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6

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. At the end of this period it will remain on steady (amber), until the 
heating demand is satisfied.

The HEAT indicator (green bar graph) will illuminate when the boiler actually produces heat when the DEMAND indicator (amber) is steady. The 
gradual build up in heating power of the boiler can be seen on the front panel. The HEAT indicator (green bar graph) also shows the boiler modulating 
when it reaches operating temperature.

The FAULT indicator (red) will only illuminate if there is a fault. The DEMAND indicator (amber) will turn off and the HEAT indicator (green bar graph) 
will flash a fault code to assist with fault diagnosis. The boiler will remain in this tripped state until it is reset. To reset a FAULT follow the ‘Fault Reset’ 
procedure (see page 15).

Minimum operating temperature setting for the boiler is approximately 65

o

C Maximum operating temperature setting is approximately 80

o

C.

CLEANING

Use only a damp cloth and mild detergent to clean the boiler outer casing. Do not use abrasive cleaners. Do not allow water inside the boiler. Do not 
immerse in water.

INSTALLATION

Care must be taken when handling and connecting the boiler not to damage or stress it in any way. Prior to installation the boiler must be stored in a 
dry safe place.

FITTING

The boiler must be mounted in an UPRIGHT position only with the electrical connections uppermost. Any deviation from vertical is unacceptable. The 
boiler must be fixed to a wall before connecting pipework. When choosing the position for the boiler, ensure sufficient clearances to house the unit 
and for servicing, 50mm minimum clearance each side of the boiler is required. A drain valve at the base of the boiler is strongly recommended. It 
must be sited in a dry, ventilated position, frost free and not subjected to extremes of temperature.

PLUMBING / HEATING INSTALLATION

IT IS THE INSTALLER’S RESPONSIBILITY TO ENSURE THE INSTALLATION DOES NOT CONTRAVENE THE 
REQUIREMENTS OF THE WATER BYLAWS OR LOCAL AUTHORITY REGULATIONS.

The boiler must be installed by a qualified, competent tradesman who is aware of and will comply with all relevant standards that are applicable: e.g. 
Building Regulations, the Local Building Regulations, the Bylaws of the Local Water Authority and Undertaking and the relevant codes of practice, the 
system must be flushed in accordance with BS.7593 and in accordance with the supplied instructions and drawings to ensure correct operation.

In operation, the boilers contain a very small amount of water in relation to the power input and so require a good flow rate of water to ensure correct 
operation. Six Kilowatt models require a minimum flow of 6 litres/minute, and nine to twelve Kilowatt models require a minimum flow of 12 litres/
minute. Insufficient flow of water through the boiler will cause nuisance trip outs. The maximum temperature differential between input and output of 
the boiler must not exceed 20

o

C. If the temperature across the boiler exceeds this then the flow rate is too low and could cause permanent damage 

to the boiler.

All Flow and Return pipework to be 22mm to ensure minimum flow rate.

Summary of Contents for Senator RFB006 6kW

Page 1: ...Models RFB006 6kW RFB009 9kW RFB011 11kW RFB012 12kW INSTALLATION AND USER INSTRUCTIONS March 2009 Issue No 3 www kingspanhws com...

Page 2: ...time of going to press however Kingspan reserves the right to change any information herein without notice Senator is a Trademark of Kingspan Plc Range Senator RFB 006 RFB 009 RFB 011 RFB 012 Your El...

Page 3: ...ber and 2 years on all other components In the event of a potential warranty claim always quote the boiler serial number No claims will be considered without this number The warranty covers the replac...

Page 4: ...NATOR FLOW BOILER Page 3 of 27 FLOW 22mm COMPRESSION RETURN NOT SHOWN ELECTRICAL CABLE ENTRY POINTS TOP SEALING GROMMET MAIN TERMINAL BLOCK MAIN POWER BOARD CONTROL PANEL FRONT COVER INSULATION PRODUC...

Page 5: ...BASIC INSTALLATION DIMENSIONS 120mm 120mm 100mm 900mm Fixing Centres 8 5mm 1050mm Cable Entry Knock Outs 1 x 25mm 2x 20mm Left Right Rear Fixing Centres Figure 2 5...

Page 6: ...mounted in an UPRIGHT position only with the electrical connections uppermost Any deviation from vertical is unacceptable The boiler must be fixed to a wall before connecting pipework When choosing th...

Page 7: ...be mounted in the return pipework pumping water upwards through the boiler Size the pump in the usual way and set to maximum to ensure sufficient flowrate The pump fitted to this system and controlled...

Page 8: ...ing the correct dosage of inhibitor must be added Fernox Superconcentrate or MB1 or Betz Dearborn Sentinel X100 can be used in most water areas however consult manufacturer s instructions and local wa...

Page 9: ...s Auto Air Vent 150mm maximum 150mm minimum Basic Plumbing Schematic Space heating only open vented DRAIN VALVE PUMP Automatic Bypass minimum of 2 metres Safety Controls Radiators Auto Air Vent 150mm...

Page 10: ...stem DRAIN VALVE PUMP Radiators Auto Air Vent Automatic Bypass minimum of 2 metres Cylinder 150mm minimum Basic Plumbing Schematic Space heating and hot water s plan system Figure 5 Figure 6 Open vent...

Page 11: ...m PIPE FLOW 12L MIN 28mm PIPE FLOW 24L MIN 35mm PIPE FLOW 36L MIN RETURN FLOW DRAIN VALVE AUTOMATIC AIR VENT 150mm minimum Automatic Bypass minimum of 2 metres 35mm 35mm 3 Boiler Plumbing Schematic Fi...

Page 12: ...CTED WITH THE RELEASE BUTTON FITTED INWARDS AND EARTH BOND TESTED AFTER ANY MAINTENANCE HAS BEEN CARRIED OUT THESE CONNECTIONS MUST BE TIGHT LOOSE CONNECTIONS COULD CAUSE A FIRE OR BURNING AT MAIN TER...

Page 13: ...1 Fully pumped system 2 Independent temperature and time controls for both heating and domestic hot water 3 Controls to interlock with the boiler TRV s alone do not comply 4 An automatic bypass is re...

Page 14: ...ns are made correctly check the main supply terminals in the boiler are tight close and secure the top front cover of the boiler MAIN TEST PROCEDURE Only after a satisfactory initial test proceed as f...

Page 15: ...to black grey to grey blue to blue and green to green and an insulation resistance greater than 2 Meg ohms between terminal and case If the elements are open circuit terminal to terminal or have short...

Page 16: ...NO NO NO NO NO YES YES YES YES APPROX 8 SECS YES Rectify supply fault Is there 230V AC at transformer TX1 on powerboard Is Fuse F1 OK rating 2 5A 20 X5 Replace powerboard Replace powerboard Is there...

Page 17: ...water in heater or no flow Check for water or flow 4 flashes Excessive current with relay s on Faulty Triac s Replace powerboard 5 flashes Excessive current with triac s on Faulty relay s Replace powe...

Page 18: ...output temperature less than 60 C NO Adjust output temperaure or flow minimum maintained Are elements within specification refer to manual page 5 NO Faulty elements Request service exchange boiler Ha...

Page 19: ...ire from main terminal block Remove 2 x screws from main terminal block to main terminal mounting Note the assembly position in relation to pipe Restrain power board assembly Remove four retaining scr...

Page 20: ...Page 18 of 27 E LOWER TEMPERATURE SENSOR MANUAL RESET HIGH LIMIT CUT OUT SWITCHES CN14 CN12 PUMP EARTH TO ELEMENTS REFER TO INDIVIDUAL MODEL DIAGRAMS TO EARTH BOND BOLT N L Black N1 Grey N2 Blue N3 Gr...

Page 21: ...21 Heat Ouput Adjustment 60 C to 80 C Supply Green LED Demand Amber LED Heat Green Bar Graph Fault Red LED Powerboard COntrol Panel Diagram...

Page 22: ...22 REAR CHASSIS EARTH BOLT FRONT COVER EARTH 6kW Internal Wiring Diagram Page 19 of 27 6kW Internal Wiring Diagram L1 L2 N1 N2 Figure 9...

Page 23: ...Page 20 of 27 REAR CHASSIS EARTH BOLT FRONT COVER EARTH 9kW Internal Wiring Diagram 9kW Internal Wiring Diagram L1 L2 L3 N1 N2 N3 Figure 10 23...

Page 24: ...11 12kW Internal Wiring Diagram REAR CHASSIS EARTH BOLT FRONT COVER EARTH Page 21 of 27 11 12kW Internal Wiring Diagram L1 L2 L3 L4 N1 N2 N3 N4 Figure 11 24...

Page 25: ...signal requires 200v 245v 50Hz DEMAND control input signal draws less than 0 25A 10mA typical Optical isolation Between the control signals and the boiler supply High limit switches trip 90 C 4 C No o...

Page 26: ...NG DIAGRAM FOR HEATING ONLY 10 10 4 4 1 1 2 2 3 3 7 7 5 5 6 6 8 8 9 9 ON ON L L N N CH CH PROGRAMMER CONSUMER UNIT MCB RCD PUMP ROOM THERMOSTAT TERMINAL BLOCK WIRING DIAGRAM FOR HEATING ONLY Figure 12...

Page 27: ...TERMINAL CONNECTORS WIRING DIAGRAM FOR Y PLAN CONTROL SYSTEM Figure 13 Page 25 of 27 MCB RCD L N 10 4 1 2 3 7 5 6 8 9 TERMINAL BLOCK N L ROOM THERMOSTAT CONSUMER UNIT ON L N ON OFF OFF CH HW CH HW PR...

Page 28: ...0 MM NYLON GABLE GLAND FBS0315 25 MM NYLON GABLE GLAND FBS0316 FIXING KIT 3 X NO12 X 50 SCREW PLASTIC WALL PLUG FBS0317 INSTRUCTION MANUAL FBS0318 MAIN TERMINAL INDICATOR LABEL FBS0319 CONTROL PANEL P...

Page 29: ...ve priority to the shower a simple relay is added as shown in diagram below When the shower is used the boiler will cease to operate When the shower is turned off the boiler operation will recommence...

Page 30: ...ntrol 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...

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