WarmFlow Kabin Pak Combi KC70HE, User Manual

Page 1: ...e only Models covered by this manual U Series Utility U70HE U90HE U120HE U150HE Utility Pumped UP70HE UP90HE UP120HE UP150HE Utility System US70HE US90HE US120HE Utility Combi UC70HE UC90HE K Series K...

Page 2: ...commission the boiler will invalidate the warranty After commissioning ensure that the attached guarantee registration card is completed and returned Alternatively you can register your guarantee onli...

Page 3: ...Pipe System 47 4 3 De aerator System 47 4 4 One Pipe Lift System 48 5 0 Flues 5 1 Installation of Balanced Flues 49 5 2 Conventional Flues 51 5 3 Low Level Balanced Flue Terminal Positions 51 6 0 Air...

Page 4: ...ill hot as this will cause damage to the thermostat Burner Lockout When the pressure jet oil fired burner stops after failing to fire the red reset button will be illuminated This indicates that there...

Page 5: ...which has a cut off point of 110 C this is factory set and is not adjustable The high limit thermostat is located under the control panel to the left hand side press button to reset As standard the p...

Page 6: ...dinary plastic pipe eg plastic overflow pipe directly into the household drain or soak away Any blockage in the drain could lead to an alteration in the combustion settings because of partially blocke...

Page 7: ...supply Systems with hard water must be fitted with a suitable chemical scale preventer eg Fernox Quantomat or Combimate 5 That the flow from any one hot water outlet does not exceed the maximum recom...

Page 8: ...e cylinder The manufacturer s guarantees are void if the appliance is not installed and commissioned in accordance with the recommendations made herein 1 2 General Requirements The installation of the...

Page 9: ...120L at 24L min with an average temperature rise of 32 C the thermal store of a 90 000 Btu h combi has a recovery time of approximately 7 minutes A 70 000 Btu h combi will take slightly longer to rec...

Page 10: ...condary heat exchanger spring baffles must be fully inserted into the heat exchanger tubes narrow end first The primary heat exchanger baffles consist of two half width baffle stacks at the bottom 3 f...

Page 11: ...Casing removable 3 Rear Casing 4 Side Casing 5 Front Casing removable 1 2 3 4 5 Models up to 120 HE 150 HE Models 1 Boiler Assembly 2 Top Front Casing removable 3 Top Rear Casing removable 4 Rear Flue...

Page 12: ...Trap 10 Riello RDB 2 2 Burner 11 Heating Flow Connection 12 Heating Return Connection 1 2 12 4 5 6 7 8 9 11 3 10 Models up to 120 HE 150 HE Models 1 2 3 4 5 6 7 8 9 11 12 10 1 Heat Exchanger 2 Condens...

Page 13: ...o RDB 2 2 Burner 15 Heating Flow Connection 16 Heating Return Connection 1 11 12 10 2 8 9 16 4 6 5 15 13 14 7 3 Models up to 120 HE 150 HE Models 1 11 12 10 2 8 9 7 4 6 5 15 13 14 16 3 1 Heat Exchange...

Page 14: ...ating Return Connection 1 6 7 3 4 2 5 1 5 5 U Series Utility Combi UCHE Key Components 1 Heat Exchanger 2 Heat Store 3 Condensing Unit 4 Service Door 5 Pipework Assembly 6 Plate Heat Exchanger 7 Twin...

Page 15: ...ing 5 Blanking Plug removable 6 Rear Casing removable 7 Side Casing 8 Front Casing removable 1 2 3 4 5 6 7 8 Models up to 120 HE 150 HE Models 1 2 3 4 5 6 7 8 1 Boiler Assembly 2 Top Casing removable...

Page 16: ...Trap 10 Riello RDB 2 2 Burner 11 Heating Flow Connection 12 Heating Return Connection 1 2 3 5 4 6 7 8 9 10 11 12 Models up to 120 HE 150 HE Models 1 2 3 4 5 6 7 8 9 11 12 10 1 Heat Exchanger 2 Conden...

Page 17: ...lo RDB 2 2 Burner 15 Heating Flow Connection 16 Heating Return Connection 1 8 2 4 5 6 7 9 10 11 12 13 14 15 16 3 Models up to 120 HE 150 HE Models 1 11 12 10 2 8 9 7 4 6 5 15 13 14 16 3 1 Heat Exchang...

Page 18: ...ating Return Connection 1 5 10 K Series Kabin Pak Combi KCHE Key Components 1 Heat Exchanger 2 Heat Store 3 Condensing Unit 4 Service Door 5 Pipework Assembly 6 Plate Heat Exchanger 7 Twin Head Pump 8...

Page 19: ...rol Panel Layout Control Thermostat Mains On Lamp Green High Limit Tripped Lamp Yellow Burner Lockout Lamp Red HW On Off Switch CH On Off Switch High Limit Thermostat Reset Underneath 1 5 12 Combi Pip...

Page 20: ...ted CH Pump Only Runs Room Stat Satisfied Boiler Stat Satisfied Boiler Limit Stat Tripped Burner Fires DHW Pump Only Runs HW Limit Stat Satisfied Boiler Limit Stat Tripped Burner Fires Burner Stops Pr...

Page 21: ...0 950 100 318 120 623 950 1050 MODEL A B C D E F G H J K L M N P R S T U V W X Y Z U 600 413 865 766 134 666 86 75 50 687 21 104 226 47 41 390 104 54 51 71 91 718 812 UP 600 413 865 766 134 666 86 75...

Page 22: ...B C D E F G H J K L M N P R S T U V W X Y 600 595 865 766 134 388 207 666 47 226 42 94 718 91 71 51 54 104 390 71 104 197 MODEL A B C D E F G H J K L M N P R S T U V W X Y UC 600 595 865 766 134 388 2...

Page 23: ...7 90 117 52 415 65 2 2 5 K Series Kabin Pak Base Tray KHE KPHE KSHE Models up to 120HE FRONT K120HE BASETRAY DIMS MODEL A B C D E F G H J K L M N P R S T U V K 700 413 900 40 67 40 210 705 50 50 161 9...

Page 24: ...70 120 55 85 155 850 100 100 320 122 630 120 2 2 7 K Series Kabin Pak Base Tray 150HE Models FRONT K150HE BASETRAY DIMS MODEL A B C D E F G H J K L M N P R S T U V K150HE 595 997 876 1155 93 161 75 70...

Page 25: ...Models KCHE DIMS A B C D E F G H J K L M N P R S T U V W X 700 600 900 770 210 396 209 92 161 52 50 50 705 117 67 40 90 40 67 415 65 FRONT KCHE BASETRAY DIMS MODEL A B C D E F G H J K L M N P R S T U...

Page 26: ...the warranty 2 3 1 HE Low Level Balanced Flue Kit FBF Comprising the following four main components 1 Diverter Assembly 2 Extension 3 Elbow 4 Terminal End 5 Mounting Brackets 1 2 5 2 3 5 5 4 2 3 2 Plu...

Page 27: ...e fitting kit required 2 If terminal is less than 2 metres above ground level terminal guard must be fitted 3 Extension pipes and flue adaptor lengths quoted are effective lengths and not the actual l...

Page 28: ...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 i...

Page 29: ...ler is a flexible plastic hose which can be trimmed to length 3 4 or 22mm pipe should be connected to the flexible hose The pipe should not be made from steel or copper The drainage pipe may run into...

Page 30: ...tory Settings Danfoss 60 ES 0 5 0 5 0 6 Danfoss 60 ES 0 6 0 65 0 75 7 0 102 9 0 130 8 0 116 8 0 116 8 0 116 7 0 102 11 5 11 5 11 5 11 5 11 5 11 5 1 65 0 36 1 98 0 44 2 35 0 52 2 35 0 52 2 65 0 58 2 98...

Page 31: ...y Settings Danfoss 60 ES 0 5 0 5 0 6 Danfoss 60 ES 0 6 0 65 0 75 7 0 102 9 0 130 8 0 116 8 0 116 8 0 116 7 0 102 11 5 11 5 11 5 11 5 11 5 11 5 1 65 0 36 1 98 0 44 2 35 0 52 2 35 0 52 2 65 0 58 2 98 0...

Page 32: ...Flow Rate gals h Flow Connection Return Connection Water litres Content gals Boiler Weight Dry kg Boiler Weight Wet kg SEDBUK Efficiency Factory Settings Danfoss 60 ES 0 5 0 5 0 6 Danfoss 60 ES 0 6 0...

Page 33: ...foss 60 ES 0 6 0 65 0 75 7 0 102 9 0 130 8 0 116 8 0 116 8 0 116 7 0 102 11 5 11 5 11 5 11 5 11 5 11 5 1 65 0 36 1 98 0 44 2 35 0 52 2 35 0 52 2 65 0 58 2 98 0 65 22mm Copper 22mm Copper 74 16 3 140 2...

Page 34: ...n Return Connection Water litres Content gals Boiler Weight Dry kg Boiler Weight Wet kg SEDBUK Efficiency Factory Settings Danfoss 60 ES 0 5 0 5 0 6 Danfoss 60 ES 0 6 0 65 0 75 Danfoss 60 ES 0 75 0 85...

Page 35: ...ry Settings Danfoss 60 ES 0 5 0 5 0 6 Danfoss 60 ES 0 6 0 65 0 75 7 0 102 9 0 130 8 0 116 8 0 116 8 0 116 7 0 102 11 5 11 5 11 5 11 5 11 5 11 5 1 65 0 36 1 98 0 44 2 35 0 52 2 35 0 52 2 65 0 58 2 98 0...

Page 36: ...Flow Rate gals h Flow Connection Return Connection Water litres Content gals Boiler Weight Dry kg Boiler Weight Wet kg SEDBUK Efficiency Factory Settings Danfoss 60 ES 0 5 0 5 0 6 Danfoss 60 ES 0 6 0...

Page 37: ...nfoss 60 ES 0 6 0 65 0 75 7 0 102 9 0 130 8 0 116 8 0 116 8 0 116 7 0 102 11 5 11 5 11 5 11 5 11 5 11 5 1 65 0 36 1 98 0 44 2 35 0 52 2 35 0 52 2 65 0 58 2 98 0 65 22mm Copper 22mm Copper 74 16 3 140...

Page 38: ...e The appliance must be effectively earthed and all external wiring should comply with current IEE Regulations 3 1 Dual Safe Thermostat Non Combi Boilers Warning Do not fit any other wires or loop wir...

Page 39: ...Page 37 3 3 Combi Wiring Details 3 3 1 Wiring Diagram The 3 pin mains plug must be supplied with a permanent live to allow the pump overrun stat and relay to operate correctly...

Page 40: ...IMIT STAT 9 BOILER LIMIT STAT 15 2 13 1 6 4 MAINS ON LAMP GREEN H L RESET LAMP YELLOW LOCKOUT LAMP GREEN LAMP 7 16 BOILER LIMIT STAT 15 H L RESET LAMP YELLOW BREAK INTO THE WHITE WIRE BETWEEN NO 16 ON...

Page 41: ...Pump Overrun Thermostat The condensing Combi boilers have been fitted with a pump overrun thermostat In order for the thermostat to work effectively the boiler must be supplied with a permanent live...

Page 42: ...ut piece ensuring that all metal tags or burrs have been removed from the hole 6 Feed the programmer and harness through the hole from the front of the panel 7 Secure in position by attaching the secu...

Page 43: ...the built in frost protection of a Kabin Pak Combi from operating 3 5 2 Installation of a remote two channel programmer option 2 Connecting the programmer in this manner will bypass the CH and HW on o...

Page 44: ...ts 1 The optional programmer as supplied will supply power to the pump and burner via the central heating channel 2 When connecting to external controls eg Y plan or S plan it will be necessary to rem...

Page 45: ...o a Utility model without an integral pump disconnect the pump plug from terminals 1 and 2 of the programmer terminal block and from the earth post Remove the pump plug then wire the external plug int...

Page 46: ...Page 44 3 6 4 Honeywell Y Plan Independent CH DHW Fully Pumped Only Note Before fitting programmer remove loop between 3 and 12 on the terminal block...

Page 47: ...Page 45 3 6 5 Honeywell S Plan Independent CH DHW Fully Pumped Only Note Before fitting programmer remove loop between 3 and 12 on the terminal block...

Page 48: ...ised pipe and fittings should not be used The pipework should terminate close to the boiler and be fitted with an isolating valve and filter A remote sensing fire valve must be fitted to the oil line...

Page 49: ...ID 8mm ID 10mm 0 5 1 2 3 35 25 15 8 100 100 70 30 0 5 30 100 3 5 6 20 1 5 20 90 Total Maximum Pipe Length m 4 2 Two Pipe System For maximum pipe length and lift contact de aerator manufacturer 4 3 De...

Page 50: ...35 25 15 8 100 100 70 30 0 5 30 100 3 5 6 20 1 5 20 90 Total Maximum Pipe Length m 4 4 One Pipe Lift System Note The pump vacuum should not exceed a maximum of 0 4 bar Above this gas is released from...

Page 51: ...Page 49 5 0 Flues 5 1 Installation of Flues...

Page 52: ...Flue Options Components and Dimensions Section for details of the maximum number of extension pieces and total flue lengths allowed 4 If installing a vertical flue correctly fit the flashing kit then...

Page 53: ...stem manufacturer s installation instruction must be followed For recommended conventional flue systems contact Warmflow 5 3 Low Level Balanced Flue Terminal Positions Attention should be given to the...

Page 54: ...erminal on the same wall K 1 500 Horizontally from a terminal on the same wall L 750 Above the highest point of an intersection with the roof M 600 From a vertical structure on the side of the termina...

Page 55: ...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 6 2 Ba...

Page 56: ...due to corrosion product in the system will not be covered by warranty 7 1 4 Air Vents The plastic plugs of the auto air vent s factory fitted to the boiler must be loosened when filling the system i...

Page 57: ...ressure Water loss from the system as indicated by a reduction in pressure on the pressure gauge may be made up through the filling loop In the first week of operation it is normal to see a drop in sy...

Page 58: ...ply pressure 7 3 2 Water Hardness 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 softe...

Page 59: ...ll by pass plug as shown 1 Pump 2 Control Box 3 Reset Button with Lock Out Lamp 4 Flange with Insulating Gasket 5 Air Damper Adjustment Screw 6 Air Tube Connection Supplied with BF Kit 7 Pump Pressure...

Page 60: ...osen the screw 2 and rotate the main air damper A to the required position Retighten the screw 2 and put back the secondary air damper B Air Damper B The purpose of this damper is to perform a fine tu...

Page 61: ...been fitted ensure the air duct connecting the flue and burner has been properly connected before commissioning To comply with the building regulations OFTEC form CD11 should be completed and a copy...

Page 62: ...e Electrodes Washing Pressure 1 2 Bar Solenoid Operating Raise Pressure Replace Nozzle Flame Off and Re Lights Check Boiler Controls Replace Motor Capacitor Replace the Control Box Drive Coupling Brok...

Page 63: ...17 and 18 on the PCB Is there continuity across the connections 28 and 30 on the PCB Check power from clock or switch check wiring fuses and mains supply Refer to burner fault finding Press reset butt...

Page 64: ...thermostat Is high limit thermostat lamp lit Does boiler shut down when tank reaches temperature Replace tank stat replace relay Check wiring replace tank limit stat Is there continuinity across 23 an...

Page 65: ...y fully for 3 seconds Then LCD display will change to 5 2d You can press DAY button to select 7d 24H programme mode This configures the timer as follows 5 2d 5 day 2 day programme option allows differ...

Page 66: ...n press DAY button to select current day of the week 2 Press and hold CLOCK button then press HOUR button until the correct hour is displayed 3 Press and hold CLOCK button then press MINUTE button unt...

Page 67: ...OFF PERIOD 3 ON PERIOD 3 OFF Switching Set Day Programme Period 2 On Off 10 30 07 30 22 30 16 30 08 30 06 30 HW CH2 CH CH1 22 30 16 30 08 30 06 30 10 30 07 30 HW CH2 CH CH1 Mon Fri Time Schedule Mon...

Page 68: ...ADV and the AUTO will stop flash 12 1 10 Manual Hour 1 Press CH ADV or HW ADV key the CH icon will flash 2 You now have approx 5 second to enter desired length of time by pressing CH ADV or HW ADV ke...

Page 69: ...07162 O Ring 18 3008653 Filter O Ring 19 3003602 Connector 20 3005720 Flexible Oil Line 21 3008644 Tube 22 3008876 Pressure Gauge 23 3000443 Joint 24 3008648 Coil Shell Knob 25 3002836 Motor Capacitor...

Page 70: ...ssembly 12 3008958 Deadening 13 3008962 Cover 14 3008646 PE Cell 15 3005799 Fan 16 3008955 Nozzle Holder 17 3008960 Capacitor 5 F No CODE 3748941 DESCRIPTION 18 3003602 Connector 19 3005720 Flexible O...

Page 71: ...odels KP70HE KP90HE KP120HE KS70HE KS90HE KS120HE 150HE Pumped Models UP150HE KP150HE Pump Flow Pipe 22mm 3015 Pump Flow Pipe 22mm 3015 Expansion Vessel Pressure Hose 3020 From Boiler to Pump 22mm 301...

Page 72: ...100 From Gate Valve to Pump 3098 From Plate Heat Exchanger to Boiler Return 3096 From Heat Store to Plate Heat Exchanger 1997 From Flowswitch to Mixing Valve Plate Heat Exchanger 1992 From Plate Heat...

Page 73: ...d 602 3 Pole Relay 1827 Auto Air Vent C W Check Valve 614 Pressure Relief Valve 2132 Filling Loop 2133 Pressure Gauge 3019 Mixer Valve 1621 PCB Controller MK4 2419 12 Litre Pressure Vessel 2128 Single...

Page 74: ...r a total of 5 years from the appliance date code subject to the above conditions being complied with Warmflow reserves the right to repair or replace components within the guarantee period at a time...

Page 75: ...gineer Name ______________________ Engineer Signature ______________________ Telephone No ______________________ Date of 5th Service ______________________ Company Name ______________________ Engineer...

Page 76: ...Page 74 Notes...

Page 77: ...Page 75 Notes...

Page 78: ...Page 76 Notes...

Page 79: ...__ __ __ __ __ __ __ __ NAME OF COMMISSIONING ENGINEER Mr Ms Mrs Miss Initials Surname __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ __ Work Telephone No inc code Mobile Telephone No __...

Page 80: ...PERFORATION BUSINESS REPLY SERVICE Licence No BEL 1609 CUSTOMERS FROM ROI PLEASE AFFIX STAMP Warmflow Engineering Ltd Appliance Registration Dept Lissue Industrial Estate Moira Road Lisburn Co Antrim...