WarmFlow 50/70 Installation & Servicing Manual
Wall mounted boiler (internal & external)
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- Page 1 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 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 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.
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Page 3: Table Of Contents
Components – Wall Mounted Boiler (External) ....................6 Introduction General Requirements ............................ 7 Dimensions 50/70 Wall Mounted Boiler (Internal) ....................... 8 50/70 Wall Mounted Boiler (External) ......................8 Easy Fit Low Level Conventional Flue (LLF-R) ....................9 Installation Requirements 4.1.1 Service Access for WM Boiler (Internal) ...................... -
Page 4: User Instructions
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. -
Page 5: User Instructions - Wall Mounted (Internal)
User Instructions – Wall Mounted (Internal) BURNER LOCK-OUT RESET LIMIT STAT RESET GREEN AMBER CONTROL THERMOSTAT (54°C – 84°C) BURNER HIGH LIMIT LOCK-OUT STAT RESET RESET (FROM (FROM UNDERNEATH) UNDERNEATH) Page 5... -
Page 6: User Instructions - Wall Mounted (External)
User Instructions – Wall Mounted (External) BURNER LOCKOUT RESET (FROM UNDERNEATH) HIGH LIMIT RESET GREEN AMBER CONTROL THERMOSTAT (54°C – 84°C) BURNER LOCKOUT RESET (FROM UNDERNEATH) Page 6... -
Page 7: Components - Wall Mounted Boiler (Internal)
Components 1.7.1 Components – Wall Mounted Boiler (Internal) Front Casing ” BSP Return Connection Combustion Chamber Door Mounting Plate Door Gasket Heat Exchanger Door Insulation Side Casing Top Baffle Support Bottom Casing Top Baffle Oil Pump Access Plate Top Casing & Insulation Burner ”... -
Page 8: Components - Wall Mounted Boiler (External)
1.7.2 Components – Wall Mounted Boiler (External) Flue Terminal Guard Top Insulation Main Casing Assembly Top Casing Combustion Chamber Door Mounting Plate Door Gasket Mounting Plate Insulation Door Insulation Heat Exchanger Insulation Heat Shield Burner Top Baffle Support Bottom Baffles Top Baffle Controls Inspection Flap Flue Elbow... -
Page 9: Introduction
(although not applicable to the Republic of Ireland). The Warmflow wall mounted oil fired boilers are designed to burn 28 second redwood No 1 (Kerosene Class C2) fuel. The boiler shells are fabricated from the best quality mild steel plate electrically welded and pressure tested to 4.5 bar (65 PSIG) making them suitable for either open... -
Page 10: Dimensions
Dimensions 50/70 Wall Mounted Boiler (Internal) FRONT VIEW SIDE VIEW REAR VIEW MODEL 50-70 WM 50/70 Wall Mounted Boiler (External) MODEL 50-70 WME 1023 Page 10... -
Page 11: Easy Fit Low Level Conventional Flue (Llf-R)
‘Easy Fit’ Low Level Conventional Flue (LLF-R) Ø125 Note: One 300mm extension piece may be used to extend the horizontal length to 1100mm max and 790mm min. 155 MIN 225 MAX 792 MAX 540 MIN Installation The boiler installation must be in compliance with BS 5410 and the Building Regulations. Failure to install and commission in accordance with the instructions contained within this booklet will invalidate the warranty. -
Page 12: Sealed Systems
In areas of hard water a suitable water softener would also be recommended. Sealed Systems All Warmflow boilers are suitable for use on a sealed heating system. It is recommended that a CE approved pressure relief valve (PRV) set at 3 bar is fitted to the system. -
Page 13: Boiler Installation
Boiler Installation Heat Exchanger Installation Make sure the wall chosen for the installation is flat level and able to support the filled weight of the appliance (128kg) and that the anchor bolts are appropriate for the wall. Place the installation template on the wall making sure it is correctly positioned using a level. -
Page 14: Internal Boiler Casing Installation
Internal Boiler Casing Installation STAGE 1 STAGE 2 Once the heat exchanger has been Attach the control panel to the mounted on wall correctly a flue can be inside of the right hand side fitted. Insert 4 no M5 x 10 pozi head casing and fix in place using 3 screws into the appropriate hank nuts no M5 x 10 pozi head screws. -
Page 15: External Boiler Casing Installation
Wall Mounted Boiler (External) Casing Installation CASING CUT-OUTS STAGE 1 STAGE 2 Fit the wall-plate, boiler and flue as per internal wall Fit the assembled casing onto the wall-plate using self mounted boiler instructions. The wall-plate for the tapping screws, ensuring the folds on the side panels external boiler can be used as a template. -
Page 16: Baffles
Baffles – Wall Mounted Boiler Electricity Supply 220 – 240V. 1PH, 50 Hz The boiler should be wired via a fused double pole isolating switch which should be fitted with a 5 amp fuse. Additionally the external wall mounted boiler should be protected by a CE approved RCD. -
Page 17: Control Panel Wiring (Wall Mounted Boilers - Internal)
6.2.1 Control Panel Wiring (Wall Mounted Boilers – Internal) Page 17... -
Page 18: Control Panel Wiring (Wall Mounted Boilers - External)
6.2.2 Control Panel Wiring (Wall Mounted Boilers – External) Note: For normal operation the servicing switch should be in the off position otherwise the boiler will run continuously independently of the time clock. Page 18... -
Page 19: Technical Data
Technical Data MODEL 50/70 WM & WM-E Output Range 14.6 – 20.5 RANGE SETTING Nominal Heat 23.3 20.0 Input 79,600 68,200 Nominal Heat 20.5 17.6 Output 70,000 60,000 Burner RDB1 Head T2 Short Flue Size 100 or 127 4 or 5 °C... -
Page 20: Air Supply
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 Balanced Flue/Room Sealed Boilers... -
Page 21: 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 22 Terminal Position Min Distance Below gutters, soil pipes or drain pipes 1,000 From a door, window or air vent Above ground, flat roof or balcony level Below eaves or balconies 1,000 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 1,500...
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Page 23: Low Level Conventional Flue Installation
Installation of a Low Level Conventional Flue (LLF-R) FLUE EXTENSION (if required) FLUE TERMINAL FLUE ELBOW Make a suitable sized hole in the wall for the flue kit. Using the paper template provided. The cavities must be sealed from the hole. Remove the top panel (kitchen and utility models) and the combustion chamber lid. -
Page 24: Installation Of Air Intake Duct
Installation of Air Intake Duct (Internal Boiler Only) The wall mounted boiler when fitted with a conventional flue or low level conventional flue can be made room sealed by fitting an air intake duct (rear outlet only). Plastic Vent Pipe Jubilee Clip Flexible Duct Jubilee Clip... -
Page 25: Wall Mounted Boiler (External) Flue Adaptor Installation
Wall Mounted Boiler (External) Flue Adaptors 9.5.1 Fitting Vertical Flue Adaptor (Option A) SIDE VIEW 460mm Vertical Flue Terminal Flue Adaptor (VFA – WMA) Remove the flue terminal (4 screws) and fit the vertical flue adaptor as shown (4 screws). 9.5.2 Fitting Vertical Flue Adaptor (Option B) FLUE ELBOW... -
Page 26: Oil Supply
10.0 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, kerosine should never be stored in translucent plastic containers. -
Page 27: Two Pipe System
10.2 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 10.3 De-aerator System DE-AERATOR MAY BE ABOVE OR BELOW BURNER AND MUST BE FIRE VALVE SENSOR POSITIONED OUTSIDE APPROVED FILTER MAY BE... -
Page 28: One Pipe Lift System
10.4 One Pipe Lift System APPROVED 20mm PER SITE GAUGE METRE SLOPE 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. WATER SEPARATOR Total Maximum Pipe Length (m) Lift H ID 8mm... -
Page 29: Rdb Burner
11.0 RDB Burner 11.1 Components 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. 1. Pump 5. Air damper adjustment screw 2. Control box 6. -
Page 30: Air Damper Adjustment
11.3 Air Damper Adjustment The setting 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. 11.4 Electrode Setting Attention... -
Page 31: Servicing & Commissioning
12.0 Servicing & Commissioning 12.1 Commissioning Note: IT IS RECOMMENDED THAT AN OFTEC TRAINED AND REGISTERED TECHNICIAN 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 32: Fault Finding
13.0 Fault Finding Is there a supply voltage to terminal 12 in the control panel or to the control thermostat. Expect 240V±10%. Page 32... -
Page 33: Spares
14.0 Spares 14.1 RDB 1 WM Burner Spares NO CODE 3513007 DESCRIPTION NO CODE 3513007 DESCRIPTION 3005787 • Gasket 16 3008654 • Pump 3006384 • Flange 17 3007162 • ‘O’ Ring 3001079 • Cup-shaped Head 18 3008653 • Filter ‘O’ Ring 3008860 •... -
Page 34: Short Parts List (Boiler)
14.2 Short Parts List (Boiler) Code Boiler Control Thermostat 2131 Boiler Limit Thermostat Drain Cock Top Baffle 2428 Top Baffle Holder 2448 Baffle 2361 Boiler Cleaning Brush 2470 Door Gasket 2457 Door Insulation 2456 Door Insulation Shield 2440 Vertical Flue Adaptor A VFA –... - Page 35 Page 35...
- Page 36 TEL: (0161) 205 4202 SCOTLAND & WALES FAX: (0161) 205 4818 FOR TECHNICAL ASSISTANCE CONTACT WARMFLOW ON TEL: (028) 9262 1515 EMAIL: technical@warmflow.co.uk This manual is accurate at the date of printing (E&OE) but will be superseded and should be disregarded Code 2614 if specifications and/or appearances are changed in the interests of continued product improvement.