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Summary of Contents for WarmFlow COMBI 70
- Page 1 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 NATIONAL ACCREDITATION OF CERTIFICATION BODIES CERT. No. FM 29884...
- Page 2 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.
- Page 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). That the flow from any one hot water outlet does not exceed the maximum recommended.
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Page 4: Table Of Contents
Contents Page User Instructions ......................... 3 Introduction ......................... 4 General Requirements ....................4 Components........................ 5 Technical Details ........................7 Sequence of Operation Flow Chart................7 Baffles ......................... 8 General Requirements ....................8 Dimensions ......................... 9 Combi Flue Options ....................10 Technical Data ...................... -
Page 5: User Instructions
1.0 User Instructions 1.0.1 Boiler Control Thermostat The boiler control thermostat is located on the front of the boiler facia panel and may be adjusted from 52°C to 85°C. The recommended minimum thermostat setting is 65°C. Below this ‘cold water corrosion’ is likely to occur thus reducing the life of the heat exchanger and is not covered by the manufacturer’s warranty. -
Page 6: Introduction
The Warmflow oil fired combis are designed to burn Class C2 (28 sec redwood) kerosine or Class D (35 sec redwood) gas oil. However to comply with building regulations only kerosine may be burned when using the low level balanced flue or low level conventional flue. -
Page 7: Components
Components 1.3.1 Combi Assembly Automatic Air Vents Filling Loop Boiler Heat Exchanger Tank Control and Limit Stat Boiler Control and Limit Stat Flow Switch 12 Litre Esxpansion vessel Mixer Valve Boiler Data Plate Plate Heat Exchanger RDB Burner CH Pump Head Boiler Drain Valve DHW Pump Head Pressure Relief Valve... - Page 8 1.3.3 Kabin Combi Assembly Flue Terminal Guard Door Panel 17. Air Intake Grill Low Level Flue 10. Burner Reset 18. Pipe Access Hole Service Access Hatch 11. Burner Reset Button 19. Plate Heat Exchanger Control Panel Cover 12. Burner 20. Mixing Valve Controls 13.
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Page 9: Technical Details
Technical Details Sequence of Operation Flow Chart Power Timer Calling For Heat Selected Flow Switch Closed Pump Only Runs Tank Stat Satisfied Burner Limit Stat Selected Stops Tripped Room Boiler Press Stat Limit Stat Reset Satisfied Tripped Button CH Pump Burner Only Runs Fires... -
Page 10: Baffles
General Requirements The Warmflow Combi is supplied with all the necessary components for a sealed heating system. However, on some larger systems with a total water content greater than approx 150L, an expansion vessel, in addition to the integral 12L vessel supplied, may be required. -
Page 11: Dimensions
Dimensions 2.4.1 Combi Dimensions MODEL 70/90 2.4.2 Combi Boiler Connections 1620 1310 REAR VIEW All dimensions are given in mm. Cold Mains (15mm) Pressure Relief Discharge (15mm) Heating Flow (22mm) Spare Connection (1” BSP) Domestic Hot Water (22mm) Central Heating Return (1” BSP) Page 9... -
Page 12: Combi Flue Options
2.4.3 Kabin Pak Combi Dimensions MODEL 70/90 Combi Flue Options (not applicable to the Kabin Pak Combi) Note: Low level flue options are rear or left hand outlet only. 2.5.1 ‘Easy Fit’ Telescopic Low Level Balanced Flue (BF-R) The horizontal dimension can be increased up to an additional 1200mm using a combination of long extension pieces (E600 = 600mm) and short extension pieces (E300 = 300mm). - Page 13 2.5.2 ‘Easy Fit’ High Level Balanced Flue (HLBF) The HLBF is available in 4 fixed horizontal lengths which are: SEE OPTIONS 160x160 Option 1 – 455mm Option 2 – 655mm Option 3 – 585mm Option 4 – 785mm 225 MAX 175 MIN 2.5.3 ‘Easy Fit’...
- Page 14 AVAILABLE FROM SPRING 2003 2.5.5 Easy Fit Telescopic High Level Balanced Flue (HLBF-R) EXTENSION KITS AS REQUIRED (PACKS C OR D) PACK E OR F PACK E OR F ALL MODELS 175 MIN 225 MAX DIM A FLUE PACKS A + E A + F A + C + E 1570 MIN...
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Page 15: Technical Data
Technical Data Model 70/90 Combi 70/90 Kabin Pak Combi Nominal heat 29.3 29.3 Input Btu/hr 100,000 100,000 Nominal heat 26.4 26.4 Output Btu/hr 90,000 90,000 Efficiency at max output (net) Burner RDB 1 RDB 1 Head Flue 100 or 127 Integral Size 4 or 5... -
Page 16: Electricity Supply
5 amp fuse. In order to ensure the safety of the Kabin Pak Combi Warmflow recommends that power to the appliance is supplied through a suitable CE approved RCD trip switch. -
Page 17: Combi Wiring Details
Combi Wiring Details 3.3.1 Wiring Diagram Page 15... - Page 18 3.3.2 Combi Wiring Schematic Page 16...
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Page 19: Kabin Pak Combi Wiring Details
Kabin Pak Combi Wiring Details 3.4.1 Kabin Pak Combi Wiring Diagram Page 17... - Page 20 3.4.2 Kabin Pak Combi Wiring Schematic Page 18...
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Page 21: Frost Thermostats
Frost Thermostats 3.5.1 Combi Boilers The switched live from the frost thermostat (the frost thermostat must be supplied by a permanent live) should be connected to number 5 on the boiler terminal block. In order to protect the fabric of the building as well as the boiler and pipework, the thermostat should be located in the coldest part of the house but where it can respond to any temperature rise. -
Page 22: Timers For Standard Combi
Timers for Standard Combi Note: Single channel timers or programmers are not recommended. 3.6.1 Installation of a remote two channel programmer (option 1) Remove the purple wire connecting 5 and 28 and the white wire connecting 3 and 19. Connect the programmer as shown via a fused isolator. - Page 23 3.6.3 Installation of Warmflow Optional Programmer (not applicable to the Kabin Pak Combi) Disconnect the electrical supply. Remove top casing (4 studs) and control box cover (1 screw). Remove 2 screws securing blanking plate/programmer bracket. Remove bracket and blanking plate from the control panel.
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Page 24: Timers For Kabin Pak Combis
Timers for Kabin Pak Combis Note: Single channel timers or programmers are not recommended. 3.7.1 Installation of a Remote Two Channel Programmer THE HW AND CH SELECTOR SWITCHES ON THE BOILER CONTROL PANEL SHOULD BE LEFT IN THE OFF POSITION BUT CAN BE USED AS L N E SERVICING SWITCHES TO... -
Page 25: Oil Supply
Oil Supply Oil Tank Steel tanks constructed to BS 799 Part 5 1987 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. -
Page 26: Two Pipe System
Two Pipe System APPROVED 20mm PER SITE GAUGE METRE SLOPE WATER SEPARATOR Total Maximum Pipe Length (m) Lift H I.D. 8 mm I.D. 10 mm De-aerator System FIRE VALVE SENSOR DE-AERATOR MAY BE ABOVE OR BELOW BURNER AND MUST BE POSITIONED OUTSIDE APPROVED SITE GAUGE... -
Page 27: One Pipe Lift
One Pipe Lift APPROVED 20mm PER METRE SLOPE SITE GAUGE Note: The pump vacuum should not exceed a maximum of 0.4 bar. Above this gas is released from the WATER oil thus leading to burner lock out. SEPARATOR Total Maximum Pipe Length (m) Lift H ID 8mm ID 10mm... -
Page 28: Flues
Flues Conventional Flues 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 (600 mm) above the ridge of the dwelling. - Page 29 Terminal Position Min Distance Below gutters, soil pipes or drain pipes 1000 From a door, window or air vent Above ground, flat roof or balcony level Below eaves or balconies 1000 From an internal or external corner From a terminal facing the terminal From a surface facing the terminal Vertically from a terminal on the same wall 1500...
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Page 30: Air Supply For Combustion And Ventilation
Air Supply for Combustion and Ventilation (see BS 5410) 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. Combustion Air Supply Boiler in Room Boiler in Compartment... -
Page 31: Installation Of Flues
Installation of Flues Easy Fit High TOP PANEL Level Balanced BLANKING PLATE Flue (HLBF-R) OPTIONAL FLUE DRESSING RING FLUE TERMINAL TOP PANEL OPTIONAL EXTENSION PIECES FLUE GASKET HORIZONTAL FLUE ADAPTOR TEST HOLE PLUG CONVENTIONAL FLUE RING AIR INTAKE ADAPTER Easy Fit Vertical BOILER LID SPIGOT &... - Page 32 6.3.1 Installation of a Balanced Flue (BF-R, HLBF-R & VBF) Make a suitable sized hole in the wall or ceiling for the flue kit. Add the dimensions given on pages 6 (Dimension G) and 8 (Flue Vertical Dimension). The cavities around the opening must be sealed and protected by a non-combustable sleeve.
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Page 33: Thermostat Control Knob Peg Setting
6.3.2 Installation of Telescopic Low Level Conventional Flue Installation instructions as per the balanced flue except there is only an inner seal, the burner does not require modification and there is no flexible hose to be fitted. In addition the low level flue should only protrude through the wall by a minimum of 155mm and a maximum of 225mm. -
Page 34: Installation
Installation The boiler installation must be in compliance with BS 5410 Part 1 1997 and the Building Regulations. 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. - Page 35 8.3.4 Boiler Connections All connections to the appliance should be made with compression fittings. 8.3.5 Additional Requirements for a Kabin Pak Combi Although the Kabin Pak is manufactured from galvanised sheet it is recommended that after a period of weathering (approx 4-8 weeks) that the Kabin Pak is painted with a suitable primer and finish coat to prevent corrosion.
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Page 36: Domestic Hot Water
It is recommended that a pumped hot water return is used in order to improve HW reaction times. Contact Warmflow for details. -
Page 37: Fitting A Vertical Flue Adaptor
Fitting a Vertical Flue Adaptor Remove the 2 self tappers connecting the flue main body to the Kabin Pak and lift off. It may be necessary to break the seal between the flue main body and the top of the flue pipe. -
Page 38: Burners
Burners RDB Burner 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. Pump Air damper adjustment screw Control box Air tube connection (supplied with BF kit) Reset button with lock-out lamp Pump pressure adjustment screw Flange with insulating gasket... -
Page 39: Electrical Connections
Electrical Connections 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. Electrode Setting Attention Before assembling or removing the nozzle, loosen the screw (A) and move the electrodes away from the nozzle. -
Page 40: Commissioning And Servicing
10.0 Commissioning and Servicing 10.1 Commissioning Note: IT IS RECOMMENDED THAT AN OFTEC TRAINED AND REGISTERED TECHNICIAN SHOULD BE USED. IT IS THE RESPONSIBILITY OF THE INSTALLER TO ENSURE THAT THE BOILER IS PROPERLY COMMISSIONED. SEE BS 5410. FAILURE TO DO SO MAY INVALIDATE THE WARRANTY. -
Page 41: Horstmann 626 Electronic Programmer
HORSTMANN TIMERS & CONTROLS Ltd: Note: Ensure selection switch on the rear of the NEWBRIDGE ROAD, BATH. programmer is at the correct setting ‘G’ for HW 626 OEM - WARMFLOW only or HW and CH. ‘P’ for independent HW and 220-250V 50Hz 5(2)A T.55... - Page 42 Setting the Time of Day Press the SET button so that the SET indicator is pointing to the CLOCK position on the front of the programmer. The DAY OF THE WEEK indicator will now flash. Use the PLUS(+) or MINUS(-) buttons to move the DAY OF THE WEEK Indicator to the current day of the week.
- Page 43 Adjust the flashing time as required by using the (+) AND (-) BUTTONS THEN PRESS ENTER. The display will now show ‘1 OFF’ and the first programmed OFF time for the day will flash. This can be altered in the same way as the ‘1 ON’. Follow the same procedure for the 2nd and 3rd ON/OFF times remembering to press ENTER after each change to the programme.
- Page 44 Hot water ON indicator. Central heating ON indicator. Advance button. Hot water programme select button. Central heating programme select button. Programme positions. Central heating programme indicator. Hot water programme. Programme Selection The following programmes can be selected for either HOT WATER by itself, CENTRAL HEATING by itself or HOT WATER and HEATING together.
- Page 45 ON/OFF settings for a period in excess of two years. This is more than sufficient to cover all the expected power interruptions during the life of the unit. Heating Systems Information for use with various systems is available on request from Warmflow on (028) 9262 1515. Page 43...
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Page 46: Fault Finding
12.0 Fault Finding 12.1 Central Heating Switch on power, set selectors for CH on and DHW off. Set all controls to call for heat. Check all valves are open and Does the burner Do radiators get pump is working, check pressure, fire? hot? check all air is... -
Page 47: Domestic Hot Water
12.2 Domestic Hot Water Switch on power, set selectors to CH off and DHW on. Is there continuity Check wiring, replace Is DHW pump working? across connection 20 tank thermostat. and 21 on the PCB? Is there continuity Check wiring, replace across 25 and 27? relay, replace PCB. -
Page 48: Burner
12.3 Burner START Switch on electricity supply. Set all boiler controls and external controls to call for heat. Check motor wiring fuse, boiler control and Does burner motor start? Is burner lockout lamp lit? limit thermostat. Check power supply. Press reset button. Check for pump seizure. -
Page 49: Spares
13.0 Spares 13.1 Riello RDB Burner NO CODE 3748757 DESCRIPTION NO CODE 3748757 DESCRIPTION 3005787 • Gasket 3008654 • Pump 3006384 • Flange 3007162 • ‘O’ Ring 3008769 • Cup-shaped Head 3008653 • Filter ‘O’ Ring 3007513 • Electrode Assembly 3003602 •... -
Page 50: Pipe Spares
13.2 Pipe Spares All Combis All Combis All Combis CH Pump to Boiler Plate Heat Exchanger to Boiler Boiler to Pressure Vessel Flexible Pipe 2056 Flexible Pipe 2057 Flexible Pipe 2056 Std Combis Std Combis Flow Switch to Strainer From CH Pump Pipe 1999 Pipe 1996 All Combis... -
Page 51: Short Parts List
13.3 Short Parts List Part Description Code Flow Switch 1476 Tank & Boiler Control Thermostat 2131 Boiler Limit Thermostat Tank Limit Thermostat 2126 Plate Heat Exchanger Twin Head Grundfoss Pump 2130 Grundfoss 15/60 Pump (for replacement head) 3 Pole Relay 1827 Auto Air Vent C/W Check Valve Pressure Relief Valve... - Page 52 TEL: (0161) 205 4202 SCOTLAND & WALES FAX: (0161) 205 4818 FOR TECHNICAL ASSISTANCE CONTACT WARMFLOW ON TEL: (028) 9262 1515 E-MAIL: technical@warmflow.co.uk This manual is accurate at the date of printing but will be superseded and should be disregarded if specifications and/or appearances are changed in the interests of continued product improvement.
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