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INSTALLATION & SERVICING
MANUAL FOR
70/90
COMBI BOILER
&
70/90
KABIN PAK COMBI
LEAVE THESE INSTRUCTIONS WITH THE END USER
BS 5750
PART 2
ISO 9002
BSI
NATIONAL
ACCREDITATION
OF CERTIFICATION
BODIES
R
CERT. No. FM 29884
ISSUE 4
MAR ’03
COMMISSIONING
*THIS APPLIANCE MUST
BE COMMISSIONED
After commissioning ensure that the pre-paid warranty
registration card is filled in and returned.
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
*Failure to commission this appliance may invalidate warranty
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
A
C to 85
A
C. The recommended minimum thermostat setting is
65
A
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
A
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
A
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
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