WarmFlow Utility Pumped UP70HE, Utility U90HE, Utility Pumped UP90HE, Utility Pumped UP120HE, Utility Pumped UP150HE User Manual

...

Download

Boiler Manual

Incorporating: Guarantee Registration User Instructions Installation Instructions Service Instructions Service Record

High Efﬁciency Condensing Boilers

For use with kerosene only

Models covered by this manual:

U-Series

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

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

Leave this manuaL with the end user

This manual is accurate at the date of printing (E&OE) but will be superseded and should be disregarded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.

Code 3307

ISSUE 3 AUG 08

LisBurn

Lissue Industrial Estate, Moira Road,

Lisburn, Co Antrim, N Ireland, BT28 2RF

Tel: (028) 9262 1515

Fax: (028) 9262 0869

Email: sales@warmﬂow.co.uk

technical@warmﬂow.co.uk

service@warmﬂow.co.uk

manChester

144 Bradford Road,

Manchester, M40 7AS

Tel: (0161) 205 4202

Fax: (0161) 205 4818

Email: sales@warmﬂowgb.co.uk

technical@warmﬂowgb.co.uk

service@warmﬂowgb.co.uk

Commissioning

This appliance must be commissioned. Failure to commission the boiler

will invalidate the warranty. After commissioning ensure that the attached

guarantee registration card is completed and returned. Alternatively,

you can register your guarantee online at www.warmﬂow.co.uk

Servicing

To ensure continued reliable operation and fuel economy

it is recommended that the boiler is serviced annually by

a Warmﬂow or an OFTEC registered technician.

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

Email: service@warmﬂow.co.uk

Web: www.warmﬂow.co.uk

For Parts, Service Technical & Warranty Contact

Great Britain & N Ireland, Tel: 0870 240 6532

Republic of Ireland, Tel: 048 9262 1515

Page 1

Contents Page

User Instructions .....................................................................................................................................................................2

Condensing Boiler Installation Requirements ......................................................................................................................4

Condensing Combi Boiler Pre-Installation Requirements...................................................................................................5

1.0 General Information

1.1 Introduction .....................................................................................................................................................

1.2 General Requirements .....................................................................................................................................

1.3 Combi General Requirements ..........................................................................................................................

1.4 Bafﬂe Positioning .............................................................................................................................................

1.5 Components ...................................................................................................................................................

2.0 Technical Details

2.1 Combi Sequence of Operation Flow Chart ....................................................................................................18

2.2 Dimensions ...................................................................................................................................................19

2.3 Flue Options, Components & Dimensions

......................................................................................................24

2.4 Condensate Disposal ....................................................................................................................................

2.5 Technical Data ...............................................................................................................................................

3.0 Electricity Supply & Wiring Details

3.1 Dual-Safe Thermostat (Non-Combi Boilers) ...................................................................................................36

3.2 RDB Burner Control Box ...............................................................................................................................

3.3 Combi Wiring Details .....................................................................................................................................

3.4 Installation of a Combi Optional Programmer (PC1) .......................................................................................

3.5 Remote Timers for Combis ............................................................................................................................41

3.6 Optional Programmer (PU1) for Non-Combi Models ......................................................................................

4.0 Oil Supply

4.1 One Pipe Gravity System ...............................................................................................................................46

4.2 Two Pipe System ...........................................................................................................................................

4.3 De-aerator System ........................................................................................................................................

4.4 One Pipe Lift System .....................................................................................................................................

5.0 Flues

5.1 Installation of Balanced Flues

.........................................................................................................................49

5.2 Conventional Flues ........................................................................................................................................51

5.3 Low Level Balanced Flue Terminal Positions ..................................................................................................51

6.0 Air Supply for Combustion & Ventilation

6.1 Open Flue Boilers ..........................................................................................................................................

6.2 Balanced Flue Boilers – Boilers in a Compartment .........................................................................................

7.0 Installation Requirements

7.1 General Requirements ...................................................................................................................................54

7.2 Sealed Systems ............................................................................................................................................

7.3 Combi Domestic Hot Water ...........................................................................................................................

8.0 Burners

8.1 RDB Burner ...................................................................................................................................................

8.2 Oil Pump .......................................................................................................................................................

8.3 Electrode Setting ...........................................................................................................................................

8.4 Burner Start-Up Cycle ...................................................................................................................................

8.5 Air Damper Adjustment .................................................................................................................................

9.0 Commissioning & Servicing

9.1 Commissioning..............................................................................................................................................59

9.2 Servicing .......................................................................................................................................................

10.0 Burner Fault Finding

10.1 Riello RDB .....................................................................................................................................................60

11.0 Combi Fault Finding

11.1 Central Heating .............................................................................................................................................61

11.2 Domestic Hot Water ......................................................................................................................................

12.0 Optional Boiler Mounted Digital Timer

12.1 Operating Instructions ...................................................................................................................................63

13.0 Spares

13.1 RDB 2.2 Spares ............................................................................................................................................

13.2 RDB 3.2 Spares ............................................................................................................................................

13.3 Pipe Spares ...................................................................................................................................................

13.4 Short Parts List – Boiler .................................................................................................................................71

14.0 Your Guarantee, Terms & Conditions .....................................................................................................................72

Commissioning/Service Record .............................................................................................................................73

Page 2

USER INSTRUCTIONS

Dual Thermostat

The radiator temperature is regulated via the boiler control thermostat. The thermostat is user adjustable from 55°C at its minimum setting (dial ‘0’) to 85°C at its maximum setting (dial ‘5’). In order to provide an additional level of safety there is a high limit thermostat which has a cut off point of 110°C; this is factory set and is not adjustable. If thermostat trips it needs to be reset manually.

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.

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.

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.

Burner Lock Out Reset

System Pressure

USER INSTRUCTIONS

Dual Thermostat

High Limit Thermostat Reset

Control Thermostat

High Limit Reset

Reset

Notes

Control Thermostat

High Limit Reset

Notes

Page 3

Filling Loop

If the system pressure falls below the minimum (eg, removal of radiator for decorating purposes) then the system should be topped up using the ﬁlling loop valve. After the system has been topped up the pressure gauge should read 1 bar when the system is cold. The valve must be fully closed and the ﬁlling loop ﬂexible removed from the valve, expect a small water loss from the pipe.

Combi Control Panel

The heating control thermostat is user adjustable from 55°C to 85°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.

High Limit Reset Button Underneath

Filling Loop Valve

Flexible Filling Loop Hose

Control Thermostat Knob

Page 4

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.

Page 5

BEFORE FITTING A COMBI BOILER

THE INSTALLER MUST CHECK:

1. What the maximum hot water demand placed on the boiler is likely

to be. Not every installation is suitable for a Combi boiler. Systems requiring very high hot water ﬂow rates may be better suited with an unvented cylinder.

2. That the mains are capable of supplying up to 24 litre/min with a

minimum dynamic pressure of 1.8 bar at the boiler. This is to ensure that the boiler can achieve its maximum output. 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 (eg 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 6

1.0 General Information

1.1 Introduction

Note: All our domestic appliances have been independently tested and

accredited as exceeding the minimum SEDBUK efﬁciency levels required for their type, in compliance with the Building Regulations Approved Document L1A, L1B for England and Wales, the Building Standards (Scotland) Regulations Section 6, Part F Northern Ireland and Part L Republic of Ireland.

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.

1.2 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

The heating system should be installed by a competent installer in accordance with

the recommendations laid down by HVCA, OFTEC and sound engineering practice.

In order to comply with building regulations 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. CD10 and CD11 forms are available from OFTEC on Tel: 0845 658 5080, Fax: 0845 658 5181.

Page 7

1.3 Combi General Requirements

The boiler will have a DHW priority when both domestic hot water (DHW) and central

heating (CH) are selected. So if the ﬂow switch is closed or the heat store has not been satisﬁed the entire output of the boiler is directed to DHW before the boiler will switch over to CH. When fully cold it can take up to 20 minutes for the heat store of a 90,000 Btu/h combi to be satisﬁed, and slightly longer for a 70,000 Btu/h combi.

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.

1.3.1 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.

Page 8

1.4 Bafﬂe Positioning

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).

The primary heat exchanger bafﬂes consist of two

half-width bafﬂe stacks at the bottom, 3 full-width

bafﬂe stacks in the middle and 1 bafﬂe plate at the

top. Upon installation or after servicing, ensure the

bafﬂes are in the correct order and correctly stacked.

To achieve maximum efﬁciency, push the primary

heat exchanger bafﬂes in the direction of the arrows

as shown. The secondary heat exchanger spring

bafﬂes must be fully inserted into the heat exchanger

tubes (narrow end ﬁrst).

Models up to 120 HE 150 HE Models

Page 9

1.5 Components

1.5.1 U-Series Utility – Casing Components

1. Boiler Assembly

2. Top Casing (removable)

3. Rear Casing

4. Side Casing

5. Front Casing (removable)

Models up to 120 HE 150 HE Models

1. Boiler Assembly

2. Top Front Casing (removable)

3. Top Rear Casing (removable)

4. Rear Flue Casing

5. Rear Casing (removable)

6. Side Casing

7. Front Casing (removable)

Page 10

1.5.2 U-Series Utility – Pre-Wired (UHE) – Key Components

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

Models up to 120 HE 150 HE Models

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 3.2 Burner

11. Heating Flow Connection

12. Heating Return Connection

Page 11

1.5.3 U-Series Utility – Pumped (UPHE) – Key Components

1. Heat Exchanger

2. Condensing Unit

3. Pipework Assembly

4. Pressure Relief Valve

5. Auto Air Vent

6. Circulating Pump

7. Auto Air Vent

8. Service Door

9. ‘Dual-Safe’ Thermostat

10. Heat Exchanger Bafﬂes

11. Service Door

12. Service Door Cover

13. Condensate Trap

14. Riello RDB 2.2 Burner

15. Heating Flow Connection

16. Heating Return Connection

Models up to 120 HE 150 HE Models

1. Heat Exchanger

2. Condensing Unit

3. Pipework Assembly

4. Pressure Relief Valve

5. Auto Air Vent

6. Circulating Pump

7. Auto Air Vent

8. Service Door

9. ‘Dual-Safe’ Thermostat

10. Heat Exchanger Bafﬂes

11. Service Door

12. Service Door Cover

13. Condensate Trap

14. Riello RDB 3.2 Burner

15. Heating Flow Connection

16. Heating Return Connection

Page 12

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

1. Pumped (UPHE) Boiler Assembly

2. System Kit (SK1)

3. Pressure Gauge

4. Expansion Vessel

5. Filling Loop

6. Heating Flow Connection

7. Heating Return Connection

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

1. Heat Exchanger

2. Heat Store

3. Condensing Unit

4. Service Door

5. Pipework Assembly

6. Plate Heat Exchanger

7. Twin Head Pump

8. Condensate Trap

9. Service Door

10. Service Door Cover

11. Control Panel

12. Expansion Vessel

13. Riello RDB 2.2 Burner

14. Heat Exchanger Bafﬂes

1213

Page 13

1.5.6 K-Series Kabin Pak – Casing Components

1. Boiler Assembly

2. Top Casing (removable)

3. Flue Assembly (removable)

4. Rear Flue Casing

5. Blanking Plug (removable)

6. Rear Casing (removable)

7. Side Casing

8. Front Casing (removable)

Models up to 120 HE 150 HE Models

1. Boiler Assembly

2. Top Casing (removable)

3. Flue Assembly (removable)

4. Rear Flue Casing

5. Blanking Plug (removable)

6. Rear Casing (removable)

7. Side Casing

8. Front Casing (removable)

Page 14

1.5.7 K-Series Kabin Pak – Pre-Wired (KHE) – Key Components

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

Models up to 120 HE 150 HE Models

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 3.2 Burner

11. Heating Flow Connection

12. Heating Return Connection

Page 15

1.5.8 K-Series Kabin Pak – Pumped (KPHE) – Key Components

1. Heat Exchanger

2. Condensing Unit

3. Pipework Assembly

4. Pressure Relief Valve

5. Auto Air Vent

6. Circulating Pump

7. Auto Air Vent

8. Service Door

9. ‘Dual-Safe’ Thermostat

10. Heat Exchanger Bafﬂes

11. Service Door

12. Service Door Cover

13. Condensate Trap

14. Riello RDB 2.2 Burner

15. Heating Flow Connection

16. Heating Return Connection

8 2

Models up to 120 HE 150 HE Models

1. Heat Exchanger

2. Condensing Unit

3. Pipework Assembly

4. Pressure Relief Valve

5. Auto Air Vent

6. Circulating Pump

7. Auto Air Vent

8. Service Door

9. ‘Dual-Safe’ Thermostat

10. Heat Exchanger Bafﬂes

11. Service Door

12. Service Door Cover

13. Condensate Trap

14. Riello RDB 3.2 Burner

15. Heating Flow Connection

16. Heating Return Connection

Page 16

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

1. Pumped (KPHE) Boiler Assembly

2. System Kit (SK1)

3. Pressure Gauge

4. Expansion Vessel

5. Filling Loop

6. Heating Flow Connection

7. Heating Return Connection

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

1. Heat Exchanger

2. Heat Store

3. Condensing Unit

4. Service Door

5. Pipework Assembly

6. Plate Heat Exchanger

7. Twin Head Pump

8. Condensate Trap

9. Service Door

10. Service Door Cover

11. Control Panel

12. Expansion Vessel

13. Riello RDB 2.2 Burner

14. Heat Exchanger Bafﬂes

Page 17

1.5.11 Combi Control Panel Layout

Control

Thermostat

Mains On

Lamp (Green)

High Limit Tripped

Lamp (Yellow)

Burner Lockout

Lamp (Red)

HW On/Off

Switch

CH On/Off

Switch

High Limit Thermostat Reset

(Underneath)

1.5.12 Combi Pipe Layout (UCHE & KCHE Models)

Page 18

2.0 Technical Details

2.1 Combi Sequence of Operation Flow Chart

Power

Timer Calling

For Heat

Selected

Flow Switch

Closed

DHW Tank

Stat Satisfied

Selected

CH Pump

Only Runs

Room Stat

Satisfied

Boiler Stat

Satisfied

Boiler Limit

Stat Tripped

Burner

Fires

DHW Pump

Only Runs

HW Limit

Stat Satisfied

Boiler Limit

Stat Tripped

Burner

Fires

Burner

Stops

Press

Reset Button

Press

Reset Button

Pump Overrun

Stat Satisfied

DHW Pump

Only Runs

YES

YES NO

Page 19

2.2 Dimensions

2.2.1 U-Series Utility (UHE, UPHE & USHE Models up to 120HE)















































2.2.2 U-Series Utility (150 HE Models)









 

















 













MODEL

ABCDEFGHJKLMNPRSTUVWXYZ

600

413

865

766

134

66686755068721104

2264741

390

10454517191

718

812

UP~

600

413

865

766

134

66686755068721104

2264741

390

10454517191

718

812

US~

600

413

865

766

134

66686755068721104

2264741

390

10454517191

718

812

MODEL

ABCDEFGHJKLMNPRSTUV

U150HE

872

595

1155

1007

134

9057571

1215785

155

850

950

100

318

120

623

950

1050

UP150HE

872

595

1155

1007

134

9057571

1215785

155

850

950

100

318

120

623

950

1050

Page 20

2.2.3 U-Series Utility (UCHE Models)











 

















 







 

MODEL

ABCDEFGHJKLMNPRSTUVWX

UC~

600

595

865

766

134

388

207

666472264294

71891715154

104

39071104

197

Page 21

2.2.4 K-Series Kabin Pak (KHE, KPHE & KSHE Models up to 120HE)























 















2.2.5 K-Series Kabin Pak Base Tray (KHE, KPHE & KSHE Models up to 120HE)









  

  

 

FRONT

MODEL

ABCDEFGHJKLMNPRSTUV

700

413

900406740210

7055050

161937736790

11752415

KP~

700

413

900406740210

7055050

161937736790

11752415

KS~

700

413

900406740210

7055050

161937736790

11752415

Page 22

2.2.6 K-Series Kabin Pak (150HE Models)





























 









2.2.7 K-Series Kabin Pak Base Tray (150HE Models)

FRONT







  



 









MODEL

ABCDEFGHJKLMNPRSTUV

K150HE

595

997

876

1155931617570

1205585

155

850

100

320

122

630

120

KP150HE

595

997

876

1155931617570

1205585

155

850

100

320

122

630

120

Page 23

2.2.8 K-Series Kabin Pak (KCHE Models)

2.2.9 K-Series Kabin Pak Base Tray (KCHE Models)



































 







FRONT



  





 



 



MODEL

ABCDEFGHJKLMNPRSTUVWX

KC~

700

600

900

770

210

396

20992161525050705

1176740904067415

Page 24

2.3 Flue Options, Components & Dimensions

The use of any ﬂue system other than that supplied or recommended by the

manufacturer will invalidate the warranty.

2.3.1 HE Low Level Balanced Flue Kit (FBF)

Comprising the following four main components.

1. Diverter Assembly

2. Extension

3. Elbow

4. Terminal End

5. Mounting Brackets

2.3.2 Plume Management Kit

Plume Management Kits are available for

our range of appliances. Please refer to the Installation Instructions supplied with the kits.

Page 25

2.3.3 Warmﬂow HE Boiler Flue Components: 80/125 Ø

Note:

1. Flue ﬁtting kit required.

2. If terminal is less than 2 metres above ground level terminal guard must be ﬁtted.

3. Extension pipes and ﬂue adaptor lengths quoted are effective lengths and not the actual length

of the piece.

4. All dimensions in mm unless otherwise stated.

Page 26

2.3.4 Vertical & High Level Terminal Options

Note:

1. All ﬂues can utilise any combination of bends, straights, adaptors and terminals.

2. Ensure ﬂue is arranged such that it falls continuously towards the boiler.

3. 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.

BOILER

OUTPUT

(kW)

TOTAL EQUIVALENT FLUE LENGTH (m)

Vertical Balanced Flue High/Low Level Balanced Flue

8.0 5.015

8.0 5.021

8.0 5.026

6.0 3.530

4.0 2.533

4.0 2.544

Page 27

2.4 Condensate Disposal

The Warmﬂow high efﬁciency condensing boiler is supplied with a factory ﬁtted, self

sealing condensate trap. The trap has been ﬁtted inside the boiler casing to the right hand side.

The condensate drainage pipe within the boiler is a ﬂexible plastic hose which can

be trimmed to length. 3/4” or 22mm pipe should be connected to the ﬂexible hose. The pipe should not be made from steel or copper. The drainage pipe may run into an internal soil stack or waste pipe, an external gulley, hopper or soakaway as shown below.

The boiler when fully condensing will produce a maximum of 1.5 litres per hour of

condensate. It is recommended that the drainage pipe should have a minimum fall of 1:20.

Page 28

2.5 Technical Data

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

U90HEU70HEMODEL

Nominal kW

Heat Output Btu/hr

Nominal kW

Heat Input Btu/hr

Burner

Head

Secondary Air Damper

Flue mm

Diameter in

Flue Gas Temp °C

Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar

Pressure psi

Max CO2 %

Approx Fuel litres/h

Flow Rate gals/h

Flow Connection

Return Connection

Water litres

Content gals

Boiler Weight Dry kg

Boiler Weight Wet

SEDBUK Efﬁciency %

Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

28mm Compression

1” BSP Female

28mm Compression

1” BSP Female

4.8

112

92.2

112

92.8

Highlighted in Bold

U120HE

27.1

92,380

32.7

111,600

95,550

99,050

116,000

RDB 2.2 26-33

T5S

N/A

100 or 125

4 or 5

95 98 110

Danfoss 60°ES

0.75 0.85 0.85

7.0

102

8.0

116

10.0

145

11.5 11.5 11.5

2.98

0.65

3.40

0.75

3.81

0.84

28mm Compression

1” BSP Female

4.8

112

92.4

102,400

U150HE

112,629

150,128

112,629

38.5

131,362

46.8

159,681

RDB 3.2 33-44

Adjustable @ setting 5

N/A

100 or 125

4 or 5

75 90 105

Danfoss 80°H

0.85 1.00 1.25

10.0

145

9.5

138

9.5

138

11.5 11.5 11.5

3.81

0.84

4.48

0.99

5.25

1.16

1¼” BSP Female

9.9

175

220

91.9

136,139

Page 29

2.5.2 U-Series Utility – Pumped (UPHE)

UP90HEUP70HEMODEL

Nominal kW

Heat Output Btu/hr

Nominal kW

Heat Input Btu/hr

Burner

Head

Secondary Air Damper

Flue mm

Diameter in

Flue Gas Temp °C

Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar

Pressure psi

Max CO2 %

Approx Fuel litres/h

Flow Rate gals/h

Flow Connection

Return Connection

Water litres

Content gals

Boiler Weight Dry kg

Boiler Weight Wet kg

SEDBUK Efﬁciency %

Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

22mm Copper

1” BSP Female

22mm Copper

1” BSP Female

4.8

117

92.2

117

92.8

Highlighted in Bold

UP150HE

112,629

150,128

112,629

38.5

131,362

46.8

159,681

RDB 3.2 33-44

Adjustable @ setting 5

N/A

100 or 125

4 or 5

75 90 105

Danfoss 80°H

0.85 1.00 1.25

10.0

145

9.5

138

9.5

138

11.5 11.5 11.5

3.81

0.84

4.48

0.99

5.25

1.16

28mm copper

1¼” BSP Female

9.9

185

230

91.9

136,139

UP120HE

27.1

92,380

102,400

32.7

111,600

95,550

116,000

RDB 2.2 26-33

T5S

N/A

100 or 125

4 or 5

95 98 110

99,050

Danfoss 60°ES

0.75 0.85 0.85

7.0

102

8.0

116

10.0

145

11.5 11.5 11.5

2.98

0.65

3.40

0.75

3.81

0.84

28mm Compression

1” BSP Female

4.8

117

92.4

Page 30

2.5.3 U-Series Utility – System (USHE)

US90HEUS70HEMODEL

Nominal kW

Heat Output Btu/hr

Nominal kW

Heat Input Btu/hr

Burner

Head

Secondary Air Damper

Flue mm

Diameter in

Flue Gas Temp °C

Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar

Pressure psi

Max CO2 %

Approx Fuel litres/h

Flow Rate gals/h

Flow Connection

Return Connection

Water litres

Content gals

Boiler Weight Dry kg

Boiler Weight Wet kg

SEDBUK Efﬁciency %

Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

22mm Copper

1” BSP Female

22mm Copper

1” BSP Female

4.8

105

127

92.2

105

127

92.8

Highlighted in Bold

US120HE

27.1

92,3802999,050

32.7

111,600

95,55030102,400

116,000

RDB 2.2 26-33

T5S

N/A

100 or 125

4 or 5

95 98 110

Danfoss 60°ES

0.75 0.85 0.85

7.0

102

8.0

116

10.0

145

11.5 11.5 11.5

2.98

0.65

3.40

0.75

3.81

0.84

28mm Compression

1” BSP Female

4.8

105

127

92.4

Page 31

2.5.4 U-Series Utility – Combi (UCHE)

UC90HEUC70HEMODEL

Nominal kW Heat Output Btu/hr

Nominal kW Heat Input Btu/hr

Burner Head Secondary Air Damper

Flue mm Diameter in

Flue Gas Temp °C Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar Pressure psi

Max CO2 % Approx Fuel litres/h

Flow Rate gals/h

Flow Connection Return Connection

Water litres Content gals

Boiler Weight Dry kg Boiler Weight Wet kg

SEDBUK Efﬁciency % Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

22mm Copper 22mm Copper

16.3 140

214

90.0 90.0

Highlighted in Bold

16.3 140

214

Domestic Hot Water (DHW) Production

Minimum Inlet Dynamic Pressure bar for Maximum DHW Flow Rate psi

Maximum Achievable DHW Flow Rate

Maximum Recommended litres/m DHW Flow Rate gals/m

Factory Set litres/m DHW Flow Rate gals/m

Minimum litres/m DHW Flow Rate gals/m

DHW Temperature Rise (at Maximum Output)

Pressure Relief bar

psi

Cold Water Mains Inlet Connection

DHW Outlet Connection

1.8 26

Unrestricted Unrestricted

4.0

5.3

4.0

2.5

0.55

2.5

0.55

32°C @ 18 litres/min for 120 litre draw-off

32°C @ 24 litres/min for 120 litre draw-off

43.5

Minimum 15mm

Unrestricted

Minimum 15mm

Unrestricted

22mm Copper 22mm Copper

Page 32

2.5.5 K-Series Kabin Pak – Pre-Wired (KHE)

K120HEK90HEK70HEMODEL

Nominal kW

Heat Output Btu/hr

Nominal kW

Heat Input Btu/hr

Burner

Head

Secondary Air Damper

Flue mm

Diameter in

Flue Gas Temp °C

Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

27.1

92,380

102,400

32.7

111,600

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,5502895,550

116,000

RDB 2.2 15-21 RDB 2.2 21-26 RDB 2.2 26-33

T1SH T2SH T5S

B N/A N/A

100 or 125

4 or 5

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95 95 98 110

0 0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar

Pressure psi

Max CO2 %

Approx Fuel litres/h

Flow Rate gals/h

Flow Connection

Return Connection

Water litres

Content gals

Boiler Weight Dry kg

Boiler Weight Wet kg

SEDBUK Efﬁciency %

Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

Danfoss 60°ES

0.75 0.85 0.85

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

7.0

102

8.0

116

10.0

145

11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

2.98

0.65

3.40

0.75

3.81

0.84

28mm Compression

1” BSP Female

28mm Compression

1” BSP Female

28mm Compression

1” BSP Female

4.8

112

92.2

112

92.8

112

92.4

99,050

Highlighted in Bold

K150HE

112,629

150,128

112,629

38.5

131,362

46.8

159,681

RDB 3.2 33-44

Adjustable @ setting 5

N/A

100 or 125

4 or 5

75 90 105

Danfoss 80°H

0.85 1.00 1.25

10.0

145

9.5

138

9.5

138

11.5 11.5 11.5

3.81

0.84

4.48

0.99

5.25

1.16

1¼” BSP Female

9.9

175

220

91.9

136,139

Page 33

2.5.6 K-Series Kabin Pak – Pumped (KPHE)

KP90HEKP70HEMODEL

Nominal kW

Heat Output Btu/hr

Nominal kW

Heat Input Btu/hr

Burner

Head

Secondary Air Damper

Flue mm

Diameter in

Flue Gas Temp °C

Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar

Pressure psi

Max CO2 %

Approx Fuel litres/h

Flow Rate gals/h

Flow Connection

Return Connection

Water litres

Content gals

Boiler Weight Dry kg

Boiler Weight Wet kg

SEDBUK Efﬁciency %

Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

22mm Copper

1” BSP Female

22mm Copper

1” BSP Female

4.8

117

92.2

117

92.8

Highlighted in Bold

KP120HE

27.1

92,380

102,400

32.7

111,600

95,550

116,000

RDB 2.2 26-33

T5S

N/A

100 or 125

4 or 5

95 98 110

99,050

Danfoss 60°ES

0.75 0.85 0.85

7.0

102

8.0

116

10.0

145

11.5 11.5 11.5

2.98

0.65

3.40

0.75

3.81

0.84

28mm Compression

1” BSP Female

4.8

117

92.4

KP150HE

112,629

150,128

112,629

38.5

131,362

46.8

159,681

RDB 3.2 33-44

Adjustable @ setting 5

N/A

100 or 125

4 or 5

75 90 105

Danfoss 80°H

0.85 1.00 1.25

10.0

145

9.5

138

9.5

138

11.5 11.5 11.5

3.81

0.84

4.48

0.99

5.25

1.16

28mm Copper

1¼” BSP Female

9.9

185

230

91.9

136,139

Page 34

2.5.7 K-Series Kabin Pak – System (KSHE)

KS90HEKS70HEMODEL

Nominal kW

Heat Output Btu/hr

Nominal kW

Heat Input Btu/hr

Burner

Head

Secondary Air Damper

Flue mm

Diameter in

Flue Gas Temp °C

Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar

Pressure psi

Max CO2 %

Approx Fuel litres/h

Flow Rate gals/h

Flow Connection

Return Connection

Water litres

Content gals

Boiler Weight Dry kg

Boiler Weight Wet kg

SEDBUK Efﬁciency %

Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

22mm Copper

1” BSP Female

22mm Copper

1” BSP Female

4.8

105

127

92.2

105

127

92.8

Highlighted in Bold

KS120HE

27.1

92,380

102,400

32.7

111,600

95,550

116,000

RDB 2.2 26-33

T5S

N/A

100 or 125

4 or 5

95 98 110

99,050

Danfoss 60°ES

0.75 0.85 0.85

7.0

102

8.0

116

10.0

145

11.5 11.5 11.5

2.98

0.65

3.40

0.75

3.81

0.84

28mm Compression

1” BSP Female

4.8

105

127

92.4

Page 35

2.5.8 K-Series Kabin Pak – Combi (KCHE)

KC90HEKC70HEMODEL

Nominal kW Heat Output Btu/hr

Nominal kW Heat Input Btu/hr

Burner Head Secondary Air Damper

Flue mm Diameter in

Flue Gas Temp °C Smoke Bacarach

14.7

50,000

17.6

60,000

71,6502171,650

23.5

80,000

27.1

92,380

15.3

52,150

18.4

62,6002275,0002275,000

24.4

83,1752895,550

RDB 2.2 15-21 RDB 2.2 21-26

T1SH T2SH

B N/A

100 or 125

4 or 5

100 or 125

4 or 5

86 88 90 90 93 95

0 0

Kerosene Settings

Nozzle make

size

Oil Pump bar Pressure psi

Max CO2 % Approx Fuel litres/h

Flow Rate gals/h

Flow Connection Return Connection

Water litres Content gals

Boiler Weight Dry kg Boiler Weight Wet kg

SEDBUK Efﬁciency % Factory Settings

Danfoss 60°ES

0.5 0.5 0.6

Danfoss 60°ES

0.6 0.65 0.75

7.0

102

9.0

130

8.0

116

8.0

116

8.0

116

7.0

102

11.5 11.5 11.5 11.5 11.5 11.5

1.65

0.36

1.98

0.44

2.35

0.52

2.35

0.52

2.65

0.58

2.98

0.65

22mm Copper 22mm Copper

16.3 140

214

90.0 90.0

Highlighted in Bold

16.3 140

214

Domestic Hot Water (DHW) Production

Minimum Inlet Dynamic Pressure bar for Maximum DHW Flow Rate psi

Maximum Achievable DHW Flow Rate

Maximum Recommended litres/m DHW Flow Rate gals/m

Factory Set litres/m DHW Flow Rate gals/m

Minimum litres/m DHW Flow Rate gals/m

DHW Temperature Rise (at Maximum Output)

Pressure Relief bar

psi

Cold Water Mains Inlet Connection

DHW Outlet Connection

1.8 26

Unrestricted Unrestricted

4.0

5.3

4.0

2.5

0.55

2.5

0.55

32°C @ 18 litres/min for 120 litre draw-off

32°C @ 24 litres/min for 120 litre draw-off

43.5

Minimum 15mm

Unrestricted

Minimum 15mm

Unrestricted

22mm Copper 22mm Copper

Page 36

3.0 Electricity Supply & Wiring Details

220 – 240V. 1PH, 50 Hz

The boiler/burner and other external electrical equipment should be wired with heat

resistant cable via a fused double pole isolating switch which should be ﬁtted with a 5 amp fuse.

The appliance must be effectively earthed and all external wiring should comply with

current IEE Regulations.

3.1 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.

3.2 RDB Burner Control Box

CONTROL BOX

535SE/LD

Oil Valve

Photoresistance

Black White Blue

Motor

Capacitor

Lock Out

Live

Neutral

Earth

Fan

Housing

To Burner

From Power Supply (Switched Live)

Page 37

3.3 Combi Wiring Details

3.3.1 Wiring Diagram

The 3 pin mains plug must be supplied with a permanent live to allow the pump overrun stat and relay to operate correctly.

Page 38

3.3.2 Wiring Schematic

BURNER

D.H.W. PUMP

C.H. PUMP

TRIPLE POLE RE LAY

N.C.

BOILER STA T

N.O.

N.C.

N.O.

N.C.

COIL

20 21

2425

3 19

MAINS PLUG

H.W.

C.H.

TANK STAT

FLOW SW ITCH

TANK LIMIT

STAT

BOILER LIMIT ST AT

MAINS ON

LAMP

(GRE EN)

H/L RESET

LAMP

(YELLOW )

LOCKOUT

LAMP

(GRE EN)

LAMP

BOILER LIMIT ST AT

H/L RESET

LAMP

(YELLO W)

BREAK INTO T HE WHITE

WIRE BETWEE N NO 16 ON

THE PCB AND THE LIMIT

STAT AND CONNECT IN THE

PRESSURE SWITCH WI TH A

WIRING BLOCK AS SHOW N

LOW PRES SURE

SWIT CH

LOW PRES SURE

SWIT CH

WIRING A L OW PRESSURE SWITCH

WIRING

BLOCK

COIL

PUMP OVER

RUN STAT

PUMP OVER

RUN RELAY

WIRING

BLOCK

Page 39

3.3.3 Fitting a Room Thermostat 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. To prevent over heating of the property a pipe thermostat should be ﬁtted on the return pipe close to the boiler. The Kabin Pak Combi boiler is factory ﬁtted with a frost thermostat as standard.

3.3.5 Combi Pump Overrun Thermostat

The condensing Combi boilers have been ﬁtted with a pump overrun thermostat.

In order for the thermostat to work effectively the boiler must be supplied with a permanent live. Failure to do this will result in nuisance trip outs.

Remove the purple wire from no 5 and no 28 on the PCB and wire the thermostat

as shown. The room thermostat should be located where it is not subjected to extraneous heat gains, direct sunlight or draughts.

3.3.4 Fitting Frost Protection to a Combi

ROOM THERMOSTAT

282726

PCB

29 30

FROST THERMOSTAT

PERMANENT

LIVE

543 6

PIPE THERMOSTAT

Page 40

3.4 Installation of a Warmﬂow Combi Optional Programmer (PC1)

1. Disconnect the electrical supply.

2. Drop down control box front (2 screws).

3. Disconnect the 6 pin plug from the CH/HW on/off switched.

4. With a sharp knife cut out the outline of the panel knockout through the facia label from the front of the panel.

5. With a hacksaw blade or snips remove the knockout piece ensuring that all metal tags or burrs have been removed from the hole.

6. Feed the programmer and harness through the hole from the front of the panel.

7. Secure in position by attaching the securing bracket to the rear of the programmer.

8. Plug the wiring harness into the 6 way socket.

9. Activate battery back up on the programmer by removing the plastic strip.

10. Close the control panel cover and reconnect the electrical supply.

11. Using the operating instructions located towards to back of this manual or supplied with the programmer, set the switching times.

Page 41

3.5 Remote Timers for Combis

3.5.1 Installation of a remote two channel programmer (option 1)

Connecting the programmer in this

manner will bypass the CH and HW on/ off switches on the boiler control panel. A separate connection to the boiler 3 pin mains plug is NOT required.

Inside the boiler control panel, remove

the purple and white wires connecting terminals 5 and 3 on the terminal block with terminals 19 and 28 on the PCB.

Connect the programmer to the

permanent live mains supply via a fused isolator as shown.

Connect the boiler to the programmer via a 5 core cable as shown ensuring that the

earth is connected to one of the earth post inside the control panel and that the

permanent live is connected to terminal 12 on the PCB. Failure to connect the permanent live to the boiler in this way will prevent the mains lamp and pump overrun thermostats from operating. It will also prevent the built-in frost protection of a Kabin Pak Combi from operating.

3.5.2 Installation of a remote two channel programmer (option 2)

Connecting the programmer in this

manner will bypass the CH and HW on/ off switches on the boiler control panel. The boiler and programmer will both be powered from the boiler 3 pin mains plug.

Inside the boiler control panel, remove

the purple, white and brown wires connecting the CH and HW switches to the 6 pin connector of the terminal block.

Connect the programmer to the 6 pin

connector via a 5 core cable as shown ensuring the earth is connected to one of the earth posts inside the control panel.

Connect the boiler 3 pin mains plug to a permanent live mains supply via a fused

isolator. Failure to connect a permanent live to the boiler will prevent the programmer, boiler mains lamp and pump overrun thermostats from operating. It will also prevent the built-in frost protection of a Kabin Pak Combi from operating.

OFFOFFE N L

COM

22 21 20 19

PCB CONTROLLER

COM

CH HW

26 25 24 2328 27

12 11

EARTH

POST

OFFOFFE N L

COM

ON ON

COM

CH HW

EARTH

POST

Page 42

3.6 Optional Programmer (PU1) for Non-Combi Models

3.6.1 Programmer Control Box Wiring Diagram

3.6.2 General Requirements

1. The optional programmer as supplied will supply power to the pump and burner via the central heating channel.

2. When connecting to external controls, eg ‘Y’ plan or ‘S’ plan it will be necessary to remove the loop between 3 and 12 on the programmer terminal block.

3. The programmer is not suitable for gravity hot water systems.

Page 43

3.6.3 Programmer Installation

1. Disconnect electrical supply.

2. Drop down control box front (2 screws).

3. Secure control box to the horizontal casing bracket (2 screws) and right hand side (1 screw).

4. Connect the thermostat, circulating pump and the mains supply to the leads on the rear of the control box.

5. Two examples of system wiring are shown in the following sections.

6. If ﬁtting the programmer to a Utility model

without an integral pump, disconnect the pump plug from terminals 1 and 2 of the programmer terminal block and from the earth post. Remove the pump plug then wire the external plug into terminals 1 and 2 of the programmer terminal block and the earth post, feeding the wire in through the pump plug cable clamp.

7. Activate battery backup on programmer by removing the plastic strip.

8. Close the control panel cover (2 screws) and reconnect the electrical supply.

9. Using the operating instructions located towards the back of this manual or supplied with the programmer, set the switching times.

Page 44

3.6.4 Honeywell ‘Y’ Plan – Independent CH & DHW (Fully Pumped Only)

Note: Before ﬁtting programmer remove loop between 3 and 12 on the terminal block.

Page 45

3.6.5 Honeywell ‘S’ Plan – Independent CH & DHW (Fully Pumped Only)

Note: Before ﬁtting programmer remove loop between 3 and 12 on the terminal block.

Page 46

4.0 Oil Supply

1. Oil Tank

Steel tanks constructed to BS799 : PART 5 should be painted on the outside only

and mounted on piers to prevent corrosion. Plastic oil tanks are also available and can be suitable for installation at ground level. However, oil should never be stored in translucent plastic containers.

The tank outlet should be at a height to provide sufﬁcient clearance to allow for

proper maintenance of any isolation valve, oil ﬁlter or water separator ﬁtted.

2. The pipe from the oil tank to the burner should be run in copper, steel or aluminium. Galvanised pipe and ﬁttings should not be used. The pipework should terminate close to the boiler and be ﬁtted with an isolating valve and ﬁlter. A remote sensing ﬁre valve must be ﬁtted to the oil line preferably before the oil line enters the building (BS5410 : PART 1).

Depending on the position of the tank a two pipe system may be required. One and

two pipe oil systems are shown below. As an alternative to a two pipe system a Tigerloop or other approved de-aerator may be used.

4.1 One Pipe Gravity System

Head H(m)

ID 8mm

ID 10mm

0.5 1 1.5 2

10 20 40 60 20 40 80 100

Total Maximum Pipe Length (m)

Note: Plastic oil level gauges may shrink when

exposed to kerosene thus allowing the ingress of water. Pump failures due to water contamination are not covered under the warranty.

Page 47

Head H(m)

ID 8mm

ID 10mm

0.5 1 2 3

35 25 15 8

100 100 70 30

0.5

100

3.5

1.5

20 90

Total Maximum Pipe Length (m)

4.2 Two Pipe System

For maximum pipe length and lift contact de-aerator manufacturer.

4.3 De-aerator System

Page 48

Head H(m)

ID 8mm

ID 10mm

0.5 1 2 3

35 25 15 8

100 100 70 30

0.5

100

3.5

1.5

20 90

Total Maximum Pipe Length (m)

4.4 One Pipe Lift System

Note: The pump vacuum should

not exceed a maximum of 0.4 bar. Above this gas is released from the oil thus leading to burner lock out.

Page 49

5.0 Flues

5.1 Installation of Flues

Page 50

5.1.1 Installation of a Balanced Flue (FBF)

1. Make a suitable sized hole in the wall or ceiling for the ﬂue. For the dimensions of the boiler, see the Dimensions Section of this manual. For the dimensions of the ﬂue system, see the Flue Kits & Dimensions Section of this manual.

Note: The cavities around the opening must be sealed and protected by a non-

combustible sleeve.

2. Remove the top casing panel. If ﬁtting a low level horizontal ﬂue (FBF), remove the upper casing panel knockout from the appropriate side or rear panel using a pair of tin snips. Push the boiler into position against the wall then install the ﬂue starter piece, securing it in position using the nuts provided and ensuring the black rubber gasket is correctly seated. The white ﬁbre gasket supplied in the Flue Fittings Kit (FFK) is not required and should NOT be ﬁtted.

3. If installing extension pieces, ensure the seals are correctly ﬁtted and lubricated before pushing through the wall and into the starter piece.

Note: Refer to the Flue Options, Components and Dimensions Section for details of

the maximum number of extension pieces and total ﬂue lengths allowed.

4. If installing a vertical ﬂue, correctly ﬁt the ﬂashing kit then slide the ﬂue terminal into position with a twisting movement. Ensure that the terminal protrudes through the roof by a minimum of 665mm.

If installing a horizontal ﬂue, slide the ﬂue terminal into position with a twisting

movement then seal the gap between the ﬂue and the wall both inside and outside. Ensure that the terminal protrudes through the wall by a minimum of 175mm and a maximum of 225mm.

If installing a Plume Management Kit, ﬁt the starter piece and horizontal terminal as

described above then install the Plume Management Kit as instructed in the leaﬂet supplied with the kit.”

5. If installing a low-level horizontal ﬂue, ﬁt the terminal guard (basket) over the ﬂue terminal using the cardboard mounting template supplied with the ﬂue kit to locate and drill the necessary screw holes in the wall.

6. Remove the air inlet cover from the burner then ﬁt the intake adaptor spigot and gasket. Connect one end of the air duct / hose to the ﬂue and the other end to the adaptor spigot and secure.

Page 51

5.2 Conventional Flues

The ﬂue system should be designed in accordance with local

bye-laws and the Building Regulations. Draught stabilisers are not recommended for oil ﬁred boilers. Sharp bends or horizontal runs should be avoided and the ﬂue should terminate 2 feet (600mm) above the ridge of the dwelling. Terminals which restrict the discharge or allow ingress of water should be avoided.

When connecting to an existing masonry chimney, a ﬂexible

ﬂue liner suitable for use with oil ﬁred condensing boilers and of an appropriate diameter must be used. The annular space must be ﬁlled with insulation and sealed top and bottom. The starter piece should be sealed into the conventional ﬂue adaptor using a high temperature silicone sealant, ﬁre cement must not be used.

Only proprietary ﬂue systems designed speciﬁcally

for use with oil-ﬁred condensing boilers may be used. The ﬂue system manufacturer’s installation instruction must be followed.

For recommended conventional ﬂue systems, contact

Warmﬂow.

5.3 Low Level Balanced Flue Terminal Positions

Attention should be given to the position of the ﬂue discharge;

we recommend the following guidelines be adopted.

1. The ﬂue should not discharge beneath opening windows or near other accesses to the building.

2. The ﬂue should not discharge near internal/external corners of the building where turbulent wind conditions could occur.

3. A terminal guard must be ﬁtted at all times.

4. The terminal should not discharge over property boundaries.

5. Discharge into narrow passageways should be avoided.

6. The location of the terminal and routing of the ﬂue should be determined by the installer after consultation with the householder.

7. In positioning the ﬂue the wind direction should be considered.

Installation in exposed positions is not recommended.

8. Account must be made of the pluming from the ﬂue. If it is likely to be a nuisance to the householder the use of a vertical balanced ﬂue or conventional ﬂue should be considered.

Page 52

These are minimum dimensions and are only quoted as a guidelines.

Terminating positions must be at least 1.8 metres from an oil storage tank unless

a wall with at least 30 min ﬁre resistance and extending 300mm higher and

wider than the tank is provided between the tank and the terminating position.

From an internal or external corner or surface or boundary alongside the terminal.F 300

Above ground or balcony level.G 300

From a surface or a boundary facing the terminal.H 600

From a terminal facing the terminal.J 1,200

Vertically from a terminal on the same wall.K 1,500

Horizontally from a terminal on the same wall.L 750

Above the highest point of an intersection with the roof.M 600

From a vertical structure on the side of the terminal.N 750

Above a vertical structure less than 750mm from the side of the terminal.O 600

From a ridge terminal to a vertical structure on the roof.P 1,500

A 600Directly below an opening, air brick, opening window etc.

B 600Horizontally to an opening, air brick, opening window etc.

C 75

Below a gutter or a balcony without protection.D 600

From vertical sanitary pipework.E 300

Below a gutter, eaves or balcony with protection.

MINIMUM DISTANCES TO TERMINALS IN MILLIMETRES AS MEASURED FROM

THE TOP OF THE CHIMNEY OR THE RIM OF A LOW LEVEL DISCHARGE OPENING

Page 53

6.0 Air Supply for Combustion & Ventilation

(see BS5410)

6.1 Open Flue Boilers

When the boiler is sited in a cellar where the only access for combustion and

ventilation air is at high level then the combustion air should be ducted to low level.

Combustion Air Supply

Boiler in Room

Boiler in Compartment

6.2 Balanced Flue Boilers – Boilers in a Compartment

Air Supply for Ventilation

No Combustion Air Inlet required to Room

Page 54

7.0 Installation Requirements

The boiler installation must be in compliance with BS5410 : PART 1 and the Building

Regulations.

7.1 General Requirements

7.1.1 Hearth

The boiler has a hearth temperature of between 50°C and 85°C and should be stood

on a rigid, non-porous, non-combustible base, which is not softened by warmth, to comply with the Building Regulations.

7.1.2 Service Access

24” (600mm) Clearance should be provided above and in front of the boiler to allow

for routine servicing. Pumped, System and Combi models may require access to the top.

7.1.3 Heating System

The heating system should be installed to HVCA current codes of practice. Before

installing the boiler the new or existing system must be thoroughly ﬂushed to clear all sludge or other foreign matter such as solder, steel wool and copper ﬁlings. The system must be cleansed, neutralised and protected from corrosion in accordance with BS5449 and BS7593 using suitable cleansing agent(s) and inhibitor(s) and carried out in accordance with the cleanser / inhibitor manufacturers’ instructions. The system must be dosed to the concentrations speciﬁed by the inhibitor manufacturer (refer to the Technical Data section of this manual for the volume of the boiler when calculating the total system volume). Failure of components such as, but not limited to, pumps, auto air vents, pressure relief valves, plate heat exchangers and non-return valves due to corrosion product in the system will not be covered by warranty.

7.1.4 Air Vents

The plastic plugs of the auto air vent(s) factory-ﬁtted to the boiler must be loosened

when ﬁlling the system in order to bleed the air from the boiler. In addition to any factory ﬁtted air vents it is recommended that another air vent is ﬁtted at the highest point in the system. Where the ﬂow pipework drops down from the boiler the installer must ensure that an automatic air vent is ﬁtted to the top of the pipework to prevent air being trapped in the boiler.

7.1.5 Drain Cock

For all appliances not factory-ﬁtted with drain cocks, one should be ﬁtted to the

boiler drain boss located to the left hand side of the burner. Drain cocks should also be ﬁtted to the lowest points in the system to allow the system to be completely drained.

7.1.6 Frost Protection

Where there is a risk to the boiler or installation from frost then a suitable frost

thermostat should be ﬁtted. Alternatively the system could be dosed with an anti freeze agent. The Kabin Pak Combi boiler is factory ﬁtted with a frost thermostat as standard. For all other Kabin Pak models covered by this manual a Frost Thermostat Kit (Code FSK1) is available as an optional extra.

7.1.7 Pipework

We strongly advise that all installation pipework is run in copper. However, if plastic

pipe is used, it must be recommended by the pipe manufacturer for use with oil ﬁred appliances and, in any case, the last 1000mm of pipework connected directly to the appliance must be of copper. All connections to the appliance must be made with compression ﬁttings.

Page 55

7.2 Sealed Systems

7.2.1 Expansion Vessel

Refer to BS7074: PART 1 and BS5449 for details of expansion vessel sizing. The

values given in the table below are for total system volumes which include the primary water capacity of the boiler which can be found in the Technical Data section of this manual. System and Combi models up to 120HE are supplied with a 12 litre expansion vessel charged to 1.0 bar. This can accommodate a maximum combined boiler and system volume of 110 litres. Where permitted by the type, size and conﬁguration of heating system the expansion vessel bladder pre-charge pressure can be reduced, prior to ﬁlling the system, to 0.5 bar in order to accommodate a total system volume of 145 litres. If these maximum total system volumes are exceed, additional expansion capacity will be required.

7.2.2 System Filling

For all System and Combi boilers a ﬁlling point complete with a ﬁlling loop is supplied

ﬁtted to the expansion vessel. The ﬁlling loop must be disconnected from the mains supply after ﬁlling. A system pressure when cold of 1 bar is recommended. After ﬁlling, vent all air from the system. The plastic plugs of the auto air vent(s) factoryﬁtted to the boiler must be loosened when ﬁlling the system in order to bleed the air from the boiler.

7.2.3 System Pressure

Water loss from the system as indicated by a reduction in pressure on the pressure

gauge may be made up through the ﬁlling loop. In the ﬁrst week of operation it is normal to see a drop in system pressure. After this time the system pressure must be rechecked and the system reﬁlled. Failure to do so may lead to boiler faults.

7.2.4 Pressure Relief Valve

Any pressure relief valve ﬁtted to the boiler or system must be able to discharge

externally to a drain where the discharge can be seen but cannot cause any injury or damage. No other valves should be positioned between the relief valve and discharge termination.

7.2.5 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.

25.0

32.7

46.8

300

VESSEL VOLUMES

22.9

30.0

42.9

275

20.8

27.2

39.0

250

18.7

24.5

35.1

225

16.7

21.8

31.2

200

14.6

19.1

27.3

175

12.5

16.3

23.4

150

10.5

13.6

19.5

125

8.3

10.9

15.6

100

6.3

8.2

11.7

4.2

5.4

7.8

2.1

2.7

2.9

0.5

1.0

1.5

TOTAL SYSTEM

VOLUME

INITIAL CHARGE

When measuring the expansion vessel bladder pre-charge pressure, using a tyre

gauge, the system should be cold and the system pressure should be relieved (by manually operating the system pressure relief valve) in order to obtain an accurate reading.

Page 56

7.3 Combi Domestic Hot Water

7.3.1 Mains Water Pressure

To protect the appliance and to prevent excessive ﬂow rates, a pressure reducing

valve must be ﬁtted to limit the maximum supply pressure to 3 bar. We strongly advise that all installation pipework is run in copper. However, if plastic pipe is used, it must be recommended by the pipe manufacturer for use with oil ﬁred appliances and, in any case, the last 1000mm of pipework connected directly to the appliance must be of copper. Whenever a pressure reducing valve or other device containing a non-return valve is ﬁtted to the mains water supply entering the boiler, a mini expansion vessel must be ﬁtted after the device in order to protect the appliance from the expansion due to heating of the water in the domestic hot water pipework. Note that the ﬂow rate from individual taps is dependant on the number of outlets being operated together, as well as the length and size of pipework and the mains supply pressure.

7.3.2 Water Hardness

Although many of the DHW components are designed to resist lime scale formation,

in areas of hard water it may still be necessary to ﬁt an inline chemical water softener. For further information contact Warmﬂow and your local water company.

7.3.4 Flow Restrictor

An 18L/min ﬂow restrictor has

been factory ﬁtted but can be easily removed if required.

7.3.5 Boreholes

Where the mains water supply to the boiler is fed from a borehole via a pump and

accumulator arrangement the variable pressure can cause the mixer valve to go to its fail safe settings thus preventing the outlet water temperature from achieving a suitable level. In order to minimise the pressure variations it is recommended that differential on the borehole pump pressure switch is kept as low as possible without adversely affecting the pump motor. The accumulator must be as large as possible in order to reduce the rate of pressure change and a pressure reducing valve (PRV) must be situated between the pump and accumulator and the boiler. The PRV must be set slightly below the minimum setting of the pressure switch on the pump.

FLOW SWITCH FLOW RESTRICTOR WASHER

Page 57

8.0 Burners

8.1 RDB Burner

8.2 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.

1. Pump

2. Control Box

3. Reset Button with Lock-Out Lamp

4. Flange with Insulating Gasket

5. Air Damper Adjustment Screw

6. Air Tube Connection (Supplied with BF Kit)

7. Pump Pressure Adjustment Screw

8. Pressure Gauge Port

1. Suction Line

2. Return Line

3. By-Pass Screw

4. Gauge Connection

5. Pressure Adjuster

6. Suction Gauge Connection

7. Valve

8. Auxiliary Pressure Test Point

Page 58

8.3 Electrode Setting

8.4 Burner Start-Up Cycle

8.5 Air Damper Adjustment

The air damper is set in factory. This regulation is purely indicative. Each installation

however, has its own working conditions: actual nozzle output; positive or negative pressure in the combustion chamber, the need of excess air, etc. All these conditions may require a different air damper setting.

Air Damper (A) – The main air damper can be set in either of two positions. To set the positions of the damper, proceed as follows: Remove the secondary air damper (B) loosening the screws (1). Loosen the screw (2) and rotate the main air damper (A) to the required position. Retighten the screw (2) and put back the secondary air damper (B).

Air Damper (B)

– The purpose of this damper is to perform a ﬁnetuning of the inlet air. Tuning of this device is possible by turning the screw (3).

Air Damper (A) – 15/21 Burner Only Air Damper (B)

~ 12s

Thermostat

Motor

Ignition Transformer

Valve

Flame

Lock-Out Lamp

~ 12s

Normal Lock-out due to failure to light

~ 5s

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.

Page 59

9.0 Commissioning & Servicing

9.1 Commissioning

Note: It is the responsibility of the installer to ensure that the boiler is properly

commissioned by an OFTEC trained and registered technician. Failure to do so WILL invalidate ALL warranties.

Before ﬁring ensure that all the bafﬂes are in place, as they may have been displaced

during transit; Refer to the General Information section. Switch the boiler on, ensuring all controls are calling for heat.

The oil pump pressure must be checked by ﬁtting a pressure gauge to the pump

pressure port. If necessary the pressure should be adjusted until it corresponds with the value in the Technical Data section for the required output. Using a smoke pump, check the smoke number. It should be zero.

Using a ﬂue gas analyser, check the CO2 content and ﬂue gas temperature once

the boiler is hot. Testing while the boiler is still relatively cold gives inaccurate results and leads to incorrect adjustments being made.

Where a balanced ﬂue has been ﬁtted ensure the air duct connecting the ﬂue and

burner has been properly connected before commissioning.

To comply with the building regulations OFTEC form CD11 should be completed

and a copy left with the householder.

9.2 Servicing

9.2.1 General Requirements

It is recommended that the appliance is serviced annually by a Warmﬂow or an

OFTEC registered service technician in accordance with the recommendations laid out in OFTEC’s technical information book 2 – ‘Pressure Jet Appliances – Commissioning Requirements for Technicians’.

Additionally, when servicing, special attention should be paid to the condition of the

oil nozzle, ﬂexible oil line, fuel ﬁlter, door insulation, sealing rope and secondary heat exchanger door seal. If found to be defective they must be replaced.

The system corrosion inhibitor level must be checked (instant on-site test kits are

available from inhibitor manufacturers) and additional inhibitor must be added if the system is found to be under-dosed. Refer to the inhibitor manufacturer for further guidance.

Note: All product warranties will be invalidated if the appliance is not serviced

annually by a Warmﬂow or OFTEC trained and registered technician.

Page 60

10.0 Burner Fault Finding

10.1 Riello RDB

YES YES YES

NO NO NO

YES

NONO

NONONONONO

YESYES YES

Burner

Motor Runs

Lock Out

within

1 second

Lock Out after

12 second

purge

Ignition

Spark Proved

Pump

Produces

Pressure

Nozzle

Atomising Fuel

Combustion

Air Set

Correct

Combustion

Head Set

Correct

Check

L & N to

Control Box

Motor or

Pump Seized

Repair/Replace

Motor/Pump

Check and Set

the Electrodes

Washing

Pressure

1-2 Bar

Solenoid

Operating

Raise Pressure

Replace

Nozzle

Flame Off

and Re-Lights

Check

Boiler Controls

Replace Motor

Capacitor

Replace the

Control Box

Drive Coupling

Broken

Replace the

Coil and/or

Stem Valve

Contaminated

Fuel Filter

Boiler or Flue

Blocked

Repair or

Replace Oil

Pump

Motor gives

50 Volts to

White Wire

Coil of

Solenoid

Functional

Photo Cell

Functional

Replace

Control Box

If B/F

application

remove burner

snorkel tube

and retest

Replace

Burner Motor

Replace

Solenoid Coil

Replace

Photo Cell

Reset B/F Flue

or Reposition

YES NO YES YES YES YES YES

NO NO NO

Page 61

11.0 Combi Fault Finding

11.1 Central Heating

YES

Switch on power,

set selectors

for CH on and

DHW off.

Set all controls to call for heat.

Does the

burner fire?

Is lockout lamp

on burner or

panel lit?

Is high limit

thermostat

lamp lit?

Is there continuity

across the boiler stat connections

17 and 18 on the

PCB?

Is there continuity

across the

connections

28 and 30 on

the PCB?

Check power from clock or switch, check

wiring fuses and

mains supply.

Refer to burner

fault finding.

Press reset

button, replace

if necessary.

Check wiring, replace boiler

thermostat.

Check relay and

PCB, replace if

necessary.

Do radiators

get hot?

Does boiler cycle on its

thermostat?

Check all valves

are open and

pump is working,

check pressure,

check all air is

vented.

Check boiler

thermostat,

replace if

necessary.

HEATING IS

WORKING

NORMALLY

YES

Page 62

11.2 Domestic Hot Water

Switch on power,

set selectors to CH

off and DHW on.

Is DHW pump

working?

Is there continuity

across connection 20

and 21 on the PCB?

Check wiring, replace

tank thermostat.

Is there continuity

across 25 and 27?

Check wiring, replace

relay, replace PCB.

Check wiring,

replace pump.

Does burner fire? Do radiators get hot?

Check plumbing,

replace non-return

valve.

Refer to burner

fault finding.

Is lockout lamp on

burner or pump lit?

Does tank get hot?

Vent all air from system

pumps, ensure all

valves are open.

Press reset button,

replace limit

thermostat.

Is high limit

thermostat lamp lit.

Does boiler shut down

when tank reaches

temperature?

Replace tank stat,

replace relay.

Check wiring, replace

tank limit stat.

Is there continuinity

across 23 and 22?

With tap closed, switch

the CH switch to on.

Check wiring, replace

relay, replace PCB.

Is there continuinity

across 22 and 16?

Do radiators get hot? Check CH fault finding.

Check power from

clock or switch, check

wiring, check fuses.

Does CH pump stop when tap is opened?

Check flow switch,

check relay.

Is hot water produced

when tap is opened.

BOILER IS WORKING

NORMALLY

NO NO

YES

Check mixer valve,

check plate heat

exchanger for blockage,

ensure all air is vented

from boiler.

YES

Page 63

12.0 Optional Boiler Mounted Digital Timer

12.1 Operating Instructions

12.1.1 After Installation

When you ﬁrst install the Cr2032 battery (by removing the clear plastic strip from the

rear of the timer) you must press the ‘RESET’ button, the LCD display will display fully for 3 seconds. Then LCD display will change to ‘5:2d’. You can press DAY button to select ‘7d’, ‘24H’ programme mode.

This conﬁgures the timer as follows:

5/2d: 5 day/2 day programme option allows different ON/OFF times on

weekday and weekend.

7d: 7 day programme option allows different programme setting on each

day of weekday and weekend.

24H: 24 hours programme option runs same programme every day.

When you ﬁnalise the setting, press the CLOCK button for normal operation.

Page 64

12.1.2 Built in Programme

For convenience, the timer module has a built in programme, however, it can be

easily adjusted (see section 12.5 To Change the Programmes).

The timer offers 3 options for both CH and HW programme period.

OFF: Off all the time.

AUTO: To run your time schedule for period one or two or three each day.

ON: Turn on all the time.

Factory Present Time Schedule

12.1.3 To Set Current Time & Day

1. Press and hold

CLOCK button then press DAY button to select current day

of the week.

2. Press and hold

CLOCK button then press HOUR button until the correct

hour is displayed.

3. Press and hold

CLOCK button then press MINUTE button until the correct

minute is displayed.

12.1.4 Select Operation Mode

Press CH SELECT / HW SELECT button to select operation mode to be

OFF,

AUTO, ON.

22:3022:30

16:30

14:00

12:00

10:30

07:30

22:3022:30

16:30

14:00

12:00

08:30

06:30

HW/CH2CH/CH1

16:30

14:00

12:00

08:30

06:30

16:30

14:00

12:00

10:30

07:30

HW/CH2CH/CH1

Mon – Fri

Time Schedule

Mon – Fri

Time Schedule

PERIOD 1 ON

PERIOD 1 OFF

PERIOD 2 ON

PERIOD 2 OFF

PERIOD 3 ON

PERIOD 3 OFF

Switching

Page 65

Set Day Programme Period 1 On/Off

22:30

07:30

22:30

06:30

HW/CH2CH/CH1

22:30

06:30

22:30

07:30

HW/CH2CH/CH1

Mon – Fri

Time Schedule

Mon – Fri

Time Schedule

PERIOD 1 ON

PERIOD 1 OFF

Switching

Set Day Programme Period 3 On/Off

22:3022:30

16:30

14:00

12:00

10:30

07:30

22:3022:30

16:30

14:00

12:00

08:30

06:30

HW/CH2CH/CH1

16:30

14:00

12:00

08:30

06:30

16:30

14:00

12:00

10:30

07:30

HW/CH2CH/CH1

Mon – Fri

Time Schedule

Mon – Fri

Time Schedule

PERIOD 1 ON

PERIOD 1 OFF

PERIOD 2 ON

PERIOD 2 OFF

PERIOD 3 ON

PERIOD 3 OFF

Switching

Set Day Programme Period 2 On/Off

10:30

07:30

22:30

16:30

08:30

06:30

HW/CH2CH/CH1

22:30

16:30

08:30

06:30

10:30

07:30

HW/CH2CH/CH1

Mon – Fri

Time Schedule

Mon – Fri

Time Schedule

PERIOD 1 ON

PERIOD 1 OFF

PERIOD 2 ON

PERIOD 2 OFF

Switching

22:30

16:30

22:30

16:30

12.1.5 To Set Programme Period

Press and hold

DAY button and press MIN until the correct programme period is

displayed.

12.1.6 Reviewing the Programmes

Press

TIMER button each time to toggle through the ON and OFF settings.

12.1.7 To Change the Programme

1. Press

TIMER key repeatedly until the particular ON or OFF time appears.

2. Press

HOUR button and MINUTE button to set new ON or OFF time.

Page 66

12.1.8 Manual Select

1. Press

SELECT to toggle through ON / AUTO / OFF modes as indicated by

the timer status.

ON mode turns on the timer.

OFF mode turns off the timer.

AUTO mode runs the set programme.

12.1.9 Manual Select

This function is only applicable when your timer is set on

AUTO mode.

You can temporarily override the normal switching times by pressing the ADV key.

The temporarily override won’t affect the normal programme after execution of the override.

1. Press CH ADV

or HW ADV key the CH icon or HW icon will ﬂash.

2. In approximately 5 seconds the display CH select mode ‘AUTO’ or HW select mode ‘AUTO’ will ﬂash and go into the manual override function.

3. OFF mode turns off the timer.

4. To cancel override by pressing CH ADV

or HW ADV and the ‘AUTO’ will stop

ﬂash.

12.1.10 Manual Hour

1. Press CH ADV

or HW ADV key, the CH icon will ﬂash.

2. You now have approx 5 second to enter desired length of time by pressing

CH ADV

or HW ADV key once for each hour the new time set should be in

affect.

3. The MANUAL HOUR function will bring the unit ON 1 hour to 3 hours in the OFF mode.

4. The MANUAL HOUR function will bring the unit OFF 1 hour to 3 hours in the ON mode.

5. The MANUAL HOUR function is in operation, a count down clock will appear. Then normal display and count down clock will appear on the LCD alternately.

6. The MANUAL HOUR function will bring the unit ON 1 hour to 3 hours in off, clock will count down immediately.

7. When MANUAL HOUR function will extend by 1 hour to 3 hours while ON, clock will count down after the programmed ON is ﬁnished.

12.1.11 Cancel Manual Hour Function

Press CH ADV

or HW ADV button again the LCD display and switching status will

return to normal.

Page 67

13.0 Spares

13.1 RDB 2.2 Spares

No CODE

3514157 3514257 3514557

DESCRIPTION

1 3005787 • • • Gasket 2 3006384 • • • Flange 3 3020494 • Cup-Shaped Head 3 3020258 • Cup-Shaped Head 3 3020055 • Cup-Shaped Head 4 3008860 • • • Electrode Assembly 5 3008875 • • • Screw 6 3008861 • • • Nozzle Holder 7 3008862 • • • Collar 8 3008794 • • • High Voltage Lead 9 3008647 • • Air Damper Assembly 9 3008839 • Air Damper Assembly 10 3005788 • • • Fan 11 3008646 • • • PE Cell 12 3002837 • • • Capacitor 4.5µF 13 3007582 • • • Needle Valve 14 3008651 • • • Regulator

No CODE

3514157 3514257 3514557

DESCRIPTION

15 3000439 • • • Pump Seal 16 3020475 • • • Pump 17 3007162 • • • O-Ring 18 3008653 • • • Filter O-Ring 19 3003602 • • • Connector 20 3005720 • • • Flexible Oil Line 21 3008644 • • • Tube 22 3008876 • • • Pressure Gauge 23 3000443 • • • Joint 24 3008648 • • • Coil-Shell & Knob 25 3002836 • • • Motor & Capacitor 26 3008649 • • • Protection 27 3008652 • • • Control Box 535RSE/LD 28 3008851 • • • Lead Coil 29 3008879 • • • Cover 30 3008878 • • • Kit Seals

Catalogo ricambi

Spare parts list

Catalogue pièces détachées

Ersatzte ile Katalog

Catálogo recambios

RDB2.2 15-21 COD. 3514157 TIPO / TYPE / TYP 744 T1K

RDB2.2 21-26 COD. 3514257 TIPO / TYPE / TYP 744 T2K

RDB2.2 25-34 COD. 3514557 TIPO / TYPE / TYP 744 T5K

Bruciatori di kerosene • Kerosene burners • Brûleurs kérosène

Kerosin - Gebläsebrenner

• Quemadores de kerosene

Page 68

13.2 RDB 3.2 Spares

No CODE

3748941

DESCRIPTION

1 3005795 • Gasket

2 3008637 • Flange

3 3005714 • End Ring

4 3005713 • Diffuser Disc

5 3007714 • Blast Tube Assembly

6 3006552 • Electrode Bracket

7 3007513 • Electrode Assembly

8 3008794 • High Voltage Lead

9 3008957 • Collar

10 3008876 • Pressure Gauge

11 3008839 • Air Damper Assembly

12 3008958 • Deadening

13 3008962 • Cover

14 3008646 • PE Cell

15 3005799 • Fan

16 3008955 • Nozzle Holder

17 3008960 • Capacitor 5 µF

No CODE

3748941

DESCRIPTION

18 3003602 • Connector

19 3005720 • Flexible Oil Line

20 3008964 • Motor

21 3000443 • Joint

22 3008648 • Coil-Shell and Knob

23 3008649 • Protection

24 3008652 • Control Box 535SE/LD

25 3008851 • Lead Coil

26 3008961 • Tube

27 3020475 • Pump

28 3008653 • Filter - O-Ring

29 3007582 • Needle Valve

30 3008651 • Regulator

31 3000439 • Pump Seal

32 3008963 • Kit Seals

33 3008959 • Air Intake

Page 69

13.3 Pipe Spares

Utility Pumped & System Models UP70HE, UP90HE, UP120HE, US70HE, US90HE & US120HE

Kabin Pak Pumped & System Models KP70HE, KP90HE, KP120HE, KS70HE, KS90HE & KS120HE

150HE Pumped Models - UP150HE & KP150HE

Pump Flow Pipe

(22mm)

3015

Pump Flow Pipe

(22mm)

3015

Expansion Vessel

Pressure Hose

3020

From Boiler to Pump

(22mm)

3017

From Boiler to Pump

(28mm)

3426

Pump Flow Pipe

(28mm)

3425

Expansion Vessel

Pressure Hose

3020

From Boiler to Pump

(22mm)

3017

Page 70

13.3 Pipe Spares cont’d

Utility and Kabin Pak Combi Models UC70HE, UC90HE, KC70HE & KC90HE

From Boiler to Gate Valve

3097

CH Flow from Pump

3100

From Gate

Valve to Pump

3098

From Plate Heat

Exchanger to Boiler

Return 3096

From Heat Store to Plate

Heat Exchanger

1997

From Flowswitch to Mixing

Valve & Plate Heat Exchanger

1992

From Plate Heat

Exchanger to Mixing Valve

1994

DHW Flow from Mixing Valve

3101

From Strainer to Flowswitch & Filling Loop

3099

Expansion Vessel

Pressure Hose

3020

Page 71

13.4 Short Parts List – Boiler

Part Description Code

Flow Switch 1476

Tank & Boiler Control Thermostat 2131

Boiler Limit Thermostat (Combi Models) 281

Tank Limit Thermostat 2126

Pump Overrun Thermostat 3108

Plate Heat Exchanger 599

Twin Head Pump 2130

15/60 Pump (for replacement head) 602

3 Pole Relay 1827

Auto Air Vent C/W Check Valve 614

Pressure Relief Valve 2132

Filling Loop 2133

Pressure Gauge 3019

Mixer Valve 1621

PCB Controller MK4 2419

12 Litre Pressure Vessel 2128

Single Pole Relay & Base 3074

Dual-Safe Thermostat for Non-Combi Models WDS2

Optional Programmer for Combi Models PC1

Optional Programmer for Non-Combi Models PU1

When ordering replacement casing panels it should be noted that due to the painting

process there may be some variation in colour.

Page 72

14.0 Your Guarantee, Terms & Conditions

1. Warmﬂow Guarantees

The boiler, including all controls, plate heat exchangers and associated equipment contained within the boiler casing, the burner and ﬂue system if supplied by Warmﬂow against defective parts and faulty workmanship, for period of 12 months from the date of installation, providing the boiler is installed and commissioned in accordance with the installation instructions supplied with the boiler. The period of guarantee will be increased to 24 months in Great Britain providing:

• The guarantee registration form is fully

completed and returned to Warmﬂow within 30 days from the date of installation, or 90 days from the date code stamped on the appliance.

• The boiler must be installed and

commissioned by a Warmﬂow or other competent engineer, who is OFTEC registered. Commissioning of the boiler must be completed immediately after the boiler is installed.

• The boiler must be serviced by a

Warmﬂow or other competent engineer, who is OFTEC registered, 12 months after the date of installation and thereafter, at 12 monthly intervals.

NOTE: In Northern Ireland and the Republic of Ireland the period of guarantee can only be increased to 24 months through the purchase of an extended warranty.

The water jacket and thermal store (in the case of a combination boiler) for a total of 5 years from the appliance date code, subject to the above conditions being complied with.

Warmﬂow reserves the right to repair or replace components within the guarantee period at a time and location that is most convenient to the company.

2. Conditions of Guarantee

The boiler must be installed, commissioned and serviced in accordance with the installation instructions supplied with the boiler.

Warmﬂow will accept no liability for the cost of repairs resulting from incorrect installation, inadequate commissioning, lack of regular maintenance, misuse, tampering or repair by unqualiﬁed persons.

All repairs must be authorised in writing by Warmﬂow prior to any work being carried out. Unauthorised claims are not covered by the guarantee.

Labour charges associated with the replacement of heat exchangers or thermal heat stores will be calculated on a sliding scale depending on the boiler output up to a set maximum. Contact Warmﬂow for current prices.

Faults and any associated costs occurring due to lack of fuel, power, water supply or scale formation are not covered by these guarantees.

Claims for consequential loss or damage are not covered by these guarantees.

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.

The statutory rights of the customer are not affected by the guarantee.

NB: The nozzle supplied with the boiler is deemed to be an expendable item and is therefore excluded from the guarantee.

Page 73

COMMISSION

Commission/Service Record Boiler Serial No |__|__|__|__|__|__|__|__|

In order that your boiler gives you many years of economical trouble free use and to validate the warranty, this boiler must be commissioned upon installation and serviced annually. Contact Warmﬂow for an approved engineer within your area.

SERVICE 1

SERVICE 3

SERVICE 2

SERVICE 5

SERVICE 4

SERVICE 7

SERVICE 6

SERVICE 9

SERVICE 8

Date of Commission ______________________

Company Name ______________________