WarmFlow COMBI 70, Installation & Servicing Instructions Manual

Page 1: ...CING MANUAL FOR 70 90 COMBI BOILER 70 90 KABIN PAK COMBI LEAVE THESE INSTRUCTIONS WITH THE END USER NATIONAL ACCREDITATION OF CERTIFICATION BODIES BSI R E G I ST E R ED F I R M CERT No FM 29884 BS 575...

Page 2: ...ng a team of Oftec trained engineers who can meet all the servicing commissioning and breakdown requirements for your appliance Simply telephone TEL 028 9262 0852 FAX 028 9262 0869 E MAIL service warm...

Page 3: ...any one hot water outlet does not exceed the maximum recommended This applies particularly to baths which are usually fitted with larger taps and larger bore supply pipes It may be necessary to restri...

Page 4: ...ischarge Low Level Balanced Flues Terminal Position 26 6 0 Air Supply for Combustion and Ventilation 28 6 1 Open Flue Boilers 28 6 2 Balanced Flue Boilers 28 6 3 Installation of Flues 29 7 0 Thermosta...

Page 5: ...power and the thermostat is calling for heat and the burner has been reset it will go through its start up cycle If the burner again fails to fire this would indicate a burner fault or oil supply prob...

Page 6: ...are covered by a manufacturer s warranty of 5 years from the boiler date stamp but does not include burner labour handling or shipping Details of any extended warranties are contained within the insta...

Page 7: ...alve 9 Strainer 10 Filling Loop 11 Tank Control and Limit Stat 12 Flow Switch 13 Mixer Valve 14 Plate Heat Exchanger 15 CH Pump Head 16 DHW Pump Head 17 Pump Gate Valves x3 18 Tank Drain Valve 1 3 2 C...

Page 8: ...mp 15 CH Pump 16 Cable on Oil Line Grommets Note To convert the Kabin Pak for use with a conventional flue use the Kabin Pak adaptor KPA 1 3 4 Kabin Pak Combi Control Panel 17 Air Intake Grill 18 Pipe...

Page 9: ...t Stat Tripped Press Reset Button The boiler will have a DHW priority when both domestic hot water DHW and central heating CH are selected So if the flow switch is closed or the heat store has not bee...

Page 10: ...elief valve and the discharge and the discharge pipe should not be used for any other purposes The discharge pipe must be plumbed to an external drain in a position where the discharge can been seen b...

Page 11: ...oiler Connections All dimensions are given in mm 1 Cold Mains 15mm 2 Heating Flow 22mm 3 Domestic Hot Water 22mm 4 Pressure Relief Discharge 15mm 5 Spare Connection 1 BSP 6 Central Heating Return 1 BS...

Page 12: ...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 incr...

Page 13: ...andard Low Level Conventional Flue LLF The factory supplied elbow may be extended up to 1m horizontally and 1 5m vertically by welding on additional pipe or by using vitreous enamelled flue pipe 2 5 3...

Page 14: ...FLAT ROOF FLASHING PACK B VBF TERMINAL SECTION MIN 435 560 735 MAX 610 860 910 A E A F A C E FLUE PACKS DIM A ALL MODELS MIN 860 1035 1160 1385 1510 MAX 1160 1210 1510 1560 1860 A C F A C C E A C C F...

Page 15: ...d water mains inlet refer to page 1 Ingress Protection 70 90 Combi 29 3 100 000 26 4 90 000 90 RDB 1 LD3 100 or 127 4 or 5 11 5 12 0 0 1 235 12 0 3 15 0 69 DANFOSS 60 S 0 75 8 116 DANFOSS 60 S 0 6 12...

Page 16: ...d and all external wiring should comply with current IEE Regulations It is the responsibility of the installer to ensure that the appliance has been properly earthed 3 1 RDB Burner Control Box CONTROL...

Page 17: ...3 3 Combi Wiring Details 3 3 1 Wiring Diagram P Purple O Orange Y Yellow R Red W White BR Brown BL Blue B Black G Y Green Yellow Page 15...

Page 18: ...3 3 2 Combi Wiring Schematic BREAK INTO THE WHITE WIRE BETWEEN NO 16 ON THE PCB AND THE LIMIT STAT AND CONNECT IN THE PRESSURE SWITCH WITH A WIRING BLOCK AS SHOWN Page 16...

Page 19: ...3 4 Kabin Pak Combi Wiring Details 3 4 1 Kabin Pak Combi Wiring Diagram P Purple O Orange Y Yellow R Red W White BR Brown BL Blue B Black G Y Green Yellow GY Grey Page 17...

Page 20: ...3 4 2 Kabin Pak Combi Wiring Schematic BREAK INTO THE WHITE WIRE BETWEEN NO 16 ON THE PCB AND THE LIMIT STAT AND CONNECT IN THE PRESSURE SWITCH WITH A WIRING BLOCK AS SHOWN Page 18...

Page 21: ...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 3 5 2 Kabin...

Page 22: ...e mains on lamp is also bypassed A separate live supply to the boiler is not required However a neutral and earth must be supplied to the boiler 3 6 2 Installation of a remote two channel programmer o...

Page 23: ...bracket The programmer is secured to the bracket with 2 screws 6 Disconnect the 6 pin plug from the CH and HW on off plugs 7 Connect the programmer 6 pin plug into the socket 8 Locate the programmer i...

Page 24: ...Two Channel Programmer ON OFF COM E N L CH ON OFF COM HW 5 3 R C D L N E BOILER MAINS PLUG ISOLATOR TO BE FITTED WITHIN BOILER CASING THE HW AND CH SELECTOR SWITCHES ON THE BOILER CONTROL PANEL SHOUL...

Page 25: ...be fitted with an isolating valve and filter It is also recommended that a remote sensing fire valve should be fitted to the oil line preferably before the oil line enters the building BS5410 PART 1...

Page 26: ...and lift contact de aerator manufacturer DE AERATOR MAY BE ABOVE OR BELOW BURNER AND MUST BE POSITIONED OUTSIDE NON RETURN VALVE FILTER MAY BE POSITIONED OUTSIDE DE AERATOR Must be upright FIRE VALVE...

Page 27: ...EPARATOR 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 Total Maximum Pipe Length m 0 5 35 100 0 5 30 100 1 25 100...

Page 28: ...l Convert Low Level Balanced Flues Terminal Positions and Kabin Pak Flues Attention should be given to the position of the flue discharge we recommend the following guidelines be adopted 1 The flue sh...

Page 29: ...nal 600 H Vertically from a terminal on the same wall 1500 I Horizontally from the terminal on the same wall 600 J Directly below an opening air brick window etc 600 K From a vertical drain pipe or so...

Page 30: ...ellar 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 Bal...

Page 31: ...Flue LLF Easy Fit Low Level Conventional Flue LLF R Easy Fit Balanced Flue BF R Easy Fit High Level Balanced Flue HLBF R RIELLO RDB BURNER AIR INTAKE COVER AIR INTAKE ADAPTER SPIGOT GASKET BOILER LID...

Page 32: ...e the seals are correctly fitted and lubricated before pushing through the wall and attaching to the flue adaptor Note Any combination of short 300mm and long 600mm extension pieces for the BF R can b...

Page 33: ...the wall Fit the steel elbow into the pressed ring on the boiler and the end of the flue kit The elbow should then be sealed into both rings using high temperature silicone sealant or fire cement whic...

Page 34: ...ystem should be installed to HVCA current codes of practice Before installing the boiler the new or existing system should be thoroughly flushed to clear all sludge or other foreign matter such as sol...

Page 35: ...e or power washer 8 3 6 Expansion Vessel A 12 litre expansion vessel charged to 0 5 bar is supplied with the boiler This can accommodate a maximum system volume of approximately 150 litres If this vol...

Page 36: ...een the device and the closed tap 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 37: ...vent tube to suit wall thickness and insert into the hole in the wall 3 Remove plastic air inlet cover on the burner Attach the air intake gasket and adapter to the burner using the screws supplied 4...

Page 38: ...ith BF kit 3 Reset button with lock out lamp 7 Pump pressure adjustment screw 4 Flange with insulating gasket 8 Pressure gauge port 9 2 Oil Supply The burner is supplied for use with a one pipe system...

Page 39: ...tions 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 9 4 Electrode Setting 9 5 Burner S...

Page 40: ...e flue and burner has been properly connected before commissioning On the Kabin Pak Combi refit the front door panel before doing a flue gas analysis To comply with GB building regulations OFTEC form...

Page 41: ...s 3 ON and 3 OFF periods every 24 hours with a choice of different programmes for each day of the week Override programme options of AUTO ALL DAY 24 HOUR and OFF A choice of HOT WATER and CENTRAL HEAT...

Page 42: ...the ENTER button and then use the SET button to return the SET indicator to the RUN POSITION Setting the ON and OFF Times Note The minimum ON OFF time that can be set is TEN MINUTES The programmer alr...

Page 43: ...entical switching times Use the and buttons to mov the DAY OF THE WEEK indicator to the next day that you wish the times to apply and press the COPY button the display will indicate IN Continue in thi...

Page 44: ...to three ON OFF periods per day ALL DAY When ALL DAY is selected the programmer will switch the system on at the 1st ON TIME and OFF at the 3rd OFF TIME 24 HOUR When 24 HOUR is selected the system rem...

Page 45: ...OFF position Electronic equipment can in exceptional circumstances be affected by electrical interference If your programmers display or switching programme becomes frozen or scrambled or you wish to...

Page 46: ...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 button replace if necessary Check wiring repl...

Page 47: ...at 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 and 22 Wit...

Page 48: ...ens Check wiring to solenoid coil Check for kinks in flexible oil pipe Check nozzle for blockage Check fire valve Check pump solenoid is operating correctly Check correct nozzle is fitted Check pump p...

Page 49: ...0 3008878 Kit Seal NO CODE 3748757 DESCRIPTION 1 3005787 Gasket 2 3006384 Flange 3 3008769 Cup shaped Head 4 3007513 Electrode Assembly 5 3006552 Electrode Bracket 6 3008642 Nozzle Holder 7 3008643 Co...

Page 50: ...to Boiler Pipe 1997 Plate Heat Exchanger to Flow Switch Pipe 1992 Hw Pump to Pipe Support Pipe 1993 Plate Heat Exchanger to Mixer Valve Pipe 1994 From Mixer Valve Pipe 1995 All Combis All Combis All...

Page 51: ...e Relay 1827 Auto Air Vent C W Check Valve 614 Pressure Relief Valve 2132 Filling Loop 2133 Pressure Gauge C W Capillary 2169 Mixer Valve 1621 Low Pressure Switch 2270 Burner Reset Button Membrane R76...

Page 52: ...flow co uk TEL 028 9262 1515 FAX 028 9262 2827 N IRELAND service warmflow co uk TEL DUBLIN 8416158 REP OF IRELAND FAX DUBLIN 8416614 TEL 0161 205 4202 ENGLAND FAX 0161 205 4818 SCOTLAND WALES Lisburn...