WarmFlow Agentis Series Manual
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WarmFlow Agentis Series Manual

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Boiler Manual
Incorporating:
Agentis Boilers
For use with Kerosene only
Models covered by this manual:
Agentis B-Series
Boilerhouse
Agentis I-Series
Internal
Internal Pumped & Pumped Professional
Internal System & System Professional
Internal Combi & Combi Professional
Agentis E-Series
External
External Pumped & Pumped Professional
External System & System Professional
External Combi & Combi Professional
Internal Combi and External Combi models Patent GB1613466.0, GB2552701, IE86968
User Instructions
Installation Instructions
Service Instructions
Guarantee Terms & Conditions
LEAVE THIS MANUAL WITH THE END USER
B21
B26
I21
I26
I21P/PRO
I26P/PRO
I21S/PRO
I26S/PRO
I21C/PRO
I26C/PRO
E21
E26
E21P/PRO
E26P/PRO
E21S/PRO
E26S/PRO
E21C/PRO E26C/PRO E33C/PRO
B33
I33
I44
I33P/PRO
I44P
I33S/PRO
I33C/PRO
E33
E44
E33P/PRO
E44P
E33S/PRO

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Summary of Contents for WarmFlow Agentis Series

  • Page 1 Boiler Manual Incorporating: User Instructions Installation Instructions Service Instructions Guarantee Terms & Conditions Agentis Boilers For use with Kerosene only Models covered by this manual: Agentis B-Series Boilerhouse Agentis I-Series Internal Internal Pumped & Pumped Professional I21P/PRO I26P/PRO I33P/PRO I44P Internal System &...
  • Page 3 After commissioning, ensure that the Boiler Passport is completed and returned. SERVICING To ensure continued reliable operation, fuel economy and to validate the guarantee, it is recommended that the boiler is serviced annually by a Warmflow or an OFTEC registered technician. NI Customers Only...

  • Page 4: Table Of Contents

    CONTENTS USER INSTRUCTIONS ......................8 Dual Thermostat – Non-Combination Boilers ................8 Burner Lockout ........................... 8 System Pressure – System & Combination Boilers ..............9 Filling Loop ..........................10 Corrosion Inhibitor ........................11 Control Panel – Combination Boilers ..................12 LCD Icon Descriptions ......................
  • Page 5 4.5.9 E-Series (External) Pump Group ..................... 36 4.5.10 E-Series (External) System Components (SK3) ................37 4.5.11 E-Series (External) Combination Boiler - Key Components............37 4.5.12 Combination Boiler Pipe Layout ..................... 38 TECHNICAL DETAILS ....................... 39 Dimensions ..........................39 5.1.1 B-Series (Boilerhouse) B21, B26 & B33..................39 5.1.2 I-Series (Internal) I21, I26 &...
  • Page 6 Fit Flue Thermostat ........................... 79 8.1.4 High Level Balanced Flue Kit (HBF) ....................84 8.1.5 Vertical Balanced Flue Kit (VBF) ..................... 86 8.1.6 Warmflow Boiler Flue Components: 80/125 Ø ................88 8.1.7 Flue Length Calculation ........................89 8.1.8 Plume Management Kits ........................90 8.1.9 Utility/Internal Plume Management Kit (UPMK) ................
  • Page 7 10.2.2 System Boiler Filling ........................100 10.2.3 Combination Boiler Filling ......................101 10.2.4 System Pressure ..........................101 10.2.5 Pressure Relief Valve ........................102 10.2.6 Low Pressure Switch ........................102 10.3 Combination Boiler Domestic Hot Water ................102 10.3.1 Mains Water Pressure ........................102 10.3.2 Water Hardness ..........................
  • Page 8 END OF LIFE INFORMATION ..................129 16.1 Safety Risks ........................... 129 16.2 Disassembly of the Product ....................129 16.3 Casing and key components ....................130 16.4 Boiler Assembly ........................131 16.5 Combination Boiler ......................... 132 Page 7...

  • Page 9: User Instructions

    1 USER INSTRUCTIONS This boiler must be serviced annually. Contact Warmflow for further details. In the event of a breakdown please contact your commissioning engineer who should contact our service department whilst at your home, to report the fault. 1.1 Dual Thermostat – Non-Combination Boilers The radiator temperature is regulated via the boiler control thermostat.

  • Page 10: System Pressure - System & Combination Boilers

    Frequent or routine topping up of the system should not be necessary and may prove harmful to the appliance. Should topping up prove necessary on a frequent or routine basis you must contact Warmflow or your installer. Special attention must be given to corrosion inhibitor concentrations where there is a need to top up the system.

  • Page 11: Filling Loop

    1.4 Filling Loop On all models, set the pressure to 1.0 bar when cold. Special attention must be given to corrosion inhibitor concentrations where there is a need to top up the system. See Section 1.5. It is recommended to isolate all electricity supplies to the appliance before topping up system pressure.

  • Page 12: Corrosion Inhibitor

    Frequent or routine topping up of the system should not be necessary and may prove harmful to the appliance. Should topping up prove necessary on a frequent or routine basis you must contact Warmflow or your installer. Page 11...

  • Page 13: Control Panel - Combination Boilers

    1.6 Control Panel – Combination Boilers Internal and External Combination Boilers are fitted with a Liquid Crystal Display (LCD), and 7 pushbuttons as identified below. The High Limit Thermostat reset button is located under the RH side of the control panel.

  • Page 14: Lcd Icon Descriptions

    1.7 LCD Icon Descriptions Icon Description DHW Status CH Status Engineer Reset System Water Pressure Unit Temperature Unit Internal Timeclock Control Manual Override Current Day Timeslot Identifier (1-4) Timeslot Programming Type DHW Setpoint 1 (Upper Bar) DHW Setpoint 1 (Lower Bar) Page 13...

  • Page 15: Home Screen

    1.8 Home Screen When the appliance is powered on, or after reset the Home Screen is displayed by default. As an example, depending on user settings: The current day is day 5 CH temperature DHW temperature setpoint is 6 setpoint is 9 CH is enabled DHW is enabled Current...

  • Page 16: Setting The Date And Time

    1.9 Setting the date and time In order for the appliance to operate with maximum DHW efficiency, and if the built in timeclock is to be used, it is necessary to correctly set the date and time upon first start-up of the appliance.

  • Page 17: Setting Ch Flow Temperature

    1.10 Setting CH flow temperature The CH Setpoint Menu is displayed when the CH+ button (7) or CH- button (6) are pressed when the LCD is displaying the Home Screen. The setpoint is adjustable from 1 (lowest) to 9 (highest). Nominally the central heating flow temperature (at the boiler) will be 50°C at the lowest setting and 82°C at the highest setting.

  • Page 18: Setting Dhw Flow Temperature

    1.11 Setting DHW flow temperature The DHW Setpoint Menu is displayed when the DHW+ button (1) or DHW- button (2) are pressed when the LCD is displaying the Home Screen. The actual DHW delivery temperature is dependent on site conditions, incoming water temperature and flow rate.

  • Page 19: Eco Mode

    Example below shows setpoint 2, displayed as ‘SEt 2’ at a setting of ‘3’: 1.12 Eco Mode Eco mode works to control burner firing based on the inputs into the control system during DHW cycles only, i.e. Eco mode has no effect on CH operation. The Eco mode function is enabled by pressing the DHW- button (2) and DHW+ button (1) simultaneously for 3 seconds, the LCD displays ‘Eco On’...

  • Page 20: Frost Protection (Ice Protection Function)

    PWM Profile A (heating). 1.15.2 Pumped and System Boilers The speed of the circulating pump can be adjusted using the pushbutton and LED indications on the pump. Please refer to the manufacturer’s documentation which is available via www.warmflow.co.uk/support/downloads. Page 19...

  • Page 21: Information Menu

    1.16 Information Menu The Information Menu is used to display selected appliance parameters in real time, it can be used during the commissioning stage, or to assist fault diagnosis. The Information Menu is displayed from the Home Screen by pressing the Information button (5).

  • Page 22: User Parameters

    1.17 User Parameters The User Parameters Menu is used to allow selected parameters to be modified by the user, without password protection. The User Parameters Menu is displayed from the Home Screen by pressing the Information button (5) for 3 seconds. The auxiliary digits then indicate the displayed variable number, and the main digits display the value.

  • Page 23: Weather Compensation Operation

    1.18 Weather Compensation Operation The Weather Compensation operates on the central heating system when the Outdoor Sensor has been connected by the installer. Depending on the outdoor temperature, the CH flow temperature is automatically reduced below the user CH setpoint. The amount of reduction depends on the Weather Compensation Coefficient (Parameter ‘u 00’).

  • Page 24: Condensing Boiler Installation Requirements

    2 CONDENSING BOILER INSTALLATION REQUIREMENTS The Warmflow condensing boiler can be fitted to most installations using standard practices and techniques. There are however a number of considerations that must be taken into account. 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.

  • Page 25: Before Fitting A Combination Boiler The Installer Must Check

    Combination boiler. Systems requiring very high hot water flow rates may be better suited with a Warmflow unvented cylinder. 3. That the mains are capable of supplying up to 24 litre/min with a minimum dynamic pressure of 1.8 bar at the boiler.

  • Page 26: General Information

    (Scotland) Regulations Section 6, Part F1 Northern Ireland and Part L Republic of Ireland. Warmflow oil fired condensing boilers are designed to burn Class C2 (28 sec redwood) kerosene only and to be used on a fully pumped system, and are suitable for connection to sealed heating systems.

  • Page 27: Combination Boiler General Requirements

    BS 7074-1: Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems. Code of practice for domestic heating and hot water supply The heating system should be installed by a competent installer in accordance with the recommendations laid down by the building services compliance guide, OFTEC and sound engineering practice.

  • Page 28: Diverting Valve Operation

    4.3.2 Diverting Valve Operation The function of the diverting valve is to direct return system water from either the central heating circuit or domestic hot water heat store to the circulating pump, depending on mode selection and thermostat requirements. The valve body has 3x ports labelled A, B and AB: The valve actuator has two positions, CH and DHW.

  • Page 40: Technical Details

    5 TECHNICAL DETAILS 5.1 Dimensions 5.1.1 B-Series (Boilerhouse) B21, B26 & B33 Page 39...

  • Page 41: I-Series (Internal) I21, I26 & I33

    5.1.2 I-Series (Internal) I21, I26 & I33 5.1.3 I-Series (Internal) I44 Page 40...

  • Page 42: I-Series (Internal) Combination Boilers I21C, I26C& I33C

    5.1.4 I-Series (Internal) Combination Boilers I21C, I26C& I33C 5.1.5 E-Series (External) E21, E26 & E33 Page 41...

  • Page 43: E-Series (External) Base Tray E21, E26 & E33

    5.1.6 E-Series (External) Base Tray E21, E26 & E33 5.1.7 E-Series (External) E44 Page 42...

  • Page 44: E-Series (External) E44 Base Tray

    5.1.8 E-Series (External) E44 Base Tray 5.1.9 E-Series (External) Combination Boilers E21C, E26C& E33C Page 43...

  • Page 45: E-Series (External) Combination Boiler Base Tray E21C, E26C & E33C

    5.1.10 E-Series (External) Combination Boiler Base Tray E21C, E26C & E33C Page 44...

  • Page 46: Condensate Disposal

    5.3 Condensate Disposal The Warmflow high efficiency condensing boiler is supplied with a factory fitted, self-sealing condensate trap. The trap has been fitted inside the boiler casing to the right hand side. The condensate drainage pipe within the boiler is a flexible plastic hose which can be trimmed to length.

  • Page 47: Technical Data

    5.4 Technical Data 5.4.1 B-Series (Boilerhouse) MODEL Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 18.4 24.4 30.0 Nominal 15.3 22.0 22.0 28.0 28.0 34.0 Heat Input Btu/hr 52,150 62,600...

  • Page 48: I-Series (Internal) Heat Only

    5.4.2 I-Series (Internal) Heat Only MODEL Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 38.5 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Nominal 15.3 18.4 22.0 22.0 24.4 28.0 28.0 30.0 34.0 46.8...

  • Page 49: I-Series (Internal) Pumped, Pumped Professional

    5.4.3 I-Series (Internal) Pumped, Pumped Professional MODEL I21P / I21P PRO I26P / I26P PRO I33P / I33P PRO I44P Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 38.5 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600...

  • Page 50: I-Series (Internal) System & System Professional

    5.4.4 I-Series (Internal) System & System Professional MODEL I21S / I21S PRO I26S / I26S PRO I33S / I26S PRO Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 Nominal...

  • Page 51: I-Series (Internal) Combination & Combination Professional Boilers

    5.4.5 I-Series (Internal) Combination & Combination Professional Boilers MODEL I21C / I21C PRO I26C / I26C PRO I33C / I33C PRO Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600...

  • Page 52: E-Series (External) Heat Only

    5.4.6 E-Series (External) Heat Only MODEL Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 38.5 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 112,629 131,362 150,128 Nominal 15.3 18.4 22.0 22.0 24.4 28.0 28.0 30.0 34.0 46.8...

  • Page 53: E-Series (External) Pumped, Pumped Professional

    5.4.7 E-Series (External) Pumped, Pumped Professional MODEL E21P / E21P PRO E26P / E26P PRO E33P / E33P PRO E44P Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 38.5 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600...

  • Page 54: E-Series (External) System & System Professional

    5.4.8 E-Series (External) System & System Professional MODEL E21S / E21S PRO E26S / E26S PRO E33S / E33S PRO Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600 Nominal...

  • Page 55: E-Series (External) Combination & Combination Professional Boilers

    5.4.9 E-Series (External) Combination & Combination Professional Boilers MODEL E21C / E21C PRO E26C / E26C PRO E33C / E33C PRO Nominal 14.7 17.6 21.0 21.0 23.5 27.1 27.1 29.0 32.7 Heat Output Btu/hr 50,000 60,000 71,650 71,560 80,000 92,380 92,380 99,050 111,600...

  • Page 58: Electricity Supply & Wiring Details

    6 ELECTRICITY SUPPLY & WIRING DETAILS Note: All wiring activities described in the following sections should only be undertaken trained persons having appropriate level competency/qualification. 220 – 240V. 1PH, 50Hz 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.

  • Page 59: Internal / External Combination Boiler Wiring Details

    6.3 Internal / External Combination Boiler Wiring Details 6.3.1 Installer Terminals Terminal Description PERMANENT IN L AC Live Supply to the appliance EARTH Protective Earth Supply to the appliance NEUTRAL N AC Neutral Supply to the appliance CONTROLS OUT L Fused output to AC Voltage Room Thermostat CH SWITCHED IN L Switched Live from AC Voltage Room Thermostat...

  • Page 60: Wiring Diagram & Fuses

    6.3.2 Wiring Diagram & Fuses The appliance must have a permanent live supply connected to operate. Page 59...

  • Page 61: External 230V Two Channel Programmer, Room Thermostat & Optional Outdoor Sensor

    6.3.3 External 230V Two Channel Programmer, Room Thermostat & Optional Outdoor sensor Page 60...

  • Page 62: Internal Two Channel Programmer And Room Thermostat, Optional Outdoor Sensor

    6.3.4 Internal Two Channel Programmer and Room Thermostat, Optional Outdoor Sensor Page 61...

  • Page 63: Building Frost Protection

    6.4 Building Frost Protection 6.4.1 Combination Boiler Models 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 - call for appropriate zone valves to open - allow the boiler to operate irrespective of time clock condition If the Internal Programmer is used, CH must be enabled, and Manual Override set to continuous, and the room thermostat set to a low setting.

  • Page 64: All Other Boiler Models

    6.4.2 All Other Boiler models For all other boiler models building frost protection measures should be based upon a thermostat fitted in the coldest room in the house and a pipe thermostat fitted on the return pipe close to the boiler. These thermostats should call for heat and open appropriate zone valves, irrespective of time clock operation.

  • Page 65: Using The Built In Programmer (Combination Boiler Models)

    6.6 Using the built in programmer (Combination Boiler models) The built in programmer can be used if this feature was enabled by the installer, consult with your installer for further information. It has the following features: Feature Day Programming 7 days 7 days Time Slots 4 per day...

  • Page 66: Programming Ch Time Slots

    6.6.1 Programming CH Time Slots 1. From the Home Screen, press the Time Programming button (4) for 3 seconds. 2. The LCD will display ‘tinE’ representing Time. Note: This menu can only be accessed if the internal time programmer is enabled for CH. See sections 11.7.1 and 11.7.2 for enabling the programmer.
  • Page 67 12. Repeat the steps as required to modify the Time Slot ON and OFF time settings. The settings are saved and the LCD returns to the Home Screen when no button presses are detected for a short period of time. 13.

  • Page 68: Programming Dhw Time Slots

    6.6.2 Programming DHW Time Slots 1. From the Home Screen, press the Time Programming button (4) for 3 seconds. 2. The LCD will display ‘tinE’ representing Time. Note: This menu can only be accessed if the internal time programmer is enabled for DHW. See sections 11.7.1 and 11.7.2 for enabling the programmer.

  • Page 69: Day Copy

    11. Confirm the setting and move to the next time to be modified by pressing the Time Programming button (4). 12. When finished programming the off time, confirm the setting by pressing the Time Programming button (4) which will return the LCD to step 7 allowing another time slot to be selected.

  • Page 70: Manual Overrides

    6.6.4 Manual Overrides It is possible to manually override the Time Slots if required. When a manual override is active, the hand symbol icon is displayed on the LCD when either CH manual overrides, DHW overrides or both are enabled. 6.6.5 Boost Mode Boost is a temporary override of either CH or DHW request for 1,2 or 3 hours, independent of Time Programming slots.

  • Page 71: Advance Mode

    6.6.6 Advance Mode Advance is a temporary override, setting the DHW or CH function OFF if it was ON, and ON if it was OFF until the next Time Slot. To Advance CH, press the CH+ button (7) for 3 seconds and then rapidly press the CH+ button (7) to select ‘Adv’.

  • Page 72: Cancelling Manual Overrides

    6.6.8 Cancelling Manual Overrides To cancel an active manual override and return to Time Slot automatic mode: To activate Auto CH, press CH+ button (7) for 3 seconds, then rapidly press to select ‘Auto’ To activate Auto DHW, press DHW+ button (1) for 3 seconds, then rapidly press to select ‘Auto’ The Function starts when no buttons are pressed for 5 seconds.

  • Page 73: Honeywell 'Y' Plan - Independent Ch & Dhw (Fully Pumped Only)

    6.6.9 Honeywell ‘Y’ Plan – Independent CH & DHW (Fully Pumped Only) 2 CHANNEL TIMECLOCK Page 72...

  • Page 74: Honeywell 'S' Plan - Independent Ch & Dhw (Fully Pumped Only)

    6.6.10 Honeywell ‘S’ Plan – Independent CH & DHW (Fully Pumped Only) 2 CHANNEL TIMECLOCK Page 73...

  • Page 75: Oil Supply

    7 OIL SUPPLY 7.1 General The oil supply system to the boiler may be of single pipe, two pipe or a suction oil supply configuration with deaerator as appropriate to the installation situation. Refer to BS5410: Part 1 and OFTEC Technical Book 3: Domestic & Commercial Requirements for Oil Storage and Supply Equipment for guidance and representative examples oil supply system types.

  • Page 76: Instructions For The Use Of Bio Fuel

    The pump vacuum should not exceed a maximum of 0.4 bar. Above this value, gas is released from the oil thus leading to burner lockout. The Warmflow Professional range of Agentis boiler appliances is supplied with an oil supply kit which provides a number of the principal components and fittings for oil supply installation.
  • Page 77 5. Warmflow recommends a good quality bio compatible oil filter at the tank and a secondary filter are used to protect the burner pump and nozzle from contamination.

  • Page 78: Fuel Additives

    7.3 Fuel Additives The use of fuel additives is not permitted without prior approval from Warmflow, use of additives may render the appliance Warranty void. Page 77...

  • Page 79: Flues

    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 Warmflow HFL or VFL flexible flue liner suitable for use with oil fired condensing boilers and of an appropriate diameter must be used.

  • Page 80: Condensing Boiler Flue Kits

    8.1.2 Condensing Boiler Flue Kits FIRE SAFETY As with a metal flue system, where a plastic flue system is used within a building which is ‘compartmentalised’ as defined by the Building Regulations, care must be taken to ensure that the installation of the flue does not contravene the Regulations and create a safety risk.
  • Page 81 CONNECT FLUE THERMOSTAT – NON COMBINATION BOILER MODELS 2. Remove the red burner cover. Isolate the electrical supply then open the burner control box cover. Disconnect the live (brown) wire of the burner power cable and connect it to the Faston link terminal of the flue thermostat cable. 3.
  • Page 82 Low Level Balanced Flue Kit (FBF) The kit comprises: FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue kit. Refer to section 8.1.3. FIT STARTER PIECE Remove the appropriate casing panel cut-out using snips, deburr edges. Ensure the gasket is placed correctly, then fit the boiler adapter, and secure with 4x M6 nuts (A).
  • Page 83 MEASURE AND CUT FLUE TERMINAL 4. Cut a hole through the wall and fit a non-combustible sleeve. 5. Ensure the locking band is open by sliding the clamp to the O (Open) position, lubricate then fit the flue terminal (C) and measure the excess length, X. 6.
  • Page 84 ONLY IF EXTENDING HORIZONTALLY i. Cut 30 mm from the outer pipe of the 1st extension only. ii. Cut 30 mm from the inner pipe of the flue terminal. Page 83...

  • Page 85: High Level Balanced Flue Kit (Hbf)

    8.1.4 High Level Balanced Flue Kit (HBF) The kit comprises: FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue kit. FIT STARTER PIECE 2. Remove the appropriate casing panel cut- out using snips, deburr edges. Ensure the gasket is placed correctly, then fit the boiler adapter, and secure with 4x M6 nuts (A).
  • Page 86 4. Ensure the locking band is open by sliding the clamp to the O (Open) position. Lubricate and fit the first extension (C) and bend (D) as required by the installation. Close the locking bands, then slide the clamps to the C (Closed) position, ensuring the flue is secure 5.

  • Page 87: Vertical Balanced Flue Kit (Vbf)

    8.1.5 Vertical Balanced Flue Kit (VBF) The kit comprises: FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue kit. FIT STARTER PIECE 2. Remove the top panel casing cut-out using snips. Fit the boiler adapter (A). 3. Lubricate the seals, then insert the starter assembly (B).
  • Page 88 CONNECT 1 EXTENSION AND AIR HOSE 4. Ensure the locking band is open by sliding the clamp to the O (Open) position. Lubricate and fit the first extension or terminal depending on installation requirements. Close the locking band, then slide the clamp to the C (Closed) position, ensuring the flue is secure.

  • Page 89: Warmflow Boiler Flue Components: 80/125 Ø

    8.1.6 Warmflow Boiler Flue Components: 80/125 Ø Note: 1. Flue fitting kit required. 2. If the terminal is less than 2 metres above ground level, a terminal guard must be fitted. 3. Extension pipes and flue adapter lengths quoted are effective lengths and not the actual length of the piece.

  • Page 90: Flue Length Calculation

    8.1.7 Flue Length Calculation Note: 1. All flues can utilise any combination of bends, straights, adapters and terminals. 2. Ensure flue is arranged such that it falls continuously towards the boiler. 3. The Low Level, High Level and Vertical Balanced Flue Systems can use any combination of flue extension pieces up to the maximum equivalent length depending upon boiler output as illustrated in the above table.

  • Page 91: Plume Management Kits

    8.1.8 Plume Management Kits Plume Management Kits are available for our range of appliances. 8.1.9 Utility/Internal Plume Management Kit (UPMK) REMOVE TERMINAL END Page 90...
  • Page 92 REMOVE TERMINAL END 1. Hold the Terminal Assembly (A) in place and extract the Terminal End (B) by gripping and pulling firmly. CUT OFF EXCESS MATERIAL 2. Using a suitable saw, cut off the highlighted portion of the end of the Terminal Assembly (A) then de-burr the cut edge.
  • Page 93 Kabin Pak/External Plume Management Kit (KPMK) The kit comprises: Page 92...
  • Page 94 1. FIT DIVERTER ASSEMBLY SEALS Apply suitable lubricant to the two Diverter Assembly Seals (supplied loose) then fit to the end of the boiler flue pipe noting the correct orientation. The seals MUST be fitted as shown with the outer surface sloping away from the end of the pipe to allow the Diverter Assembly to push over the seals.

  • Page 95: Flexible Flue Liner Kit (Hfl & Vfl)

    8.1.10 Flexible Flue Liner Kit (HFL & VFL) These boiler connection kits (F16 or F18) contain: Installation instructions FIT FLUE THERMOSTAT 1. Fit the flue thermostat BEFORE fitting the flue. FIT STARTER PIECE 2. Remove the top casing panel cut-out using snips. Fit the boiler adapter (A). 3.
  • Page 96 CONNECT 1 EXTENSION AND AIR HOSE 4. Ensure the locking band is open by sliding the clamp to the O (Open) position. Lubricate and fit the first extension or terminal depending on installation requirements. Close the locking band, then slide the clamp to the C (Closed) position, ensuring the flue is secure.

  • Page 97: Flue Terminal Locations

    8.2 Flue Terminal Locations MINIMUM DISTANCES TO TERMINALS IN MILLIMETRES AS MEASURED FROM THE TOP OF THE CHIMNEY OR THE RIM OF A LOW LEVEL DISCHARGE OPENING Directly below an opening, air brick, opening window etc. Horizontally to an opening, air brick, opening window etc. Below a gutter, eaves or balcony with protection.

  • Page 98: Air Supply For Combustion & Ventilation

    9 AIR SUPPLY FOR COMBUSTION & VENTILATION (see BS5410) 9.1 Open Flue Boilers When the boiler is sited in a cellar where the only access for combustion and ventilation air is at high level then the combustion air should be ducted to low level.

  • Page 99: Balanced Flue Boilers - Boilers In A Compartment

    OPEN FLUE OPEN FLUE VENTILATED FROM OUTSIDE VENTILATED FROM ROOM 9.2 Balanced Flue Boilers – Boilers in a Compartment VENTILATED FROM OUTSIDE VENTILATED FROM ROOM Air Supply for Ventilation No Combustion Air Inlet Required to Room Page 98...

  • Page 100: Installation Requirements

    10 INSTALLATION REQUIREMENTS The boiler installation must be in compliance with relevant standards and Building Regulations. See Section 4.2 of this manual. 10.1 General Requirements 10.1.1 Hearth The boiler has a hearth temperature of between 50°C and 85°C and should be stood on a rigid, non-porous, non-combustible base, which is not softened by warmth, to comply with the Building Regulations.

  • Page 101: Frost Protection

    10.1.6 Frost Protection Where there is a risk to the boiler or installation from frost then a suitable frost thermostat should be fitted. Alternatively the system could be dosed with an antifreeze agent. Combination Boiler models are fitted with frost protection as standard to protect the fabric of the boiler only. For all other External models covered by this manual, a Frost Thermostat Kit (Code FSK2) is available as an optional extra.

  • Page 102: Combination Boiler Filling

    Frequent or routine refilling and topping up of the system should not be necessary on an ongoing basis and may prove harmful to the appliance. Should topping up prove necessary on a frequent or routine basis you must contact Warmflow or your installer. Page 101...

  • Page 103: Pressure Relief Valve

    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. 10.3.3 Boreholes...

  • Page 104: Flow Restrictor

    Due to the relatively high ambient temperature within the Combination Boiler casing, a balanced flue should be fitted in order to draw in cooler outside air. For external models, an air inlet adapter, AID, is available from Warmflow. 10.3.7 Plinth / Base The boiler should be installed on a plinth or base with a thermal break such as non-combustible solid insulation.

  • Page 105: Burners, Commissioning And Servicing

    11 BURNERS, COMMISSIONING AND SERVICING 11.1 RDB BX Burner Oil Pump Air Inlet Air Damper Adjustment Screw Motor Reset Button with Lockout Lamp Motor Ignition Capacitor Flame Sensor Fuel Suction Line Control Box Return Line Pump Pressure Adjustment Screw Combustion Head Adjustment Handle Extension for Gauge Connection Coil Combustion Head...

  • Page 106: Electrode Setting

    11.3 Electrode Setting When removing or replacing the nozzle, move the electrodes forward to avoid the risk of damage. The electrodes are slackened by unscrewing the brass post that passes from the electrode holder out of the side of the burner. When work is complete, ensure the electrodes are reset as shown and secured by tightening the brass post.

  • Page 107: Burner Start-Up Cycle

    11.4 Burner Start-Up Cycle Lock out is indicated by a lamp on the control box. Page 106...

  • Page 108: Air Damper Adjustment

    11.5 Air Damper Adjustment The air damper is set in factory. This regulation is purely indicative. Each installation however, has its own working conditions: actual nozzle output; positive or negative pressure in the combustion chamber, the need of excess air, etc. All these conditions may require a different air damper setting.

  • Page 109: Ambient Air Correction

    11.5.1 Ambient Air Correction The combustion air is drawn from outside, therefore ambient temperature changes can influence the percentage of flue gas CO It is recommended to adjust the CO according to the graph below: For example, with an external air temperature of 20°C, adjust the CO to 12.5% (±...

  • Page 110: Combustion Head Adjustment

    11.6 Combustion Head Adjustment If the heat output of the burner is to be changed from the factory default setting, then the combustion head must be repositioned in order to maintain low NOx levels. 11.6.1 RDB 2.2 BX Adjustment Adjustments on the basis of the required output can be made by rotating the adjustment knob (1 complete revolution = 1 millimetre adjustment).

  • Page 111: Rdb 3.2 Bx Adjustment

    11.6.2 RDB 3.2 BX Adjustment The RDB 3.2 BX has a slightly different adjustment mechanism than the RDB 2.2 BX. Adjustments on the basis of the required output can be made by rotating the adjustment screw. Distance between the indentations = 3mm. Each complete rotation of the screw = 1mm. The setting for the mid-range output is shown in the table below.

  • Page 112: Commissioning

    Warmflow or OFTEC trained and registered technician and the commissioning certificate of the OFTEC Boiler Passport completed and returned to Warmflow within 30 days from the date of installation and 90 days from the date code stamped on the appliance.

  • Page 113: Programming Engineer Parameters - Combination Boilers

    11.7.1 Programming Engineer Parameters – Combination Boilers NOTE: ENGINEER PARAMETERS MUST ONLY BE ADJUSTED BY AN OFTEC TRAINED AND COMPETENT PERSON Combination Boilers are fitted with parameters that may need to be adjusted upon commissioning, depending the specific installation. The Engineer Parameters Menu is used to allow selected parameters to be modified by the engineer, these items are password protected.

  • Page 114: Engineer Parameter List

    11.7.2 Engineer Parameter List Parameter number Description Units Range Default Value P 00 CH Anti-Cycle time mins 0-10 P 01 CH Pump Overrun time secs 0-240 P 02 DHW Pump Overrun time secs 0-240 P 03 DHW min flowrate l/min/10 15-40 P 04 CH Pump Speed...

  • Page 115: Servicing

    11.8 Servicing 11.8.1 General Requirements The appliance must be serviced annually by a Warmflow or OFTEC registered service technician in accordance with the recommendations laid out in OFTEC’s Technical Book 2: ‘Domestic & Light Commercial Servicing and Commissioning – Requirements for Oil Fired Systems –...

  • Page 116: Test Mode

    11.8.2 Test Mode Test mode allows a forced CH demand, this allows for flue gas analysis tests to be performed following a service operation, even if a switched live demand is not present. Note. The appliance must have CH mode enabled, as indicated by the CH icon shown on the LCD.

  • Page 117: Burner Fault Finding

    12 BURNER FAULT FINDING WARNING: The burner fault finding chart is to only be used by competent and suitably qualified engineers. It may be necessary to check live terminals inside the control panel. Extreme care should be taken when doing so. 12.1 Riello RDB BX Page 116...

  • Page 118: Combination Boiler Fault Finding

    13 COMBINATION BOILER FAULT FINDING WARNING: The Combination Boiler fault finding tables (Central Heating and Hot Water) are to only be used by competent and suitably qualified engineers. It may be necessary to check live terminals inside the control panel. Extreme care should be taken when doing 13.1 Error codes displayed on the LCD.

  • Page 119: Error Codes Stored In The Error Logger

    *Error Codes E11, E15 are not displayed on the LCD, and are only stored in the Error History for diagnosis. 13.2 Error codes stored in the Error Logger Review the appliance history by accessing the Error Logger from the Home Screen on the control panel.

  • Page 120: Central Heating Fault Finding Table

    13.3 Central Heating Fault Finding Table Check Item to check Answer Corrective Action (s) Is AC Power Supply healthy to the Rectify AC Power supply problem appliance and LCD operational? Go to Check 2 Are Error Codes displayed on LCD? Rectify Error Code problems, see Section 13.1 Go to Check 3 Is the CH Radiator symbol displayed...

  • Page 121: Domestic Hot Water Fault Finding Table

    13.4 Domestic Hot Water Fault Finding Table Check Item to check Answer Corrective Action (s) Is AC Power Supply healthy to the Rectify AC Power supply problem appliance and LCD operational? Go to Check 2 Are Error Codes displayed on LCD? Rectify Error Code problems, see Section 13.1 Go to Check 3 Is the DHW Tap symbol displayed solid...

  • Page 122: Spares

    14 SPARES 14.1 RDB 2.2 BX Spares Page 121...

  • Page 124: Rdb 3.2 Bx Spares

    14.2 RDB 3.2 BX Spares Page 123...

  • Page 126: Baffles - From September 2016 Manufacture

    14.3 Baffles – from September 2016 Manufacture For appliances with a date manufacture date during or after September 2016, the baffles have a V Notch in the burner facing edge for identification. Do not attempt to fit baffles without this identification marker to appliances manufactured after this date.

  • Page 127: Short Parts List

    14.4 Short Parts List 21-33 Models Part Description Code Flow Sensor 5317 Pressure Sensor 6210 22mm NTC Sensor 5656 15mm NTC Sensor 5655 6mm Probe NTC Sensor with cable 5320 Combination Boiler High Limit Thermostat 5223 Combination Boiler Tank Limit Thermostat 5318 Plate Heat Exchanger 5789...

  • Page 128: Your Guarantees, Terms & Conditions

    Faults and any associated costs occurring due to lack of fuel, power, water supply, scale formation or corrosion are not covered by these guarantees. If the boiler has not been installed within 3 months of the date of despatch from Warmflow, then the warranty will deem to have started.
  • Page 129 Claims for consequential loss or damage are not covered by these guarantees. In the event of a breakdown please contact your commissioning engineer who should then contact our service department whilst at your home, to report the fault. The statutory rights of the customer are not affected by the guarantee. NB: The nozzle, fuel lines and refractory items supplied with the boiler are deemed to be consumable items and are therefore excluded from the guarantee.

  • Page 130: End Of Life Information

    16 END OF LIFE INFORMATION Warmflow High Efficiency Condensing Boilers must be disposed of according to local regulations by using a public or private waste collection service. 16.1 Safety Risks Prior to disassembly, the appliance should be electrically isolated and disconnected.

  • Page 131: Casing And Key Components

    16.3 Casing and key components Item Description Main Materials Special Notes Boiler Assembly Various See Table Below Top Casing Galvanised Steel Rear Casing Galvanised Steel Side Casing Galvanised Steel Insulation Foil Backed Glass Fibre Wear Appropriate PPE Front Casing Galvanised Steel Page 130...

  • Page 132: Boiler Assembly

    16.4 Boiler Assembly Item Description Main Materials Special Notes Heat Exchanger Mild Steel Welded Construction Condensing Unit Stainless Steel & Viton Seal Auto Air Vent Brass Service Door Stainless Steel & Natural Rubber Thermostat Plastic, Copper, Electronic Components Heat Exchanger Baffles Mild Steel Service Door Mild Steel, Ceramic Fibre...

  • Page 133: Combination Boiler

    16.5 Combination Boiler Item Description Main Materials Special Notes Heat Exchanger Mild Steel Heat Store Mild Steel Condensing Unit Stainless Steel & Viton Seal Service Door Stainless Steel & Natural Rubber Pipework Assembly Copper, Brass, Stainless Steel Circulating Pump & Valve Various Consult Manufacturer Condensate Trap...
  • Page 134 Intentionally left blank - Page 133...
  • Page 136 This manual is accurate at the date of printing (E&OE) but will be superseded CODE 6572 and should be disregarded if specifications and/or appearances are changed ISSUE C in the interests of continued product improvement. NOV 2019...

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