Summary of Contents for Range Senator RFB006 6kW
- Page 1 March 2009 Issue No. 3 INSTALLATION AND Models: USER INSTRUCTIONS RFB006 6kW RFB009 9kW RFB011 11kW RFB012 12kW www.kingspanhws.com...
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Page 2: Table Of Contents
INTRODUCTION These instructions are applicable to the following models of electric flow boiler: Range Senator RFB 006 RFB 009 RFB 011 RFB 012 Your Electric Flow Boiler has been developed to provide many years of trouble free service when installed and maintained correctly. Every effort has been taken to ensure the highest standards of reliability and safety from your purchase, however in the event of a suspected fault never attempt to repair the boiler yourself. -
Page 3: Description
DESCRIPTION The Electric Flow Boiler is designed to heat re-circulated water in wet central heating systems. The water is heated when it is passed over electric immersion elements, which are contained within a stainless steel chamber. The temperature of the water is monitored and controlled by a modulation technique switching the immersion elements. -
Page 4: Basic Components Diagram
THE MAIN COMPONENTS OF THE ELECTRIC FLOW BOILER MAIN TERMINAL BLOCK FLOW 22mm COMPRESSION TOP SEALING GROMMET ELECTRICAL CABLE ENTRY POINTS MAIN POWER BOARD MANUAL RESET HIGH LIMIT CUT OUT SWITCHES CONTROL PANEL INSULATION FRONT COVER RETURN NOT SHOWN PRODUCT DATA &... -
Page 5: Basic Installation Dimensions
BASIC INSTALLATION DIMENSIONS 120mm 120mm Cable Entry “Knock Outs” 1 x 25mm & 2x 20mm Left, Right & Rear 900mm Fixing Centres 1050mm 8.5mm 100mm Fixing Centres Figure 2... -
Page 6: Operation And Indicators
OPERATION AND INDICATORS The SUPPLY indicator (green) will remain illuminated whenever the supply is present to the boiler. The DEMAND indicator (amber) will illuminate on demand from the programmer and thermostats. It will flash (amber) for 1 to 2 minutes during which it automatically carries out self-tests before allowing the boiler to produce heat. - Page 7 BOILER The Electric Flow Boiler is suitable for installation in either open vented or sealed system (max pressure 0.35Mpa/3.5 bar) primary circuits. The lower cost and therefore most popular option will use the boiler to provide space heating only. Hot water provision will be via an unvented direct stainless steel or open vented direct copper cylinder heated by immersion heaters.
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Page 8: Sealed Systems
SEALED SYSTEMS Where used in sealed (pressurised) system, the system kit should be mounted in the return pipework behind the pump, see fig 4 (page 9). Use standard calculations for an 82 c flow temperature when sizing the vessel. Max system pressure: 0.35Mpa/3.5 bar. Always mount the vessel in a vertical upright position. -
Page 9: Basic Plumbing Layout
BASIC PLUMBING SCHEMATIC SPACE HEATING ONLY - OPEN VENTED 150mm minimum Auto Air Vent PUMP 150mm maximum Figure 3 DRAIN VALVE BASIC PLUMBING SCHEMATIC SEALED SYSTEM 150mm minimum Auto Air Vent Safety PUMP Controls DRAIN VALVE Figure 4... - Page 10 BASIC PLUMBING SCHEMATIC SPACE HEATING AND HOT WATER - Y PLAN SYSTEM 150mm minimum Auto Air Vent Cylinder PUMP DRAIN VALVE Open vented pipework or sealed system safety controls to be installed as fig. 3 on page 4 Figure 5 BASIC PLUMBING SCHEMATIC SPACE HEATING AND HOT WATER - S PLAN SYSTEM 150mm...
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Page 11: Boiler Plumbing Schematic
3 BOILER PLUMBING SCHEMATIC AUTOMATIC AIR VENT FLOW 35mm 150mm minimum RETURN 35mm 22mm PIPE 28mm PIPE 35mm PIPE FLOW =12L/MIN FLOW =24L/MIN FLOW =36L/MIN DRAIN VALVE Figure 7... -
Page 12: Wiring Instructions
WIRING INSTRUCTIONS ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS. The boiler must be installed by a qualified competent tradesman in accordance with these instructions and drawings to ensure correct operation. Check the main incoming supply to the property to ensure there is sufficient current and voltage for the size of the boiler or boilers to be installed. Remember to also take account of the supply requirements for the rest of the property. - Page 13 WARNING: THIS APPLIANCE MUST BE EARTHED. All exposed pipework must be earthed in accordance with IEE regulations. After installation, preliminary electrical checks i.e. short circuit, earth continuity, resistance to earth and check for correct polarity etc. must be carried out. Before connecting the electrical supply, ensure the system is full of water and set to the correct pressure (pressurized systems), check for leaks.
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Page 14: Set Up And Test
SET UP AND TEST The boiler controls are fully automatic, making the operation very simple. Only after the system has been flushed through and then filled with water, inhibitor and set to the correct pressure (pressurized systems), can the electrical supply be connected. Check 1. -
Page 15: Parts Location
SERVICING IT IS ESSENTIAL THAT THE BOILER IS CHECKED ANNUALLY TO VALIDATE THE WARRANTY Checks must include the electrical connections and inhibitor concentration. Before any servicing or maintenance is carried out on the system, ensure that the electrical supply has been disconnected first. Care must also be taken as the water may be scalding hot and at a high pressure. -
Page 16: Fault Tracing Chart One
Fault Tracing Chart One Is the supply Is there 230V (Green) LED Rectify, supply, fault AC at main Illuminated? terminals? Is there 230V Is Fuse F1 OK? Replace AC at transformer (rating 2.5A 20 X5) Fuse TX1 on powerboard? Replace powerboard Is there 5V DC at Replace... -
Page 17: Fault Tracing Chart Two
Fault Tracing Chart Two Excessive current Triac(s) or relay(s) Replace 1 flash flow on switch on faulty powerboard From page 16 Temperature not Check pump Are flow & return 2 flashes stabilised before operation & valves temperatures equal preheat open Replace fault sensor(s) Temperature FBS0117 upper... -
Page 18: Fault Tracing Chart Three
Fault Tracing Chart Three From page 17 Does the heat (Green) Refer to manual Is the demand Is the boiler on bar graph illuminate & page 7 (capacitor voltage correct Y plan system? stay on 1,2,3 or 4 installed) Does the boiler Is the fault (red) LED produce heat flashing... -
Page 19: Replacing The Main Powerboard
REPLACING THE MAIN POWER BOARD NOTE. BEFORE ANY MAINTENANCE IS CARRIED OUT ON THE SYSTEM, ENSURE THAT THE ELECTRICAL SUPPLY HAS BEEN DISCONNECTED FIRST. CARE MUST BE TAKEN AS THE WATER MAY BE SCALDING HOT AND AT HIGH PRESSURE. Maintenance on the boiler can only be carried out by a qualified and competent tradesman in accordance with these instructions. Removal of the Main Power Board Switch OFF ALL electrical supply to the boiler. -
Page 20: Powerboard Connections
POWER BOARD CONNECTIONS PUMP EARTH TO EARTH BOND BOLT DEMAND SIGNAL PUMP PRE HEAT CN13 FUSE F1 RESISTORS UPPER TEMPERATURE SENSOR Black N1 Grey N2 TRANSFORMER Blue N3 Green N4 Black L1 PIN 1 Grey L2 CONTROL PANEL Blue L3 Green L4 CN12 CN14... -
Page 21: Control Diagram
CONTROL PANEL DIAGRAM Powerboard Fault (Red) LED Heat (Green) Bar Graph Demand (Amber) LED Supply (Green) LED Heat Ouput Adjustment (60ºC to 80°C) -
Page 22: Kw Boiler Wiring Diagram
6kW INTERNAL WIRING DIAGRAM FRONT COVER EARTH REAR CHASSIS EARTH BOLT 6kW Internal Wiring Diagram Page 19 of 27 Figure 9... -
Page 23: Kw Boiler Wiring Diagram
9kW INTERNAL WIRING DIAGRAM FRONT COVER EARTH REAR CHASSIS EARTH BOLT 9kW Internal Wiring Diagram Page 20 of 27 Figure 10... -
Page 24: 12 Kw Boiler Wiring Diagram
11 & 12kW INTERNAL WIRING DIAGRAM FRONT COVER EARTH REAR CHASSIS EARTH BOLT 11 & 12kW Internal Wiring Diagram Page 21 of 27 Figure 11... -
Page 25: Technical Specification
TECHNICAL SPECIFICATION Output Temperature Control Range: 65°C to 80°C. Operating voltage 200V -245V 50Hz. Pump supply fuse (internal) T 2A 240v -20x5mm. ‘DEMAND’ control input signal requires 200v -245v 50Hz. ‘DEMAND’ control input signal draws less than 0.25A. 10mA typical. -
Page 26: Heating Only Wiring Diagram
WIRING DIAGRAM FOR HEATING ONLY WIRING DIAGRAM FOR HEATING ONLY PUMP PROGRAMMER ROOM CONSUMER UNIT THERMOSTAT TERMINAL BLOCK 1 1 2 2 Figure 12... -
Page 27: Typical Y Plan Wiring Diagram
WIRING DIAGRAM FOR Y PLAN CONTROL SYSTEM WIRING DIAGRAM FOR Y PLAN CONTROL SYSTEM PUMP PROGRAMMER CH HW CYLINDER THERMOSTAT ROOM CONSUMER UNIT THERMOSTAT TERMINAL BLOCK TERMINAL CONNECTORS 470nF (0.47ųF) 275vac Class X2 DIVERTER VALVE Figure 13 WIRING DIAGRAM FOR S PLAN CONTROL SYSTEM WIRING DIAGRAM FOR S PLAN CONTROL SYSTEM PUMP PROGRAMMER... -
Page 28: Parts Listing
PARTS LIST PART NUMBER DESCRIPTION FBS0112 67 ID X 13THK X 740 LONG CLASS “O” ARMAFLEX INSULATION FBS0113 MANUAL RESET HIGH LIMIT SWITCH ASSEMBLY FBS0115 PREHEAT BRACKET FBS0116 PREHEAT RESISTOR ASSEMBLY (ALL MODELS) FBS0117 UPPER/PRE HEAT TEMPERATURE SENSOR INC WIRE X 200MM FBS0118 LOWER TEMPERATURE SENSOR INC WIRE X 950MM FBS0203... -
Page 29: Limitations On Electrical Supply
LIMITATIONS ON ELECTRICAL SUPPLY If on installation of the Flow boiler, the site survey indicates that the total demand for power exceeds the incoming supply if all devices are switched on at the same time, the priority must be given to one device. Typically but not always this other unit is the electric shower, to give priority to the shower a simple relay is added as shown in diagram below. -
Page 30: Multiple Boiler Relay
MULTIPLE BOILER INSTALLATIONS RELAY CONTROL. Where the operational load calls for a multiple boiler installation (up to three number) isolation relays are required to operate the pump. To enable this connection, Kingspan offer a multiple relay kit. PART NUMBER FBP 0531 Figure 16...
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