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<!DOCTYPE html PUBLIC "-//W3C//DTD HTML 4.01//EN" "http://www.w3.org/TR/html4/strict.dtd">
INSTALLATION & SERVICING MANUAL FOR
50/70
WALL MOUNTED BOILER
(INTERNAL)
&
50/70
WALL MOUNTED BOILER
(EXTERNAL)
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 1
FEB ’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 2827
E-MAIL: service@warmflow.co.uk
*Failure to commission the boiler may invalidate warranty
Contents
Page
1.0
User Instructions
1.1
Thermostat Control ......................................................................................................................................... 2
1.2
Mains Indicator ................................................................................................................................................ 2
1.3
Lock Out .......................................................................................................................................................... 2
1.4
Servicing ......................................................................................................................................................... 2
1.5
User Instructions – Wall Mounted (Internal) .................................................................................................... 3
1.6
User Instructions – Wall Mounted (External) ................................................................................................... 4
1.7.1
Components – Wall Mounted Boiler (Internal) ................................................................................................ 5
1.7.2
Components – Wall Mounted Boiler (External) ............................................................................................... 6
2.0
Introduction
2.1
General Requirements .................................................................................................................................... 7
3.0
Dimensions
3.1
50/70 Wall Mounted Boiler (Internal) ............................................................................................................... 8
3.2
50/70 Wall Mounted Boiler (External) ............................................................................................................. 8
3.3
Easy Fit Low Level Conventional Flue (LLF-R) .............................................................................................. 9
4.0
Installation Requirements
4.1.1
Service Access for WM Boiler (Internal) ......................................................................................................... 9
4.1.2
Servicing ......................................................................................................................................................... 9
4.1.3
Heating System ............................................................................................................................................... 9
4.2
Sealed Systems ............................................................................................................................................ 10
4.2.1
Air Vents ........................................................................................................................................................ 10
4.2.2
Drain Cock .................................................................................................................................................... 10
4.2.3
Expansion Vessels ........................................................................................................................................ 10
4.2.4
System Filling ................................................................................................................................................ 10
4.2.5
Pressure Relief Valve .................................................................................................................................... 10
4.2.6
Low Pressure Switch .................................................................................................................................... 10
5.0
Boiler Installation
5.1
Heat Exchanger Installation .......................................................................................................................... 11
5.2
Internal Boiler Casing Installation ................................................................................................................. 12
5.3
External Boiler Casing Installation ................................................................................................................ 13
5.4
Baffles ........................................................................................................................................................... 14
6.0
Electricity Supply
6.1
RDB Burner Control Box ............................................................................................................................... 14
6.2.1
Control Panel Wiring (Wall Mounted Boilers – Internal) ................................................................................ 15
6.2.2
Control Panel Wiring (Wall Mounted Boilers – External) ............................................................................... 16
7.0
Technical Data
............................................................................................................................................................. 17
8.0
Air Supply
8.1
Open Flue Boilers ......................................................................................................................................... 18
8.2
Balanced Flue/Room Sealed Boilers ............................................................................................................ 18
9.0
Flues
9.1
Conventional Flues ....................................................................................................................................... 19
9.2
Low Level Conventional Flue Positions ........................................................................................................ 19
9.3
Low Level Conventional Flue Installation ...................................................................................................... 21
9.4
Installation of Air Intake Duct ........................................................................................................................ 22
9.5
Wall Mounted Boiler (External) Flue Adaptor Installation .............................................................................. 23
9.5.1
Option A ........................................................................................................................................................ 23
9.5.2
Option B ........................................................................................................................................................ 23
10.0
Oil Supply
10.1
One Pipe System .......................................................................................................................................... 24
10.2
Two Pipe System .......................................................................................................................................... 25
10.3
De-aerator System ........................................................................................................................................ 25
10.4
One Pipe Lift System .................................................................................................................................... 26
11.0
RDB Burner
11.1
Components .................................................................................................................................................. 27
11.2
Oil Pump ....................................................................................................................................................... 27
11.3
Air Damper Adjustment ................................................................................................................................. 28
11.4
Electrode Setting ........................................................................................................................................... 28
11.5
Start-Up Cycle ............................................................................................................................................... 28
12.0
Servicing & Commissioning
12.1
Commissioning ............................................................................................................................................. 29
12.2
Servicing ....................................................................................................................................................... 29
12.2.1
General Requirements .................................................................................................................................. 29
12.2.2
External Wall Mounted Boilers ...................................................................................................................... 29
13.0
Fault Finding
............................................................................................................................................................... 30
14.0
Spares
14.1
Burner Spares ............................................................................................................................................... 31
14.2
Short Parts List (Boiler) ................................................................................................................................. 32
Page 1
User Instructions
1.0
All our domestic appliances have been independently tested and accredited 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.
1.1
Thermostat Control
The recommended minimum thermostat is 65
C. Below this ‘cold water corrosion’ is likely
to occur which can reduce the life of the heat exchanger and is not covered by the boiler
warranty. The boiler thermostat is adjustable from 54
C to 84
C.
1.2
Mains Indicator
The green mains lamp will be lit when there is power to the control and limit thermostats.
The yellow high limit reset lamp will be lit when the boiler has overheated and tripped the
high limit thermostat, which then needs to be manually reset. If the high limit thermostat
continues to trip, contact Warmflow or your service engineer/technician. The manual reset
thermostat has a cut out point of 110
°
C.
1.3
Lock Out
The red lock out lamp will be lit when the burner has failed to fire and can be reset by
pressing the illuminated red reset button on the burner control box.
Note
:
On the external wall mounted boiler the thermostat control indication lamps and high limit
reset button are located behind the lockable plastic cover.
1.4
Servicing
It is recommended that the boiler is serviced annually by an OFTEC registered engineer.
Page 2
1.5
User Instructions – Wall Mounted (Internal)
BURNER
LOCK-OUT
RESET
LIMIT STAT RESET
GREEN
AMBER
RED
CONTROL
THERMOSTAT
(54
C – 84
C)
BURNER
LOCK-OUT
RESET (FROM
UNDERNEATH)
HIGH LIMIT
STAT RESET
(FROM
UNDERNEATH)
Page 3
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