WarmFlow COMBI 70 Nota de publicación
INSTALLATION & SERVICING
MANUAL FOR
70/90
COMBI BOILER
&
70/90
KABIN PAK COMBI
LEAVE THESE INSTRUCTIONS WITH THE END USER
NATIONAL
ACCREDITATION
OF CERTIFICATION
BODIES
BSI
R
E
G
I
S
T
E
R
E
D
F
I
R
M
CERT. No. FM 29884
BS 5750 PART 2
ISO 9002
ISSUE 4
MAR ’03
SERVICING
To ensure continued reliable operation and
fuel economy it is recommended that the
boiler is serviced annually.
Warmflow Engineering Service division
provides an excellent back-up service,
operating a team of Oftec trained engineers
who can meet all the servicing,
commissioning and breakdown
requirements for your appliance.
Simply telephone
TEL: (028) 9262 0852
FAX: (028) 9262 0869
E-MAIL: service@warmflow.co.uk
COMMISSIONING
*THIS APPLIANCE MUST
BE COMMISSIONED
*Failure to commission this appliance may invalidate warranty
After commissioning ensure that the pre-paid warranty
registration card is filled in and returned.
BEFORE FITTING THIS BOILER THE
INSTALLER MUST CHECK:
1. What the maximum hot water demand is likely to be placed on
the boiler. Not every installation is suitable for a Combi boiler.
Systems requiring very high hot water flow rates may be better
suited with an unvented cylinder.
2. That the mains are capable of supplying up to 24 litre/min with a
minimum dynamic pressure of 1.8 bar at the boiler. This is to
ensure that the boiler can achieve its maximum output.
3. The hardness of the mains water supply. Systems with hard water
must be fitted with a suitable chemical scale preventer (eg Fernox
Quantomat or Combimate alternatively contact Warmflow for
further details).
4. That the flow from any one hot water outlet does not exceed the
maximum recommended. This applies particularly to baths which
are usually fitted with larger taps and larger bore supply pipes. It
may be necessary to restrict the flow to these taps by reducing
the bore of the supply pipework or by fitting a restrictor into the
pipework.
5. That any outlet when opened does not starve all the other outlets
of hot water. If more than one outlet is open at the same time
then the total flow from all the outlets should not exceed the
maximum flow rate of the boiler.
6. That any showers being supplied hot water by the boiler are
compatible with this type of appliance.
It should be noted that the boiler has been factory fitted with
an 18 litre/min flow restrictor.
The manufacturers guarantees are void if the appliance is
not installed and commissioned in accordance with the
recommendations made herein.
Page 1
Contents Page
1.0 User Instructions ................................................................................................................. 3
1.1 Introduction .................................................................................................................4
1.2 General Requirements ................................................................................................ 4
1.3 Components................................................................................................................ 5
2.0 Technical Details .................................................................................................................. 7
2.1 Sequence of Operation Flow Chart............................................................................. 7
2.2 Baffles ......................................................................................................................... 8
2.3 General Requirements ................................................................................................ 8
2.4 Dimensions ................................................................................................................. 9
2.5 Combi Flue Options .................................................................................................. 10
2.6 Technical Data .......................................................................................................... 13
3.0 Electricity Supply............................................................................................................... 14
3.1 RDB Burner Control Box ........................................................................................... 14
3.2 Fitting a Room Thermostat ....................................................................................... 14
3.3 Combi Wiring Details ................................................................................................ 15
3.4 Kabin Pak Combi Wiring Details ............................................................................... 17
3.5 Frost Thermostats ..................................................................................................... 19
3.6 Timers for Standard Combi ....................................................................................... 20
3.7 Timers for Kabin Pak Combis ................................................................................... 22
4.0 Oil Supply ........................................................................................................................... 23
4.1 One Pipe System ...................................................................................................... 23
4.2 Two Pipe System ...................................................................................................... 24
4.3 De-aerator System .................................................................................................... 24
4.4 One Pipe Lift ............................................................................................................. 25
5.0 Flues .................................................................................................................................. 26
5.1 Conventional Flues ................................................................................................... 26
5.2 Low Level Discharge/Low Level Balanced Flues Terminal Position ......................... 26
6.0 Air Supply for Combustion and Ventilation..................................................................... 28
6.1 Open Flue Boilers ..................................................................................................... 28
6.2 Balanced Flue Boilers ............................................................................................... 28
6.3 Installation of Flues ................................................................................................... 29
7.0 Thermostat Control Knob Peg Setting............................................................................. 31
8.0 Installation .......................................................................................................................... 32
8.1 Hearth .......................................................................................................................32
8.2 Service Access.......................................................................................................... 32
8.3 Heating System......................................................................................................... 32
8.4 Domestic Hot Water .................................................................................................. 34
8.5 Removal of Flow Restrictor ....................................................................................... 34
8.6 Fitting a Vertical Flue Adaptor ................................................................................... 35
8.7 Installation of Air Intake Duct .................................................................................... 35
9.0 Burners ............................................................................................................................... 36
9.1 RDB Burner............................................................................................................... 36
9.2 Oil Supply.................................................................................................................. 36
9.3 Electrical Connections .............................................................................................. 37
9.4 Electrode Setting....................................................................................................... 37
9.5 Burner Start-up Cycle ............................................................................................... 37
10.0 Commissioning and Servicing ......................................................................................... 38
10.1 Commissioning ......................................................................................................... 38
10.2 Servicing ...................................................................................................................38
11.0 Horstmann 626 Electronic Programmer .......................................................................... 39
12.0 Fault Finding ...................................................................................................................... 44
12.1 Central Heating ......................................................................................................... 44
12.2 Domestic Hot Water .................................................................................................. 45
12.3 Burner ....................................................................................................................... 46
13.0 Spares ................................................................................................................................. 47
13.1 Riello RDB Burner..................................................................................................... 47
13.2 Pipe Spares .............................................................................................................. 48
13.3 Short Parts List ......................................................................................................... 49
Page 2
1.0 User Instructions
1.0.1 Boiler Control Thermostat
The boiler control thermostat is located on the front of the boiler facia panel and may
be adjusted from 52°C to 85°C. The recommended minimum thermostat setting is
65°C. Below this ‘cold water corrosion’ is likely to occur thus reducing the life of the
heat exchanger and is not covered by the manufacturer’s warranty. When using hot
water only it is recommended that the boiler control thermostat is switched to the off
position.
1.0.2 Mains Indicator
The green mains light will be lit when there is power to the control panel.
1.0.3 H/L Reset
The yellow H/L reset lamp will be lit when the high limit thermostat has tripped at its set
temperature of 110°C. This cuts off power to the burner and may indicate that there is
a fault in the heating system. The high limit thermostat has a manual reset button
located underneath the control panel in line with the control thermostat. Once the
temperature has fallen and the reset button has been pressed the boiler should restart.
If the high limit thermostat continues to trip contact your service engineer/technician.
1.0.4 Lock Out
The red lock out lamp will be lit when the burner has failed and can be reset by pressing
the illuminated red reset button on the burner control box. If there is power and the
thermostat is calling for heat and the burner has been reset it will go through its start
up cycle. If the burner again fails to fire this would indicate a burner fault or oil supply
problem (oil supply problems are not covered by manufacturers warranty).
1.0.5 Tank Control Thermostat
Located on the right hand side of the control panel the tank control thermostat controls
the temperature in the thermal store. The temperature is adjustable up to a maximum
of 80°C. A peg has been fitted to the rear of the knob to prevent the temperature being
set too high. To change the setting see page 31.
1.0.6 Tank Limit Thermostat
Located inside the control panel the tank limit thermostat is a thermal resetting device
controlling the on/off operation of the burner in hot water mode.
1.0.7 Hot Water and Central Heating On/Off Switch
Both hot water and central heating operations can be controlled via these switches.
However it should be noted that when both switches are in the ‘on’ position hot water
will have priority. In addition whenever a timer or programmer is connected to the
boiler one or more of these switches may be bypassed.
1.0.8 Pressure Gauge
The pressure gauge fitted to the front of the control panel measures system pressure.
The pressure should be set at 1 bar when the boiler is cold. As the boiler heats up, the
pressure will rise but should not exceed 3 bar.
1.0.9 Servicing
It is recommended that the boiler is serviced annually by an OFTEC registered engineer.
Page 3
1.1 Introduction
Note:All our domestic applianceshavebeen independently tested andaccredited
as exceeding the minimum SEDBUK efficiency levels required for its type, in
compliance with the Building Regulations Approved Document L1 2001 for
England and Wales and the Building Standards (Scotland) Regulations 2001
Part J.
The Warmflow oil fired ‘Combi’ boiler and Kabin Pak Combi are suitable for sealed
central heating systems and can provide at mains pressure domestic hot water without
the use of a cylinder.
The Warmflow oil fired combis are designed to burn Class C2 (28 sec redwood) kerosine
or Class D (35 sec redwood) gas oil. However to comply with building regulations only
kerosine may be burned when using the low level balanced flue or low level conventional
flue.
As standard the appliance is fitted with a system expansion vessel, circulating pumps,
filling loop, pressure gauge and safety valve. An optional 7-day electronic programmer
is also available.
The pressure jet oil burner is covered by the manufacturer’s parts and labour warranty
valid for one year (from the boiler date stamp). The boiler and heat store are covered
by a manufacturer’s warranty of 5 years (from the boiler date stamp) but does not
include burner, labour, handling or shipping. Details of any extended warranties are
contained within the installation pack.
Optional extended guarantees, for the appliance covering parts and labour of up to 5
years initially are also available (although not applicable to the Republic of Ireland).
The manufacturer’s guarantees are void if the appliance is not installed and
commissioned in accordance with the recommendations made herein.
1.2 General Requirements
The installation of the boiler must be in accordance with the following regulations.
BS5410 : PART 1 : 1997 Code of practice for oil firing.
BS5449 : PART 1 : 1997 Forced circulation hot water systems.
BS7593 : 1992 Treatment of water in domestic hot water central heating systems.
Current Building Regulations: Part J England and Wales
Part F Scotland
Part L Northern Ireland
Current IEE Regulations:
BS7074 : PART 1 : Application Selection & Installation of Expansion Vessels
The heating system should be installed by a competent installer in accordance with
the recommendations laid down by HVCA, OFTEC and a sound engineering practice.
In order to comply with GB building regulations OFTEC forms CD10 for
installations and CD11 for commissioning should be left with the customer.
Page 4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1.3 Components
1.3.1 Combi Assembly
1. Automatic Air Vents
2. Boiler Heat Exchanger
3. Boiler Control and Limit Stat
4. 12 Litre Esxpansion vessel
5. Boiler Data Plate
6. RDB Burner
7. Boiler Drain Valve
8. Pressure Relief Valve
9. Strainer
10. Filling Loop
11.Tank Control and Limit Stat
12. Flow Switch
13. Mixer Valve
14. Plate Heat Exchanger
15. CH Pump Head
16. DHW Pump Head
17. Pump Gate Valves (x3)
18. Tank Drain Valve
1.3.2 Combi Control Panel
BLANKING
PLATE
CH ON/OFF
SWITCH
TANK CONTROL
THERMOSTAT
MAINS ON
LAMP (GREEN)
HIGH LIMIT TRIPPED
LAMP (YELLOW)
BURNER LOCKOUT
LAMP (RED)
SYSTEM
PRESSURE
GAUGE
DHW
PUMP
BOILER
CONTROL
THERMOSTAT
CH
PUMP
HIGH LIMIT THERMOSTAT
RESET (UNDERNEATH)
Page 5
1
2
3
4
5
6
7
8
9
10
11 12 13 16 17 18
20
19
22
21
24
23
14 15
1.3.3 Kabin Combi Assembly
1. Flue Terminal Guard
2. Low Level Flue
3. Service Access Hatch
4. Control Panel Cover
5. Controls
6. Pressure Vessel
7. Control Panel Flap Lock
8. Control Panel Flap
9. Door Panel
10. Burner Reset
11. Burner Reset Button
12. Burner
13. Return Connection
14. DHW Pump
15. CH Pump
16. Cable on Oil Line Grommets
Note: To convert the Kabin Pak for use with a conventional flue use the Kabin Pak adaptor
(KPA).
1.3.4 Kabin Pak Combi Control Panel
17. Air Intake Grill
18. Pipe Access Hole
19. Plate Heat Exchanger
20. Mixing Valve
21. Side Panel
22. Pipe Entry Grommets
23. Auto Air Vent
24. Pressure Relief Valve
Mains On (Green)
High Limit (Yellow)
Burner Lockout (Red)
CH Pump
DHW Pump
Boiler Control
Thermostat
DHW ON/OFF
Switch
CH ON/OFF
Switch
High Limit
Thermostat Reset
Tank Control
Thermostat
System
Pressure Gauge
Page 6
2.0 Technical Details
2.1 Sequence of Operation Flow Chart
YES
NO
YES
DHW
Tank Stat
Satisfied
Flow
Switch
Closed
Timer
Calling For
Heat
Power
On
DHW
Pump Only
Runs
HW
Limit Stat
Tr ipped
Burner
Fires
Burner
Stops
CH
Selected
Burner
Fires
CH Pump
Only Runs
Boiler
Stat
Satisfied
Boiler
Limit Stat
Tr ipped
YES NO
YES
YES
NO
NO
YES
NO
YES
NO
NO
NO
YES
YES
HW
Selected
YES
NO
Room
Stat
Satisfied
NO
YES
Press
Reset
Button
YES
NO
Boiler
Limit Stat
Tr ipped
Press
Reset
Button
The boiler will have a DHW priority when both domestic hot
water (DHW) and central heating (CH) are selected. So if
the flow switch is closed or the heat store has not been
satisfied the entire output of the boiler is directed to DHW
before the boiler will switch over to CH. When fully cold it
can take up to 20 minutes for the heat store to be satisfied.
After a draw-off of 120L at 24L/min, with an average
temperature rise of 32°C, the thermal store has a recovery
time of approximately 7 mins.
Note: If HW has not been selected no hot water can be
produced even if the heat store is up to temperature.
Page 7
2.2 Baffles
FRONT
Before firing make sure the baffles have not been dislodged in transit and are correctly
positioned. To achieve maximum efficiency push the baffles in the direction of the
arrows as shown.
2.3 General Requirements
1. The Warmflow Combi is supplied with all the necessary components for a sealed heating
system. However, on some larger systems with a total water content greater than
approx 150L, an expansion vessel, in addition to the integral 12L vessel supplied, may
be required.
2. The pressure relief discharge shall be positioned away from any electrical components.
No other valves should be positioned between the relief valve and the discharge, and
the discharge pipe should not be used for any other purposes. The discharge pipe
must be plumbed to an external drain in a position where the discharge can been seen
but cannot cause any injury or damage.
3. Where there is a catastrophic loss of water from the system the boiler thermostats
may fail to operate which would result in serious damage to the appliance. To prevent
this it is recommended that a low pressure cut out switch set at 0.2 bar is fitted to the
system and wired in series with the boiler limit thermostat.
4. The boiler should be stored in a dry environment. No heavy objects should be placed
on top of the boiler. Where possible the boiler should be moved on its pallet or trucked
from its rear. Manhandling the boiler by its casings will result in damage and must be
avoided.
Page 8
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