Embed Size (px)
Citation preview
Boiler ManualIncorporating: GuaranteeRegistration UserInstructions InstallationInstructions ServiceInstructions ServiceRecord
High Efficiency Condensing BoilersModelscoveredbythismanual:
U-SeriesUtility U70HE U90HE U120HEUtility Pumped UP70HE UP90HEUtility System US70HE US90HEUtility Combi UC70HE UC90HE
K-SeriesKabin Pak K70HE K90HE K120HEKabin Pak Pumped KP70HE KP90HEKabin Pak System KS70HE KS90HEKabin Pak Combi KC70HE KC90HE
Leave this manuaL with the end user
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.
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 6532Fax: 028 9262 2827
Email: [email protected]: www.warmflow.co.uk
For Parts, Service Technical & Warranty Contact
Great Britain & N Ireland, Tel: 0870 240 6532Republic of Ireland, Tel: 048 9262 1515
Thismanualisaccurateatthedateofprinting(E&OE)butwillbesupersededandshouldbedisregardedifspecificationsand/orappearancesarechangedintheinterestsofcontinuedproductimprovement. Code3307
ISSUE 1JAN 07
LISBURNLissueIndustrialEstate,MoiraRoad,
Lisburn,CoAntrim,NIreland,BT282RFTel:(028)92621515Fax:(028)92620869
Email:[email protected]@[email protected]
MANCHESTER144BradfordRoad,
Manchester,M407ASTel:(0161)2054202Fax:(0161)2054818
Page �
Contents Page
UserInstructions .....................................................................................................................................................................2
CondensingBoilerInstallationRequirements ......................................................................................................................4
CondensingCombiBoilerPre-InstallationRequirements...................................................................................................5
1.0 GeneralInformation �.� Introduction .....................................................................................................................................................6 �.2 General Requirements .....................................................................................................................................6 �.3 Combi General Requirements ..........................................................................................................................7 �.4 Baffle Positioning .............................................................................................................................................7 �.5 Components ...................................................................................................................................................8
2.0 TechnicalDetails 2.� Combi Sequence of Operation Flow Chart ....................................................................................................�5 2.2 Dimensions ...................................................................................................................................................�6 2.3 Flue Options, Components & Dimensions......................................................................................................�8 2.4 Condensate Disposal ....................................................................................................................................2� 2.5 Technical Data ...............................................................................................................................................22
3.0 ElectricitySupply&WiringDetails 3.� Dual Immersion Thermostat ...........................................................................................................................30 3.2 RDB Burner Control Box ...............................................................................................................................30 3.3 Combi Wiring Details .....................................................................................................................................3� 3.4 Installation of a Combi Optional Programmer .................................................................................................34 3.5 Standard Timers for Combis ..........................................................................................................................35 3.6 Standard/System Boiler Optional Programmer ..............................................................................................35
4.0 OilSupply 4.� One Pipe Gravity System ...............................................................................................................................39 4.2 Two Pipe System ...........................................................................................................................................40 4.3 De-aerator System ........................................................................................................................................40 4.4 One Pipe Lift System .....................................................................................................................................4�
5.0 Flues 5.� Installation of Balanced Flues.........................................................................................................................42 5.2 Conventional Flues ........................................................................................................................................44 5.3 Flue Terminal Positions ..................................................................................................................................44
6.0 AirSupply 6.� Open Flue Boilers ..........................................................................................................................................46 6.2 Balanced Flue Boilers ....................................................................................................................................46
7.0 InstallationRequirements 7.� General Requirements ...................................................................................................................................47 7.2 Sealed Systems ............................................................................................................................................48 7.3 Combi Domestic Hot Water ...........................................................................................................................49
8.0 Burners 8.� RDB Burner ...................................................................................................................................................50 8.2 Oil Pump .......................................................................................................................................................50 8.3 Electrical Connections ...................................................................................................................................50 8.4 Electrode Setting ...........................................................................................................................................5� 8.5 Burner Start-Up Cycle ...................................................................................................................................5� 8.6 Air Damper Adjustment .................................................................................................................................5�
9.0 Commissioning&Servicing 9.� Commissioning..............................................................................................................................................52 9.2 Servicing .......................................................................................................................................................52
10.0 BurnerFaultFinding �0.� Riello RDB .....................................................................................................................................................53
11.0 CombiFaultFinding ��.� Central Heating .............................................................................................................................................54 ��.2 Domestic Hot Water ......................................................................................................................................55
12.0 OptionalBoilerMountedDigitalTimer �2.� Operational Instructions .................................................................................................................................56
13.0 Spares �3.� RDB 2.2 Spares ............................................................................................................................................60 �3.2 Pipe Spares ...................................................................................................................................................6� �3.3 Boiler Short Parts List ....................................................................................................................................62
14.0 GuaranteeTerms&Conditions...............................................................................................................................63
Commissioning/ServiceRecord .............................................................................................................................64
Page 2
USERINSTRUCTIONS
DualThermostat
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 ��0°C; this is factory set and is not adjustable. If thermostat trips it needs to be reset manually.
HighLimitThermostatReset
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.
BurnerLockout
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.
SystemPressure–System&CombiBoilers
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.
ControlThermostat
HighLimitReset
Reset
BurnerLockOutReset
SystemPressure
Page 3
FillingLoop
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 � 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.
CombiControlPanel
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 ��0°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.
Thisboilermustbeservicedannually.ContactWarmflowforfurtherdetails.
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.
HighLimitResetButtonUnderneath
FillingLoopValve
FlexibleFillingLoopHose
ControlThermostatKnob
Page 4
CONDENSINGBOILERINSTALLATIONREQUIREMENTS
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.
�. 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
BEFOREFITTINGACOMBIBOILERTHEINSTALLERMUSTCHECK:
�. 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 �.8 bar at the boiler. This is to ensure that the boiler can achieve its maximum output. To prevent excessive flow rates ie greater than 24 litre/min it is recommended that a pressure reducing valve is fitted to the incoming mains water supply, set at 2 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 alternatively contact Warmflow for further details).
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 �5mm) 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 (contact Warmflow for further details).
It should be noted that the boiler has been factory fitted with an �8 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 6
1.0 GeneralInformation
1.1 Introduction
Note: All our domestic appliances have been independently tested andaccreditedasexceedingtheminimumSEDBUKefficiencylevelsrequiredforits type, incompliancewith theBuildingRegulationsApprovedDocumentL1A, L1B for England and Wales, the Building Standards (Scotland)Regulations Section 6, Part F northern Ireland and Part L Republic ofIreland.
Warmflow oil fired condensing boilers are designed to burn Class C2 (28 sec redwood) kerosine 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.
The Combi can provide at mains pressure domestic hot water without the need for a storage cylinder.
Themanufacturer’sguaranteesarevoidiftheapplianceisnotinstalledandcommissionedinaccordancewiththerecommendationsmadeherein.
1.2 GeneralRequirements
The installation of the boiler must be in accordance with the following regulations.
BS54�0 : PART � Code of practice for oil firing. BS5449 : PART � 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 � 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 forinstallationsandCD11forcommissioningshouldbeleftwiththecustomer,alternatively the installationcanbe inspectedandapprovedbyabuildingcontrol officer. CD10 and CD11 forms are available from OFTEC onTel:08456585080,Fax:08456585181.
Page 7
1.3 CombiGeneralRequirements
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 �20L 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.
1.3.1 PumpOver-Run
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 over-run 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 over-run stat is satisfied or the central heating pump starts to operate, then the hot water pump will stop.
1.4 BafflePositioning
Before firing make sure the baffles have not been dislodged in transit. To achieve maximum efficiency push the primary heat exchanger baffles in the direction of the arrows as shown. The secondary heat exchanger spring baffles must be fully inserted into the heat exchanger tubes (narrow end first).
Page 8
1.5 Components
1.5.1 U-SeriesUtility–CasingComponents
1. BoilerAssembly2. TopCasing(removable)3. RearCasing4. SideCasing5. FrontCasing(removable)
1.5.2 U-SeriesUtility–Pre-Wired(UHE)–KeyComponents
1. HeatExchanger2. CondensingUnit3. AutoAirVent4. ServiceDoor5. ‘Dual-Safe’Thermostat6. HeatExchangerBaffles7. ServiceDoor8. ServiceDoorCover9. CondensateTrap10.RielloRDB2.2Burner11.HeatingFlowConnection12.HeatingReturnConnection
1
2
3
45
1
2
12
4
56
7
8
9
11
3
10
Page 9
1.5.3 U-SeriesUtility–Pumped(UPHE)–KeyComponents
1. HeatExchanger2. CondensingUnit3. PipeworkAssembly4. PressureReliefValve5. AutoAirVent6. CirculatingPump7. AutoAirVent8. ServiceDoor9. ‘Dual-Safe’Thermostat10.HeatExchangerBaffles11.ServiceDoor12.ServiceDoorCover13.CondensateTrap14.RielloRDB2.2Burner15.HeatingFlowConnection16.HeatingReturnConnection
1.5.4 U-SeriesUtility–System(USHE)–KeyComponents
1. Pumped(UPHE)BoilerAssembly2. SystemKit(SK1)3. PressureGauge4. ExpansionVessel5. FillingLoop6. HeatingFlowConnection7. HeatingReturnConnection
11112
10
28
9
16
4
6
5
15
13
14
7
3
16
7
3
4
2
5
Page �0
1.5.5 U-SeriesUtility–Combi(UCHE)–KeyComponents
1. HeatExchanger2. HeatStore3. CondensingUnit4. ServiceDoor5. PipeworkAssembly6. PlateHeatExchanger7. TwinHeadPump8. CondensateTrap9. ServiceDoor10.ServiceDoorCover11.ControlPanel12.ExpansionVessel13.RielloRDB2.2Burner14.HeatExchangerBaffles (seedimensiondrawing
fordetailsofconnections)
1.5.6 U-SeriesUtility–Combi(UCHE)–ControlPanel
ControlThermostat
MainsOnLamp(Green)
HighLimitTrippedLamp(Yellow)
BurnerLockoutLamp(Red)
HWOn/OffSwitch
CWOn/OffSwitch
HighLimitThermostatReset(Underneath)
1
2
34
5
6
7
8
9
10
11
1213
14
Page ��
1.5.7 K-SeriesKabinPak–CasingComponents
1. BoilerAssembly2. TopCasing(removable)3. FlueAssembly(removable)4. RearFlueCasing5. BlankingPlug(removable)6. RearCasing(removable)7. SideCasing8. FrontCasing(removable)
1
2
3
4
5
6
7
8
Page �2
1.5.8 K-SeriesKabinPak–Pre-Wired(KHE)–KeyComponents
1. HeatExchanger2. CondensingUnit3. AutoAirVent4. ServiceDoor5. ‘Dual-Safe’Thermostat6. HeatExchangerBaffles7. ServiceDoor8. ServiceDoorCover9. CondensateTrap10.RielloRDB2.2Burner11.HeatingFlowConnection12.HeatingReturnConnection
1.5.9 K-SeriesKabinPak–Pumped(KPHE)–KeyComponents
1. HeatExchanger2. CondensingUnit3. PipeworkAssembly4. PressureReliefValve5. AutoAirVent6. CirculatingPump7. AutoAirVent8. ServiceDoor9. ‘Dual-Safe’Thermostat10.HeatExchangerBaffles11.ServiceDoor12.ServiceDoorCover13.CondensateTrap14.RielloRDB2.2Burner15.HeatingFlowConnection16.HeatingReturnConnection
1
2
3
5
4
6
78
9
10
11
12
1
8 2
45
6
7
910
1112
13
14
15
16
3
Page �3
1.5.10K-SeriesKabinPak–System(KSHE)–KeyComponents
1. Pumped(KPHE)BoilerAssembly2. SystemKit(SK1)3. PressureGauge4. ExpansionVessel5. FillingLoop6. HeatingFlowConnection7. HeatingReturnConnection
1.5.11K-SeriesKabinPak–Combi(KCHE)–KeyComponents
1. HeatExchanger2. HeatStore3. CondensingUnit4. ServiceDoor5. PipeworkAssembly6. PlateHeatExchanger7. TwinHeadPump8. CondensateTrap9. ServiceDoor10.ServiceDoorCover11.ControlPanel12.ExpansionVessel13.RielloRDB2.2Burner14.HeatExchangerBaffles (seedimensiondrawing
fordetailsofconnections)
6
7
4
23
5
1
1
2
34
5
6
7
8
9
10
11
1213
14
Page �4
1.5.12KSeriesKabinPak–Combi(KCHE)–ControlPanel
ControlThermostat
MainsOnLamp(Green)
HighLimitTrippedLamp(Yellow)
BurnerLockoutLamp(Red)
HWOn/OffSwitch
CWOn/OffSwitch
HighLimitThermostatReset(Underneath)
Page �5
2.0 TechnicalDetails
2.1 CombiSequenceofOperationFlowChart
PowerOn
Timer CallingFor Heat
HWSelected
Flow SwitchClosed
DHW TankStat Satisfied
CHSelected
CH PumpOnly Runs
Room StatSatisfied
Boiler StatSatisfied
Boiler LimitStat Tripped
BurnerFires
DHW PumpOnly Runs
HW LimitStat Satisfied
Boiler LimitStat Tripped
BurnerFires
BurnerStops
PressReset Button
PressReset Button
Pump OverrunStat Satisfied
DHW PumpOnly Runs
YES
YES
YES
NO
YES
NO
YES
YES
YES
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES NO
NO
NO
Page �6
NMLKJHGFEDCBAMODELU~
UP~US~
865 4�3 60� 666 766 42 �04 583 50 75 86 �34 2�865 4�3 60� 666 766 42 �04 583 50 75 86 �34 2�865 4�3 60� 666 766 42 �04 583 50 75 86 �34 2�
QPNMLKJHGFEDCBAMODEL R SUC~ 596 865 60� 766 �34 207 390 84� 8�7 840 845 74 ��5 �67 205 3�0 666
2.2 Dimensions
2.2.1 U-SeriesUtility(UHE,UPHE&USHEModels)
2.2.2 U-SeriesUtility(UCHEModels)
1. PressureReliefDischarge(15mm)2. HeatingFlow(22mm)3. DomesticHotWater(22mm)
4. ColdWaterMains(15mm)5. Knock-OutforHeating
ReturnConnection
Page �7
2.2.3 K-SeriesKabinPak(KHE,KPHE&KSHEModels)
QPNMLKJHGFEDCBAMODELK~ 4�3 900 700 773 2�0 95 �6� 67 40 90 40 67 705 50 50
KP~ 4�3 900 700 773 2�0 95 �6� 67 40 90 40 67 705 50 50KS~ 4�3 900 700 773 2�0 95 �6� 67 40 90 40 67 705 50 50
QPNMLKJHGFEDCBAMODEL R SKC~ 600
2.2.4 K-SeriesKabinPak(KCHEModels)
900 700 772 2�0 95 �6� 67 40 90 40 67 705 50 50 396 209
Page �8
2.3 FlueOptions,Components&Dimensions
2.3.1 HELowLevelBalancedFlueKit(FBF)
Comprising the following four main components.
Page �9
2.3.2 WarmflowHEBoilerFlueComponents:80/125Ø
Note:1. Fluefittingkitrequired.2. Ifterminalislessthan2metresabovegroundlevelterminalguardmustbefitted.3. Extensionpipesandflueadaptorlengthsquotedareeffectivelengthsandnottheactuallength
ofthepiece.4. Alldimensionsinmmunlessotherwisestated.
Page 20
2.3.3 Vertical&HighLevelTerminalOptions
Note:1. Allfluescanutiliseanycombinationofbends,straights,adaptorsandterminals.2. Ensureflueisarrangedsuchthatitfallscontinuouslytowardstheboiler.3 TheLowLevelBalancedFlueKitcanuseanycombinationofflueextensionpiecesuptothe
maximumequivalentlengthdependinguponboileroutputasillustratedintheabovetable.
BOILEROUTPUT
(kW)
TOTALEQUIVALENTFLUELENGTH(m)
Vertical Balanced Flue High/Low Level Balanced Flue
8.0 5.0�5
8.0 5.02�
8.0 5.026
6.0 3.530
4.0 2.533
Page 2�
2.4 CondensateDisposal
The Warmflow high efficiency condensing boiler is supplied with a factory fitted, self sealing condensate trap. The trap has been fitted inside the boiler casings 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 �.5 litres per hour of condensate. It is recommended that the drainage pipe should have a minimum fall of �:20.
Page 22
2.5 TechnicalData
2.5.1 U-SeriesUtility–Pre-Wired(UHE)
U120HEU90HEU70HEMODEL
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
�4.7
50,000
17.6
60,000
2�
7�,650
2�
7�,650
23.5
80,000
27.�
92,380
27.�
92,380
32.7
���,600
�5.3
52,�50
18.4
62,600
22
75,000
22
75,000
24.4
83,175
28
95,550
28
95,550
29
99,050
34
��6,000
RDB 2.2 �5-2� RDB 2.2 2�-26 RDB 2.2 26-33
T� SHORT T2 SHORT T5 SHORT
B N/A N/A
�00 or �25
4 or 5
�00 or �25
4 or 5
�00 or �25
4 or 5
86 88 90 90 93 95 95 98 ��0
0 0 0
KeroseneSettings
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 0.55 0.6
Danfoss 60°ES
0.6 0.65 0.75
Danfoss 60°ES
0.75 0.85 0.85
7.0
�00
8.0
116
8.0
��6
8.0
��6
8.0
116
7.0
�00
7.0
�00
8.0
116
�0.0
�45
��.5 11.5 ��.5 ��.5 11.5 ��.5 ��.5 11.5 ��.5
�.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
3.8�
0.84
28mm Compression
�” BSP Female
28mm Compression
�” BSP Female
28mm Compression
�” BSP Female
22
4.8
22
4.8
22
4.8
90
��2
92.2
90
��2
92.8
90
��2
92.4
Highlighted in Bold
30
102,400
Page 23
2.5.2 U-SeriesUtility–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
�4.7
50,000
17.6
60,000
2�
7�,650
2�
7�,650
23.5
80,000
27.�
92,380
�5.3
52,�50
18.4
62,600
22
75,000
22
75,000
24.4
83,175
28
95,550
RDB 2.2 �5-2� RDB 2.2 2�-26
T� SHORT T2 SHORT
B N/A
�00 or �25
4 or 5
�00 or �25
4 or 5
86 88 90 90 93 95
0 0
KeroseneSettings
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 0.55 0.6
Danfoss 60°ES
0.6 0.65 0.75
7.0
�00
8.0
116
8.0
��6
8.0
��6
8.0
116
7.0
�00
��.5 11.5 ��.5 ��.5 11.5 ��.5
�.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
�” BSP Female
22mm Copper
�” BSP Female
22
4.8
22
4.8
90
��2
92.2
90
��2
92.8
Highlighted in Bold
Page 24
2.5.3 U-SeriesUtility–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
�4.7
50,000
17.6
60,000
2�
7�,650
2�
7�,650
23.5
80,000
27.�
92,380
�5.3
52,�50
18.4
62,600
22
75,000
22
75,000
24.4
83,175
28
95,550
RDB 2.2 �5-2� RDB 2.2 2�-26
T� SHORT T2 SHORT
B N/A
�00 or �25
4 or 5
�00 or �25
4 or 5
86 88 90 90 93 95
0 0
KeroseneSettings
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 0.55 0.6
Danfoss 60°ES
0.6 0.65 0.75
7.0
�00
8.0
116
8.0
��6
8.0
��6
8.0
116
7.0
�00
��.5 11.5 ��.5 ��.5 11.5 ��.5
�.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
�” BSP Female
22mm Copper
�” BSP Female
22
4.8
22
4.8
�00
�22
92.2
�00
�22
92.8
Highlighted in Bold
Page 25
2.5.4 U-SeriesUtility–Combi(UCHE)
UC90HEUC70HEMODELNominal kWHeat Output Btu/hr
Nominal kWHeat Input btu/hr
BurnerHeadSecondary Air Damper
Flue mmDiameter in
Flue Gas Temp °CSmoke Bacarach
�4.750,000
17.660,000
2�7�,650
2�7�,650
23.580,000
27.�92,380
�5.352,�50
18.462,600
2275,000
2275,000
24.483,175
2895,550
RDB 2.2 �5-2� RDB 2.2 2�-26T� SHORT T2 SHORT
B N/A
�00 or �254 or 5
�00 or �254 or 5
86 88 90 90 93 950 0
KeroseneSettings
Nozzle makesize
Oil Pump barPressure psi
Max CO2 %
Approx Fuel litres/hFlow Rate gals/h
Flow ConnectionReturn Connection
Water litresContent gals
Boiler Weight Dry kgBoiler Weight Wet kg
SEDBUK Efficiency %Factory Settings
Danfoss 60°ES0.5 0.55 0.6
Danfoss 60°ES0.6 0.65 0.75
7.0�00
8.0116
8.0��6
8.0��6
8.0116
7.0�00
��.5 11.5 ��.5 ��.5 11.5 ��.5
�.650.36
1.980.44
2.350.52
2.350.52
2.650.58
2.980.65
22mm Copper 22mm Copper
74�6.3
�402�4
90.0 90.0Highlighted in Bold
74�6.3
�402�4
DomesticHotWater(DHW)Production
Minimum Inlet Dynamic Pressure barfor Maximum DHW Flow Rate psi
Maximum AchievableDHW Flow Rate (refer to page 5)
Maximum Recommended litres/mDHW Flow Rate gals/m
Factory Set litres/mDHW Flow Rate gals/m
Minimum litres/mDHW Flow Rate gals/m
DHW Temperature Rise(at Maximum Output)
Pressure Relief barpsi
Cold Water Mains Inlet Connection(refer to page �)
DHW Outlet Connection
�.826
�.826
Unrestricted Unrestricted
�84.0
245.3
�84.0
�84.0
2.50.55
2.50.55
32°C @ �8 litres/minfor �20 litre draw-off
32°C @ 24 litres/minfor �20 litre draw-off
343.5
343.5
Minimum �5mmUnrestricted
Minimum �5mmUnrestricted
22mm Copper 22mm Copper
22mm Copper 22mm Copper
Page 26
2.5.5 K-SeriesKabinPak–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
�4.7
50,000
17.6
60,000
2�
7�,650
2�
7�,650
23.5
80,000
27.�
92,380
27.�
92,380
30
102,400
32.7
���,600
�5.3
52,�50
18.4
62,600
22
75,000
22
75,000
24.4
83,175
28
95,550
28
95,550
34
��6,000
RDB 2.2 �5-2� RDB 2.2 2�-26 RDB 2.2 26-33
T� SHORT T2 SHORT T5 SHORT
B N/A N/A
�00 or �25
4 or 5
�00 or �25
4 or 5
�00 or �25
4 or 5
86 88 90 90 93 95 95 98 ��0
0 0 0
KeroseneSettings
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 0.55 0.6
Danfoss 60°ES
0.6 0.65 0.75
Danfoss 60°ES
0.75 0.85 0.85
7.0
�00
8.0
116
8.0
��6
8.0
��6
8.0
116
7.0
�00
7.0
�00
8.0
116
�0.0
�45
��.5 11.5 ��.5 ��.5 11.5 ��.5 ��.5 11.5 ��.5
�.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
3.8�
0.84
28mm Compression
�” BSP Female
28mm Compression
�” BSP Female
28mm Compression
�” BSP Female
22
4.8
22
4.8
22
4.8
90
��2
92.2
90
��2
92.8
90
��2
92.4
29
99,050
Highlighted in Bold
Page 27
2.5.6 K-SeriesKabinPak–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
�4.7
50,000
17.6
60,000
2�
7�,650
2�
7�,650
23.5
80,000
27.�
92,380
�5.3
52,�50
18.4
62,600
22
75,000
22
75,000
24.4
83,175
28
95,550
RDB 2.2 �5-2� RDB 2.2 2�-26
T� SHORT T2 SHORT
B N/A
�00 or �25
4 or 5
�00 or �25
4 or 5
86 88 90 90 93 95
0 0
KeroseneSettings
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 0.55 0.6
Danfoss 60°ES
0.6 0.65 0.75
7.0
�00
8.0
116
8.0
��6
8.0
��6
8.0
116
7.0
�00
��.5 11.5 ��.5 ��.5 11.5 ��.5
�.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
�” BSP Female
22mm Copper
�” BSP Female
22
4.8
22
4.8
90
��2
92.2
90
��2
92.8
Highlighted in Bold
Page 28
2.5.7 K-SeriesKabinPak–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
�4.7
50,000
17.6
60,000
2�
7�,650
2�
7�,650
23.5
80,000
27.�
92,380
�5.3
52,�50
18.4
62,600
22
75,000
22
75,000
24.4
83,175
28
95,550
RDB 2.2 �5-2� RDB 2.2 2�-26
T� SHORT T2 SHORT
B N/A
�00 or �25
4 or 5
�00 or �25
4 or 5
86 88 90 90 93 95
0 0
KeroseneSettings
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 0.55 0.6
Danfoss 60°ES
0.6 0.65 0.75
7.0
�00
8.0
116
8.0
��6
8.0
��6
8.0
116
7.0
�00
��.5 11.5 ��.5 ��.5 11.5 ��.5
�.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
�” BSP Female
22mm Copper
�” BSP Female
22
4.8
22
4.8
�00
�22
92.2
�00
�22
92.8
Highlighted in Bold
Page 29
2.5.8 K-SeriesKabinPak–Combi(KCHE)
KC90HEKC70HEMODEL
Nominal kWHeat Output Btu/hr
Nominal kWHeat Input btu/hr
BurnerHeadSecondary Air Damper
Flue mmDiameter in
Flue Gas Temp °CSmoke Bacarach
�4.750,000
17.660,000
2�7�,650
2�7�,650
23.580,000
27.�92,380
�5.352,�50
18.462,600
2275,000
2275,000
24.483,175
2895,550
RDB 2.2 �5-2� RDB 2.2 2�-26T� SHORT T2 SHORT
B N/A
�00 or �254 or 5
�00 or �254 or 5
86 88 90 90 93 950 0
KeroseneSettings
Nozzle makesize
Oil Pump barPressure psi
Max CO2 %
Approx Fuel litres/hFlow Rate gals/h
Flow ConnectionReturn Connection
Water litresContent gals
Boiler Weight Dry kgBoiler Weight Wet kg
SEDBUK Efficiency %Factory Settings
Danfoss 60°ES0.5 0.55 0.6
Danfoss 60°ES0.6 0.65 0.75
7.0�00
8.0116
8.0��6
8.0��6
8.0116
7.0�00
��.5 11.5 ��.5 ��.5 11.5 ��.5
�.650.36
1.980.44
2.350.52
2.350.52
2.650.58
2.980.65
22mm Copper 22mm Copper
74�6.3
�402�4
90.0 90.0Highlighted in Bold
74�6.3
�402�4
DomesticHotWater(DHW)Production
Minimum Inlet Dynamic Pressure barfor Maximum DHW Flow Rate psi
Maximum AchievableDHW Flow Rate (refer to page 5)
Maximum Recommended litres/mDHW Flow Rate gals/m
Factory Set litres/mDHW Flow Rate gals/m
Minimum litres/mDHW Flow Rate gals/m
DHW Temperature Rise(at Maximum Output)
Pressure Relief barpsi
Cold Water Mains Inlet Connection(refer to page �)
DHW Outlet Connection
�.826
�.826
Unrestricted Unrestricted
�84.0
245.3
�84.0
�84.0
2.50.55
2.50.55
32°C @ �8 litres/minfor �20 litre draw-off
32°C @ 24 litres/minfor �20 litre draw-off
343.5
343.5
Minimum �5mmUnrestricted
Minimum �5mmUnrestricted
22mm Copper 22mm Copper
22mm Copper 22mm Copper
Page 30
3.0 ElectricitySupply&WiringDetails
220 – 240V. �PH, 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 DualImmersionThermostat(Pre-Wired,Pumped&SystemBoilers)
Warning: Do not fit any other wires or loop wires to this stat as this will bypass the thermostats.
3.2 RDBBurnerControlBox
CONTROL BOX535SE/LD
M
M
Oil Valve
Photoresistance
BlackWhiteBlue
Motor
Capacitor
Lock
Out
Live
Neu
tral
Ear
th
FanHousing
ToBurner
FromPowerSupply(SwitchedLive)
Page 3�
3.3 CombiWiringDetails
3.3.1 WiringDiagram
The
3 pi
n m
ains
plu
g m
ust b
e su
pplie
d w
ith a
per
man
ent l
ive
to a
llow
the
pum
p ov
er-r
un s
tat a
nd re
lay
to o
pera
te c
orre
ctly.
1297
321
BU
RN
ER
BO
ILE
RL
IMIT
TH
ER
MO
ST
AT
LIM
ITT
HE
RM
OS
TA
TLA
MP
(YE
LLO
W)
EA
RT
HP
OS
T
L1N E
L1N
MA
INS
PL
UG
BO
ILE
RT
HE
RM
OS
TA
T
654
TA
NK
LIM
ITT
HE
RM
OS
TA
T
TA
NK
TH
ER
MO
ST
AT
FLO
WS
WIT
CH
EA
RT
HP
OS
T
DH
WP
UM
P
CH
PU
MP
CH
DH
W
242322212019
COIL
N.O.N.O.N.O.
N.C.N.C.N.C.
CCC
8 10
MA
INS
ON
LAM
P(G
RE
EN
)
LOC
K-O
UT
LAM
P(R
ED
)
PC
BC
ON
TR
OLL
ER
18171615141311
302928272625
G/Y
G/Y
G/Y
G/Y
BR
BR
BR
BR
BR
BR
BR
BR
BR
BL
BL
BK
BL
BK
BL
BL
BL
BL
BK
W
W
W
P
P
PW
W
OO
R
R
RR
BK B
K
Y
Y
O O
BL
P
ON
/OF
FS
WIT
CH
ES
P-
Pur
ple
O-
Ora
nge
Y-
Yel
low
R-
Red
W-
Whi
teB
R-
Bro
wn
BL
-B
lue
B-
Bla
ckG
/Y-
Gre
en/Y
ello
wG
-G
rey
A2
A1
CO
MNo
Nc
No
Nc
CO
MP
UM
PO
VE
RR
UN
TH
ER
MO
ST
AT
PU
MP
OV
ER
RU
NR
ELA
Y
32 4G
W
Y
R
BR
BL
R
Page 32
3.3.2 WiringSchematic
BU
RN
ER
D.H
.W.P
UM
P
C.H
.PU
MP
TRIPLEPOLERELAY
N.C
.
BO
ILE
RS
TA
T
N.O
.
N.C
.
N.O
.
N.O
.
N.C
.
C
C
C
COIL
7
202124
25
22
14
NN N
N
N
10
8
1
26
29
N26
2830
319
23
17
18
16
5
L1 NE
L1 N
MA
INS
PLU
GH
.W.
C.H
.
TA
NK
ST
AT
FLO
WS
WIT
CHT
AN
KLI
MIT
ST
AT
9
BO
ILE
RLI
MIT
ST
AT
15
2
13 1
6 4
MA
INS
ON
LAM
P(G
RE
EN
)
H/L
RE
SE
TLA
MP
(YE
LLO
W)
LOC
KO
UT
LAM
P(G
RE
EN
)LA
MP
716
BO
ILE
RLI
MIT
ST
AT
15
H/L
RE
SE
TLA
MP
(YE
LLO
W)
BR
EA
KIN
TO
TH
EW
HIT
EW
IRE
BE
TW
EE
NN
O16
ON
TH
EP
CB
AN
DT
HE
LIM
ITS
TA
TA
ND
CO
NN
EC
TIN
TH
EP
RE
SS
UR
ES
WIT
CH
WIT
HA
WIR
ING
BLO
CK
AS
SH
OW
N
LOW
PR
ES
SU
RE
SW
ITC
HLO
WP
RE
SS
UR
ES
WIT
CH
WIR
ING
ALO
WP
RE
SS
UR
ES
WIT
CH
12
WIR
ING
BLO
CK
COIL
N11
PU
MP
OV
ER
RU
NS
TA
T
PU
MP
OV
ER
RU
NR
ELA
Y
27
WIR
ING
BLO
CK
NC
NO
C
2 43
Page 33
3.3.3 FittingaRoomThermostattoaCombi
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 and 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 PumpOver-RunStat
The condensing Combi boilers have been fitted with a pump over-run 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 FittingFrostProtectiontoaCombi
ROOM THERMOSTAT
282726
PCB
N5
29 30
FROST THERMOSTAT
PERMANENTLIVE
543 6
PIPE THERMOSTAT
Page 34
3.4 InstallationofaWarmflowCombiOptionalProgrammer(PC1)
�. Disconnect the electrical supply.
2. Drop down control box front (2 screws).
3. Disconnect the 6 pin plug from the CH/HW on/off switch.
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.
�0. Close the control panel cover and reconnect the electrical supply.
��. Using the operational instructions in section �2 or supplied with the programmer, set the switching times.
Page 35
3.5 StandardTimersforCombis
3.5.1 Installationofaremotetwochannelprogrammer(option1)
Remove the purple wire connecting 5 and 28 and the white wire connecting 3 and �9.
Connect the programmer as shown via a fused isolator.
This bypasses the central heating and hot water on/off switch.
If the connection to terminal �2 is not made the mains on lamp is also bypassed.
A separate live supply to the boiler is not required. However a neutral and earth must be supplied to the boiler.
3.5.2 Installationofaremotetwochannelprogrammer(option2)
Remove the purple, white and brown wires connecting the central heating and hot water on/off switches to the 6 pin male plug.
Connect the programmer as shown.
The mains is supplied via a fused isolator to the boiler 3 pin mains plug.
3.6 Standard/SystemOptionalProgrammer(PU1)
3.6.1 ProgrammerControlBoxWiringDiagram
OFFOFFE N L
COM
ON
22 21 20 19
PCB CONTROLLER
ON
COM
CH HW
26 25 24 2328 27
1211
EARTHPOST
OFFOFFE N L
COM
ON ON
COM
CH HW
1
2
3
4
5
6
EARTHPOST
Page 36
3.6.2 GeneralRequirements
�. 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 �2 on the thermal block.
3. The programmer is not suitable for gravity hot water systems.
3.6.3 ProgrammerInstallation
�. 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 (� 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 section 3.6.4 and 3.6.5 of the manual.
6. When fitting the programmer to a standard utility boiler remove the pump lead from the box. A spare cable clamp is supplied to connect the new cable from the installer supplied pump.
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 operational instructions in section �2 of the manual or supplied with the programmer, set the switching times.
Page 37
3.6.4 Honeywell‘Y’Plan–IndependentCH&DHW(FullyPumpedOnly)
Note: Before fitting programmer remove loop between 3 and �2 on the terminal block.
Page 38
3.6.5 Honeywell‘S’Plan–IndependentCH&DHW(FullyPumpedOnly)
Note: Before fitting programmer remove loop between 3 and �2 on the terminal block.
Page 39
4.0 OilSupply
�. 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. It is also recommended that a remote sensing fire valve should be fitted to the oil line preferably before the oil line enters the building (BS54�0 : PART �).
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 OnePipeGravitySystem
HeadH(m)ID8mmID10mm
0.5 1 1.5 2�0 20 40 6020 40 80 �00
TotalMaximumPipeLength(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 40
HeadH(m)ID8mmID10mm
0.5 1 2 335 25 �5 8�00 �00 70 30
0.530�00
3.5620
1.52090
TotalMaximumPipeLength(m)
4.2 TwoPipeSystem
Formaximumpipelengthandliftcontactde-aeratormanufacturer.
4.3 De-aeratorSystem
Page 4�
HeadH(m)ID8mmID10mm
0.5 1 2 335 25 �5 8�00 �00 70 30
0.530�00
3.5620
1.52090
TotalMaximumPipeLength(m)
4.4 OnePipeLiftSystem
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 42
5.0 Flues
5.1 InstallationofFlues
OPTIONALEXTENSION PIECES
VerticalBalanced
Flue
LowLevelBalancedFlue
HighLevelBalanced
Flue
RIELLO RDBBURNER
AIR INTAKECOVER
AIR INTAKEADAPTERSPIGOT &GASKET
BOILER LID
HORIZONTALFLUE ADAPTOR
FLUE TERMINAL
TOP PANEL
TEST HOLEPLUG
FLUEGASKET
Page 43
5.1.1 InstallationofaBalancedFlue
�. Make a suitable sized hole in the wall or ceiling for the flue kit. Add the dimensions given in section 2 as required. The cavities around the opening must be sealed and protected by a non-combustable sleeve.
2. Remove the top panel.
3. Break out the required knock out piece in the casing panel for the flue.
4. Carefully fit the inner and out seals to the flue adaptor. After fitting the seals to the flue smear them with the lubricant supplied.
5. Place the gasket correctly on the boiler and locate the flue adaptor over this, fixing it in position using the nuts and bolts provided. For the low level flue side outlet options on white case boilers it will be necessary to manoeuvre the adaptor through the side panel before fixing it to the boiler after the blanking plate has been removed. Push boiler into position against the wall.
6. If fitting extension pieces or bends ensure the seals are correctly fitted and lubricated before pushing through the wall and attaching to the flue adaptor.
7. Slide the flue terminal into position with a twisting movement ensuring that it protrudes through the wall by a minimum of �75mm and a maximum of 225mm or through the roof by a minimum of 665mm.
8. Seal the gap between the flue and the wall both inside and out after which the protective basket must be fitted to the wall over the flue terminal.
9. After removing the air inlet cover fit the air intake adaptor spigot and gasket to the burner. Connect one end of the air duct to the flue and the other end to the air intake spigot on the burner. Both ends should be securely fastened with the jubilee clips.
�0. The boiler is now ready to be connected to the plumbing, oil supply and mains electricity.
��. The side casings of the boilers have been designed with knockouts to allow the oil pipe and electric cable to pass unnoticed inside the unit.
Note: Where a knockout has been removed ensure that a grommet or cable gland is fitted to the hole prior to passing any cable through it.
�2. A test hole for commissioning purposes has been provided on the secondary heat exchanger door.
Page 44
5.2 ConventionalFlues
The flue should be designed in accordance with the local bye-laws and the Clean Air Act. 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 stainless steel liner of the correct 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.
Onlyfluessuitableforusewithoilfired condensing boilers must beused.
5.3 LowLevelBalancedFluesTerminalPositions
Attention should be given to the position of the flue discharge; we recommend the following guidelines be adopted.
�. The flue should not discharge beneath opening windows or within 2 metres of 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 actual siting 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.
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.
Installationinexposedpositionsisnotrecommended.
Cowls and pots that may restrict the flue should not be used
TERRACOTA POTConsidered good practice but is not a guarantee of overcoming down drafts
LINERSuitable liner same diameter as Boiler Flue connection
Starter piece stainless steel same
diameter as flue
SORTDOOR
FLUE PIPE BENDSDO NOT USE 90°
Typical Conventional Flue with Brick Chimney
TEST POINT �35°2 m
etre
s m
ax
Page 45
TheseareminimumdimensionsandareonlyquotedasaguidelinebuttheywillsatisfytherequirementsoftheBuildingregulations.
Terminatingpositionsmustbeatleast1.8metresdistantfromanoilstoragetankunlessawallwithatleast30minfireresistanceandextendinghigherandwiderthanthetankisprovidedbetweenthetankandtheterminatingposition.
From an internal or external corner or surface or boundary alongside the terminal.F 300 600
NI&ROI
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 �,200
Vertically from a terminal on the same wall.K �,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 �,500
APPLIANCEBURNERTYPE
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
GB
Below a gutter, eaves or balcony with protection.
MINIMUMDISTANCESTOTERMINALSINMILLIMETRESASMEASUREDFROMTHETOPOFTHECHIMNEYORTHERIMOFALOWLEVELDISCHARGEOPENING
300
600
�,200
�,500
750
600
750
750
�,500
600
600
75
600
300
Page 46
6.0 AirSupplyforCombustion&Ventilation (seeBS5410)
6.1 OpenFlueBoilers
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 BalancedFlueBoilers–BoilersinaCompartment
Air Supply for VentilationNo Combustion Air Inlet required to Room
Page 47
7.0 InstallationRequirements
The boiler installation must be in compliance with BS54�0 : PART � and the Building Regulations.
7.1 GeneralRequirements
7.1.1 Hearth
The boiler hearth temperature is 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 ServiceAccess
24” (600mm) Clearance should be provided above and in front of the boiler to allow for routine servicing.
7.1.3 HeatingSystem
The heating system should be installed to HVCA current codes of practice. Before installing the boiler the new or existing system should be thoroughly flushed to clear all sludge or other foreign matter such as solder, steel wool and copper fillings. We recommend that the system is cleaned out in accordance with BS5449 and BS7593 using a suitable non-corrosive commission cleanser. It is further recommended that a suitable corrosion inhibitor is added to the heating system, which will not damage the synthetic rubber parts within the boiler.
7.1.4 AirVents
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 DrainCock
Drain cock(s) should be fitted to a bottom connection on the boiler and to the lowest points in the system to enable the system to be fully drained.
7.1.6 FrostProtection
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.
7.1.7 BoilerConnections
All connections to the appliance should be made with compression fittings, with the last 600mm of the primary flow and return pipework made from copper.
Page 48
7.2 SealedSystems
7.2.1 ExpansionVessel
A �2 litre expansion vessel charged to 0.5 bar is supplied with both the system and Combi boiler. This can accommodate a maximum combined boiler and system volume of approximately �50 litres. If this volume is exceeded an additional vessel will be required. Refer to BS7074: PART � or BS5449 for details of sizing. The values given in the table are for total system values which includes the primary water capacity. See page �2 and �3.
The pressure in the vessel(s) should be checked annually during the normal boiler service by fitting a gauge to the schrader valve on the vessel. Ensure the system pressure is at zero to ensure an accurate reading.
7.2.2 SystemFilling
As standard, a filling point complete with a filling loop has been included within the appliance. The temporary hose must be disconnected after filling. A system pressure when cold of � bar is recommended. After filling, vent all air from the system. Ensure the caps on the automatic air vents are loose or removed and bleed both circulating pumps.
7.2.3 SystemPressure
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 PressureReliefValve
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 LowPressureSwitch
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 thesystem and wired in series with the boiler limit thermostat (see page �6).
25.0
32.7
46.8
300
VESSELVOLUMES
22.9
30.0
42.9
275
20.8
27.2
39.0
250
�8.7
24.5
35.�
225
�6.7
2�.8
3�.2
200
�4.6
�9.�
27.3
�75
�2.5
�6.3
23.4
�50
�0.5
�3.6
�9.5
�25
8.3
�0.9
�5.6
�00
6.3
8.2
��.7
75
4.2
5.4
7.8
50
2.�
2.7
2.9
25
0.5
�.0
�.5
TOTALSYSTEMVOLUME
INIT
IAL
CH
AR
GE
Page 49
7.3 CombiDomesticHotWater
7.3.1 MainsWaterPressure
To reduce the likelihood of leaking joints the mains water supply pressure must not exceed the factory test pressure of 5 bar. If the mains water pressure exceeds 2 bar then a pressure reducing valve must be fitted. The final 600mm of the mains supply pipe to the appliance must be in copper. The flow rate of water from individual taps is dependant on the number of outlets being operated together, as well as the length and size of pipework in the system and the mains supply pressure. Whenever a pressure reducing valve or any other device containing a non-return valve is fitted to the mains water supply pipe entering the boiler, it is recommended that a mini expansion vessel, suitable for use on potable water, is fitted between the device and the closed tap.
7.3.2 WaterHardness
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.
7.3.3 HotWaterPumpedReturn
To ensure economic use, the pipe runs between the boiler and the taps should be as short as possible and insulated to reduce heat loss. For boilers that have to be sited remotely from the main point of use, there is likely to be very long pipe runs which can lead to excessive water usage and poor fuel efficiency. It is recommended that a pumped hot water return is used in order to improve HW reaction times. Contact Warmflow for details.
7.3.4 FlowRestrictor
An �8L/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.
FLOWSWITCHFLOWRESTRICTORWASHER
Page 50
8.0 Burners
8.1 RDBBurner
The burner is fitted with the correct nozzle and the pressure set. All that is further required before commissioning, is to connect the oil and electricity supply.
8.2 OilPump
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.
8.3 ElectricalConnections
The boiler control equipment and the burner are provided ex works, it is only necessary to connect a 230V 50Hz supply in accordance with the electrical drawings.
1. Pump2. ControlBox3. ResetButtonwithLock-OutLamp4. FlangewithInsulatingGasket
5. AirDamperAdjustmentScrew6. AirTubeConnection(SuppliedwithBFKit)7. PumpPressureAdjustmentScrew8. PressureGaugePort
1. SuctionLine2. ReturnLine3. By-PassScrew4. GaugeConnection5. PressureAdjuster6. SuctionGaugeConnection7. Valve8. AuxiliaryPressureTestPoint
Page 5�
8.4 ElectrodeSetting
8.5 BurnerStart-UpCycle
8.6 AirDamperAdjustment
The air damper is set in factory. This regulation is purely indicative. Each installation however, has its own unpredictable 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 (�). 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 fine-tuning of the inlet air. Tuning of this device is possible by turning the screw (3).
AirDamper(A)–15/21BurnerOnly AirDamper(B)
~12s
Thermostat
Motor
Ignition Transformer
Valve
Flame
Lock-Out Lamp
~12s
Normal Lock-outduetofailuretolight
~5s
Beforeassemblingorremovingthenozzle,loosenthescrew(A)andmovetheelectrodesawayfromthenozzle.
Page 52
9.0 Commissioning&Servicing
9.1 Commissioning
Note:It is the responsibility of the installer toensure that theboiler isproperlycommissionedbyanOFTECtrainedandregisteredtechnician.FailuretodosoWILLinvalidateALLwarranties.
Combustion tests must be carried out using a Combustion Analyser. The pump pressure can be checked by fitting a manifold and a pressure gauge to the oil pump.
Before firing ensure that all the baffles are in place as they may have been displaced during transit as shown on page 7. Switch the boiler on, ensuring all controls are calling for heat. Typical burner settings and test data are shown in section 2.5.
Check the smoke reading, CO2 content and flue gas temperature with the boiler up to temperature. 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 GB building regulations OFTEC form CD�� should be completed and a copy left with the householder.
9.2 Servicing
9.2.1 GeneralRequirements
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 defective they must be replaced.
Note:Secondyearorotherextendedwarrantieswillbeinvalidatediftheapplianceis not serviced annually by a Warmflow or OFTEC trained and registeredtechnician.
Page 53
10.0 BurnerFaultFinding
10.1 RielloRDB
OK
YE
SY
ES
YE
S
NO
NO
NO
YE
S
NO
NO
NO
NO
NO
NO
NO
NO
NO
YE
SY
ES
YE
S
Bur
ner
Mot
or R
uns
Lock
Out
with
in1
seco
nd
Lock
Out
aft
er12
sec
ond
pur
ge
Igni
tion
Sp
ark
Pro
ved
Pum
pP
rod
uces
Pre
ssur
e
Noz
zle
Ato
mis
ing
Fuel
Com
bus
tion
Air
Set
Cor
rect
Com
bus
tion
Hea
d S
etC
orre
ct
Che
ckL
& N
to
Con
trol
Box
Mot
or o
rP
ump
Sei
zed
Rep
air/
Rep
lace
Mot
or/P
ump
Che
ck a
nd S
etth
e E
lect
rod
es
Was
hing
Pre
ssur
e1-
2 B
ar
Sol
enoi
dO
per
atin
gR
aise
Pre
ssur
e
Rep
lace
Noz
zle
Flam
e O
ffan
d R
e-Li
ghts
Che
ckB
oile
r C
ontr
ols
Rep
lace
Mot
orC
apac
itor
Rep
lace
the
Con
trol
Box
Driv
e C
oup
ling
Bro
ken
Rep
lace
the
Coi
l and
/or
Ste
m V
alve
Con
tam
inat
edFu
el F
ilter
Boi
ler
or F
lue
Blo
cked
Rep
air
orR
epla
ce O
ilP
ump
Mot
or g
ives
50 V
olts
to
Whi
te W
ire
Coi
l of
Sol
enoi
dFu
nctio
nal
Pho
to C
ell
Func
tiona
lR
epla
ceC
ontr
ol B
ox
If B
/Fap
plic
atio
nre
mov
e b
urne
rsn
orke
l tub
ean
d r
etes
t
Rep
lace
Bur
ner
Mot
orR
epla
ceS
olen
oid
Coi
lR
epla
ceP
hoto
Cel
lR
eset
B/F
Flu
eor
Rep
ositi
on
YE
SN
OY
ES
YE
SY
ES
YE
SY
ES
NO
NO
NO
Page 54
11.0 CombiFaultFinding
11.1 CentralHeating
YESYES
YES
NO
YES
YES
NO
YES
NO
NO
NO
Switch on power,set selectors
for CH on andDHW off.
Set all controlsto call for heat.
Does theburner fire?
Is lockout lampon burner or
panel lit?
Is high limitthermostatlamp lit?
Is there continuityacross the boilerstat connections17 and 18 on the
PCB?
Is there continuityacross the
connections28 and 30 on
the PCB?
Check powerfrom clock orswitch, check
wiring fuses andmains supply.
Refer to burnerfault finding.
Press resetbutton, replace
if necessary.
Check wiring,replace boilerthermostat.
Check relay andPCB, replace if
necessary.
Do radiatorsget hot?
Does boilercycle on itsthermostat?
Check all valvesare open and
pump is working,check pressure,check all air is
vented.
Check boilerthermostat,replace if
necessary.
HEATINGISWORKING
NORMALLY
NO
NO
YES
Page 55
11.2 DomesticHotWater
Switch on power,set selectors to CH
off and DHW on.
Is DHW pumpworking?
Is there continuityacross connection 20and 21 on the PCB?
Check wiring, replacetank thermostat.
Is there continuityacross 25 and 27?
Check wiring, replacerelay, replace PCB.
Check wiring,replace pump.
Does burner fire? Do radiators get hot?Check plumbing,
replace non-returnvalve.
Refer to burnerfault finding.
Is lockout lamp onburner or pump lit? Does tank get hot?
Vent all air from systempumps, ensure allvalves are open.
Press reset button,replace limitthermostat.
Is high limitthermostat lamp lit.
Does boiler shut downwhen tank reaches
temperature?
Replace tank stat,replace relay.
Check wiring, replacetank limit stat.
Is there continuinityacross 23 and 22?
With tap closed, switchthe CH switch to on.
Check wiring, replacerelay, replace PCB.
Is there continuinityacross 22 and 16? Do radiators get hot? Check CH fault finding.
Check power fromclock or switch, checkwiring, check fuses.
Does CH pump stopwhen tap is opened?
Check flow switch,check relay.
Is hot water producedwhen tap is opened.
BOILERISWORKINGNORMALLY
NO NO
NO
YES
NO
NO
NO
YES
YES
YES
NO
NO
NO
NO
YES
YES
NO
YES
YES
YES
YES
YES
Check mixer valve,check plate heat
exchanger for blockage,ensure all air is vented
from boiler.
YES
YES
NO
NO
NO
YES
Page 56
12.0 OptionalBoilerMountedDigitalTimer
12.1 OperationalInstructions
12.1.1AfterInstallation
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 57
12.1.2BuiltinProgramme
For convenience, the timer module has a built in programme, however, it can be easily adjusted (see section �2.5 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.
FactoryPresentTimeSchedule
12.1.3ToSetCurrentTime&Day
�. 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.
12.1.4SelectOperationMode
Press CH SELECT / HW SELECT button to select operation mode to be OFF, AUTO, ON.
22:3022:30
�6:30
�4:00
�2:00
�0:30
07:30
22:3022:30
�6:30
�4:00
�2:00
08:30
06:30
HW/CH2CH/CH1
�6:30
�4:00
�2:00
08:30
06:30
�6:30
�4:00
�2:00
�0:30
07:30
HW/CH2CH/CH1
Mon – FriTime Schedule
Mon – FriTime Schedule
PERIOD � ON
PERIOD � OFF
PERIOD 2 ON
PERIOD 2 OFF
PERIOD 3 ON
PERIOD 3 OFF
Switching
Page 58
SetDayProgrammePeriod1On/Off
22:30
07:30
22:30
06:30
HW/CH2CH/CH1
22:30
06:30
22:30
07:30
HW/CH2CH/CH1
Mon – FriTime Schedule
Mon – FriTime Schedule
PERIOD � ON
PERIOD � OFF
Switching
SetDayProgrammePeriod3On/Off
22:3022:30
�6:30
�4:00
�2:00
�0:30
07:30
22:3022:30
�6:30
�4:00
�2:00
08:30
06:30
HW/CH2CH/CH1
�6:30
�4:00
�2:00
08:30
06:30
�6:30
�4:00
�2:00
�0:30
07:30
HW/CH2CH/CH1
Mon – FriTime Schedule
Mon – FriTime Schedule
PERIOD � ON
PERIOD � OFF
PERIOD 2 ON
PERIOD 2 OFF
PERIOD 3 ON
PERIOD 3 OFF
Switching
SetDayProgrammePeriod2On/Off
�0:30
07:30
22:30
�6:30
08:30
06:30
HW/CH2CH/CH1
22:30
�6:30
08:30
06:30
�0:30
07:30
HW/CH2CH/CH1
Mon – FriTime Schedule
Mon – FriTime Schedule
PERIOD � ON
PERIOD � OFF
PERIOD 2 ON
PERIOD 2 OFF
Switching
22:30
�6:30
22:30
�6:30
12.1.5ToSetProgrammePeriod
Press and hold DAY button and press MIN until the correct programme period is displayed.
12.1.6ReviewingtheProgrammes
Press TIMER button each time to toggle through the ON and OFF settings.
12.1.7ToChangetheProgramme
�. 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 59
12.1.8ManualSelect
�. Press SELECT to toggle through ON/AUTO/OFF modes as indicated by the timer status.
2. ON mode turns on the timer.
3. OFF mode turns off the timer.
4. AUTO mode runs the set programme.
12.1.9ManualSelect
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.
�. Press CHADV or HWADV 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 CHADV or HWADV and the ‘AUTO’ will stop flash.
12.1.10ManualHour
�. Press CHADV or HWADV key, the CH icon will flash.
2. You now have approx 5 second to enter desired length of time by pressing CHADV or HWADV key once for each hour the new time set should be in affect.
3. The MANUAL HOUR function will bring the unit ON � hour to 3 hours in the OFF mode.
4. The MANUAL HOUR function will bring the unit OFF � 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 � hour to 3 hours in off, clock will count down immediately.
7. When MANUAL HOUR function will extend by � hour to 3 hours while ON, clock will count down after the programmed ON is finished.
12.1.11CancelManualHourFunction
Press CHADV or HWADV button again the LCD display and switching status will return to normal.
Page 60
13.0 Spares
13.1 RDB2.2Spares
No CODE 3514157 3514257 3514557 DESCRIPTION
� 30085�2 • • • Gasket
2 3006384 • • • Flange
3 300255� • Cup-Shaped Head
3 300�079 • Cup-Shaped Head
3 3020055 • Cup-Shaped Head
4 3008860 • • • Electrode Assembly
5 3008875 • • • Screw
6 300886� • • • Nozzle Holder
7 3008862 • • • Collar
8 3008794 • • • High Voltage Lead
9 3008647 • • Air Damper Assembly
9 3008839 • Air Damper Assembly
�0 3005788 • • • Fan
�� 300754� • • • PE Cell
�2 3002837 • • • Capacitor 4.5µF
�3 3007582 • • • Needle Valve
�4 300865� • • • Regulator
No CODE 3514157 3514257 3514557 DESCRIPTION
�5 3000439 • • • Pump Seal
�6 3008654 • • • Pump
�7 3007�62 • • • O-Ring
�8 3008653 • • • Filter O-Ring
�9 3003602 • • • Connector
20 3005720 • • • Flexible Oil Line
2� 3008644 • • • Tube
22 3008876 • • • Pressure Gauge
23 3000443 • • • Joint
24 3008648 • • • Coil-Shell & Knob
25 3008650 • • • Motor
25 3002836 • • • Motor & Capacitor
26 3008649 • • • Protection
27 3008652 • • • Control Box 535RSE/LD
28 300885� • • • Lead Coil
29 3008879 • • • Cover
30 3008878 • • • Kit Seals
Page 6�
13.2 PipeSpares
Page 62
13.3 ShortPartsList–Boiler
PartDescription Code
Flow Switch �476
Tank & Boiler Control Thermostat 2�3�
Boiler Limit Thermostat (Combi) 28�
Tank Limit Thermostat 2�26
Pump Over-Run Thermostat 3�08
Plate Heat Exchanger 599
Twin Head Pump 2�30
�5/60 Pump (for replacement head) 602
3 Pole Relay �827
Auto Air Vent C/W Check Valve 6�4
Pressure Relief Valve 2�32
Filling Loop 2�33
Pressure Gauge 30�9
Mixer Valve �62�
Low Pressure Switch 2270
PCB Controller MK4 24�9
Air Intake Duct AID
�2 Litre Pressure Vessel 2�28
Single Pole Relay & Base 3074
Dual Stat (Standard and System) WDS2
Optional Programmer (Combi) PC�
Optional Programmer (Standard & System) PU�
When ordering replacement casing panels it should be noted that due to the painting process there may be some variation in colour.
Page 63
14.0 YourGuarantee,Terms&Conditions
1. WarmflowGuarantees
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 �2 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 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, �2 months after the date of installation and thereafter, at �2 monthly intervals.
NOTE: In Northern Ireland and theRepublic of Ireland the period ofguarantee can only be increased to24monthsthroughthepurchaseofanextendedwarranty.
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.ConditionsofGuarantee
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.
If the boiler has not been installed within 3 months from the date of despatch from Warmflow, then the warranty will deem to have started.
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 pleasecontact your commissioning engineerwho should then contact our servicedepartment whilst at your home, toreportthefault.
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 64
COMMISSION
Commission/ServiceRecord 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 3SERVICE 2
SERVICE 5SERVICE 4
SERVICE 7SERVICE 6
SERVICE 9SERVICE 8
Date of Commission ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of �st Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 3rd Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 2nd Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 5th Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 4th Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 7th Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 6th Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 9th Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
Date of 8th Service ______________________
Company Name ______________________
Engineer Name ______________________
Engineer Signature ______________________
Telephone No ______________________
YOUR DETAILS
Mr/Ms/Mrs/Miss Initials Surname|__|__|__|__| |__|__|__|__| |__|__|__|__|__|__|__|__|__|__|__|__|__|
HomeTelephoneNo(inccode) MobileTelephoneNo|__|__|__|__|__|__|__|__|__|__|__|__|__| |__|__|__|__|__|__|__|__|__|__|__|__|__|
EmailAddress|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
HouseNumber/Name/Street|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
Town/City|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
County Postcode|__|__|__|__|__|__|__|__|__|__|__|__|__| |__|__|__|__|__|__|__|__|
PRODUCT DETAILS(foundonwarrantylabellocatedonthefrontorinsidefrontoftheappliance)
ApplianceType SerialNumber|__|__|__|__|__|__|__|__|__|__|__|__|__| |__|__|__|__|__|__|__|__|
DateofInstallation|__|__|__|__|__|__|__|__|
NAME OF INSTALLER
Mr/Ms/Mrs/Miss Initials Surname|__|__|__|__| |__|__|__|__| |__|__|__|__|__|__|__|__|__|__|__|__|__|
WorkTelephoneNo(inccode) MobileTelephoneNo|__|__|__|__|__|__|__|__|__|__|__|__|__| |__|__|__|__|__|__|__|__|__|__|__|__|__|
NAME OF COMMISSIONING ENGINEER
Mr/Ms/Mrs/Miss Initials Surname|__|__|__|__| |__|__|__|__| |__|__|__|__|__|__|__|__|__|__|__|__|__|
WorkTelephoneNo(inccode) MobileTelephoneNo|__|__|__|__|__|__|__|__|__|__|__|__|__| |__|__|__|__|__|__|__|__|__|__|__|__|__|
Your details will be used by Warmflow Engineering to provide customer services, information about extendedwarrantiesandforothermarketingpurposes.Wewilldiscloseyourinformationtoourserviceprovidersandagentsfor thesepurposes.Yourdetailsmayalsobeusedbyother thirdparties forothermarketingpurposes.Weandthethirdpartiesmaycontactyoubymail,emailortelephone.IfyoudonotwishforustouseyourdataforothermarketingpurposespleaseputanXinthisbox
Tohelpkeepyourdetailsaccuratewemayuseinformationwereceivefromourpartners.Youcanaskforacopyofyourdetails(forasmallfee)andtocorrectanyinaccuracies.Tomakesurewefollowyourinstructionscorrectlyand to improveour servicewemaymonitoror recordourcommunicationswith you.Pleasenote that failure toprovidesomeoralloftheinformationrequesteddoesnotaffectyourstatutoryrightsbutmayaffectthequalityoftheserviceprovided.
TEA
RA
LON
GP
ER
FOR
ATION
TEA
RA
LON
GP
ER
FOR
ATIO
N
BU
SIN
ES
S R
EP
LY S
ER
VIC
ELi
cenc
e N
o B
EL
1609
CU
STO
ME
RS
FR
OM
RO
IP
LEA
SE
AFF
IXS
TAM
P
War
mfl
ow
Eng
inee
ring
Ltd
Ap
plia
nce
Reg
istr
atio
n D
ept
Liss
ue In
dus
tria
l Est
ate
Moi
ra R
oad
Lisb
urn
Co
Ant
rimB
T28
2RF
2
