3

1.4 System Pressure – System & Combi Boilers .............................................................................. 4

1.5 Filling Loop ................................................................................................................................. 4

1.6 Combi Control Panel .................................................................................................................. 4

2 CONDENSING BOILER INSTALLATION REQUIREMENTS ............................................... 5

3 BEFORE FITTING A COMBI BOILER THE INSTALLER MUST CHECK: .......................... 6

4 GENERAL INFORMATION ................................................................................................... 7

4.1 Introduction ................................................................................................................................ 7

4.2 General Requirements ............................................................................................................... 7

4.3 Combi General Requirements .................................................................................................... 8

4.4 Baffle Positioning........................................................................................................................ 9

4.5 Components ............................................................................................................................. 10

5 TECHNICAL DETAILS ....................................................................................................... 21

5.1 Combi Sequence of Operation Flow Chart ............................................................................... 21

5.2 Dimensions .............................................................................................................................. 22

5.3 Condensate Disposal ............................................................................................................... 27

5.4 Technical Data ......................................................................................................................... 28

6 ELECTRICITY SUPPLY & WIRING DETAILS ................................................................... 37

6.1 Dual-Safe Thermostat (Non-Combi Boilers) ............................................................................. 37

6.2 RDB Burner Control Box .......................................................................................................... 37

6.3 Combi Wiring Details ................................................................................................................ 38

6.4 Installation of a Warmflow Combi Optional Programmer (PC1) ................................................ 41

6.5 Remote Timers for Combis ....................................................................................................... 42

6.6 Optional Programmer (PC1) for Non-Combi Models ................................................................. 43

7 OIL SUPPLY ....................................................................................................................... 47

7.1 One Pipe Gravity System ......................................................................................................... 47

7.2 Two Pipe System ..................................................................................................................... 48

7.3 De-aerator System ................................................................................................................... 48

7.4 One Pipe Lift System ................................................................................................................ 49

7.5 Instructions for the use of Bio Fuel ........................................................................................... 50

8 FLUES ................................................................................................................................. 52

8.1 Flue Options, Components & Dimensions ................................................................................ 52

8.2 Flue Terminal Locations ........................................................................................................... 68

9 AIR SUPPLY FOR COMBUSTION & VENTILATION ......................................................... 69

9.1 Open Flue Boilers..................................................................................................................... 69

9.2 Balanced Flue Boilers – Boilers in a Compartment ................................................................... 69

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10 INSTALLATION REQUIREMENTS ................................................................................. 70

10.1 General Requirements ............................................................................................................. 70

10.2 Sealed Systems ....................................................................................................................... 71

10.3 Combi Domestic Hot Water ...................................................................................................... 72

11 BURNERS ....................................................................................................................... 73

11.1 RDB Burner .............................................................................................................................. 73

11.2 Oil Pump .................................................................................................................................. 73

11.3 Electrode Setting ...................................................................................................................... 74

11.4 Burner Start-Up Cycle .............................................................................................................. 74

11.5 Air Damper Adjustment ............................................................................................................ 74

12 COMMISSIONING & SERVICING ................................................................................... 75

12.1 Commissioning ......................................................................................................................... 75

12.2 Servicing .................................................................................................................................. 75

13 BURNER FAULT FINDING ............................................................................................. 76

13.1 Riello RDB................................................................................................................................ 76

14 COMBI FAULT FINDING ................................................................................................. 77

14.1 Central Heating ........................................................................................................................ 77

14.2 Domestic Hot Water ................................................................................................................. 78

15 OPTIONAL BOILER MOUNTED DIGITAL TIMER .......................................................... 79

15.1 Operating Instructions .............................................................................................................. 79

16 SPARES .......................................................................................................................... 83

16.1 RDB 2.2 Spares ....................................................................................................................... 83

16.2 RDB 3.2 Spares ....................................................................................................................... 84

16.3 Pipe Spares .............................................................................................................................. 85

16.3 Pipe Spares cont‟d ................................................................................................................... 86

16.4 Short Parts List - Boiler ............................................................................................................ 87

17 YOUR GUARANTEES, TERMS & CONDITIONS ........................................................... 88

Page 3

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.

1.2 High Limit Thermostat Reset

If the high level thermostat trip has operated, remove the reset cover by using a coin or screwdriver (turning anti clockwise) and press the small red button now exposed. Do not press the reset button while the boiler is still hot as this will cause damage to the thermostat.

1.3 Burner Lockout

When the pressure jet oil fired burner stops after failing to fire the red reset button will be illuminated. This indicates that there is a fault or there is no fuel getting to the burner. The house holder should only reset the burner twice in succession. If the burner continues to lockout contact Warmflow or your service engineer.

Control dial

Reset button

Page 4

1.4 System Pressure – System & Combi Boilers

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., due to the removal of a 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 flexible filling loop removed from the valve, expect a small water loss from the pipe.

Special attention must be given to the concentration of corrosion inhibitors in the system water where there is a need for topping up. Concentrations must be restored to inhibitor manufacturers‟ recommendations and monitored going forward.

Frequent or routine topping up of the system should not be necessary and may prove harmful to the appliance. Should topping up prove necessary on a frequent or routine basis you must contact Warmflow or your installer.

1.6 Combi Control Panel

The heating control thermostat is user adjustable from 50°C to 80°C. 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. The high limit thermostat is located under the control panel to the left hand side, press button to reset. As standard the panel is fitted with two on/off selector switches to control hot water and central heating. These switches can be replaced by the optional two channel digital programmer, instructions for use are provided in the main boiler handbook.

This boiler must be serviced annually. Contact Warmflow for further details.

In the event of a breakdown please contact your commissioning engineer who should then contact our service department whilst at your home, to report the fault.

Filling Loop Ball Valve

System Pressure

Page 5

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. The primary difference between an ordinary boiler and a condensing boiler is the condensate drain. The drain can be plumbed from the condensate trap in any ordinary plastic pipe, eg, plastic overflow pipe, directly into the household drain or soak away.

Any blockage in the drain could lead to an alteration in the combustion settings because of partially blocked flueways.

Where the boiler is fitted into a basement a condensate pump may be required.

4. As an indicator of the increased efficiency of a condensing boiler there may be a visible plume of „steam‟ from the flue. Care needs to be exercised when positioning the appliance and selecting the type of flue to ensure that the plume does not cause a nuisance to the householder or to surrounding properties.

As the water temperature in the system rises the pluming effect will diminish. Even where pluming is not visible the boiler is still operating more efficiently than a standard boiler.

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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. 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.

3. Where the mains water pressure is supplied via a borehole pump and

accumulator the pressure variation must not affect the thermostatic mixer valve. Contact Warmflow for further details.

4. The hardness of the mains water supply. Systems with hard water must be

fitted with a suitable chemical scale preventer (e.g. Fernox Quantomat or Combimate).

5. 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 (eg 15mm) or by fitting a restrictor into the pipework.

6. 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.

7. That any showers being supplied with 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 manufacturer‟s guarantees are void if the appliance is not installed and commissioned in accordance with the recommendations made herein.

Page 7

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.

Warmflow oil fired condensing boilers are designed to burn Class C2 (28 sec redwood) kerosene only and to be used on a fully pumped system, and are suitable for connection to sealed heating systems.

As standard the Combi and System boilers are fitted with a system expansion vessel, circulating pumps, filling loop, pressure gauge and safety valve. An optional 7-day electronic programmer kit is also available for all Utility boiler models.

The Combi can provide, at mains pressure domestic hot water without the need for a storage cylinder.

The manufacturer‟s guarantees are void if the appliance is not installed and commissioned in accordance with the recommendations made herein.

4.2 General Requirements

The installation of the boiler must be in accordance with the following regulations.

BS5410 : PART 1 Code of practice for oil firing. BS5449 : PART 1 Forced circulation hot water systems. BS7593 : Treatment of water in domestic hot water central heating systems.

Current Building Regulations: Part J England and Wales

Section 3 Scotland Part L Northern Ireland Part J Republic of Ireland

Current IEE Regulations

BS7074 : PART 1 Application Selection & Installation of Expansion Vessels

Page 8

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.

4.3 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.

After a draw-off of 120L at 24L/min, with an average temperature rise of 32ºC, the thermal store of a 90,000 Btu/h combi has a recovery time of approximately 7 minutes. A 70,000 Btu/h combi will take slightly longer to recover.

Note: If HW has not been selected no hot water can be produced even if the heat store is up to temperature.

4.3.1 Pump Overrun

Where there is a build up of excess heat in the boiler primary heat exchanger and the central heating has not been selected then the pump overrun thermostat will operate. The excess heat will then be pumped into the heat store. Once the temperature has fallen in the boiler and the pump overrun stat is satisfied, then the hot water pump will stop.

4.4 Baffle Positioning

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. The secondary heat exchanger spring baffles must be fully inserted into the heat exchanger tubes (narrow end first).

150 HE Models

The primary heat exchanger baffles consist of two halfwidth 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. The secondary heat exchanger spring baffles must be fully inserted into the heat exchanger tubes (narrow end first).

Page 9

4.5 Components

4.5.1 B-Series Boilerhouse – Casing Components & Key Components

1 4 5 6 2

Page 10

1. Boiler Assembly

2. Top Front Casing (removable)

3. Top Rear Casing (removable)

4. Sides & Rear Casing

5. Front Casing (removable)

6. 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. Heating Return Connection

4.5.2 U-Series Utility – Casing Components

Models up to 120 HE

150 HE Models

Page 11

4.5.3 U-Series Utility – Pre-Wired (UHE)

Key Components

Models up to 120 HE

150 HE Models

Page 12

4.5.4 U-Series Utility – Pumped (UPHE)

Key Components

Models up to 120 HE

150 HE Models

Page 13

Page 14

4.5.5 U-Series Utility – System (USHE) - Key Components

4.5.6 U-Series Utility – Combi (UCHE) - Key Components

4.5.7 K-Series Kabin Pak – Casing Components

Models up to 120 HE

150 HE Models

Page 15

4.5.8 K-Series Kabin Pak - Pre-Wired (KHE)

Key Components

Models up to 120 HE

150 HE Models

Page 16

4.5.9 K-Series Kabin Pak - Pumped (KPHE)

Key Components

Models up to 120 HE

150 HE Models

Page 17

Page 18

4.5.10 K-Series Kabin Pak – System (KSHE) - Key Components

4.5.11 K-Series Kabin Pak – Combi (KCHE) - Key Components

Page 19

4.5.12 Combi Control Panel Layout

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). Should this thermostat ever trip, it must be reset by pressing the small red button underneath the control panel towards the left hand side. Do NOT reset when the boiler is still hot.

3) Hot Water On/Off Switch

4) Heating On/Off Switch

Heating and Hot Water modes are controlled via the on/off switches unless a remote time clock has been fitted. Consult your installer.

5) Mains On Lamp

If this lamp is not lit there may be no power coming to the appliance. Check fuses and heating controls.

6) High Limit Lamp

If this lamp is lit, the high limit thermostat has tripped. Press the high limit reset (2).

7) Burner Lockout Lamp

If this lamp is lit, the burner has locked out after failing to fire. Press the red reset button on the front of the burner.

8) Low Pressure Lamp

If this lamp is lit, the system pressure has fallen below 0.3 bar. Refer to the instructions in Sections 1.4 and 1.5. Additionally, top up the pressure until the light goes out then release pressure via the pressure relief valve until system pressure is 1 bar when the boiler is cold.

2 5 6

(underneath)