WarmFlow Boilerhouse B120HE Page 24 User Manual Download

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5.2 Dimensions
5.2.1 B-Series Boilerhouse (B70HE, B90HE & B120HE Models)

395

600

685

332

118

664

197

371

5.2.2 U-Series Utility (UHE, UPHE & USHE Models up to 120HE)

Summary of Contents for Boilerhouse B120HE

Page 1: ...ies Boilerhouse B70HE B90HE B120HE U Series Utility U70HE U90HE U120HE U150HE Utility Pumped UP70HE UP90HE UP120HE UP150HE Utility System US70HE US90HE US120HE Utility Combi UC70HE UC90HE UC120HE K Se...

Page 2: ...a team of OFTEC trained engineers who can meet all the servicing commissioning and breakdown requirements for your appliance Tel 028 9262 1515 Fax 028 9262 2827 E mail service warmflow co uk Web www w...

Page 3: ...Dimensions 22 5 3 Condensate Disposal 27 5 4 Technical Data 28 6 ELECTRICITY SUPPLY WIRING DETAILS 37 6 1 Dual Safe Thermostat Non Combi Boilers 37 6 2 RDB Burner Control Box 37 6 3 Combi Wiring Deta...

Page 4: ...ment 74 12 COMMISSIONING SERVICING 75 12 1 Commissioning 75 12 2 Servicing 75 13 BURNER FAULT FINDING 76 13 1 Riello RDB 76 14 COMBI FAULT FINDING 77 14 1 Central Heating 77 14 2 Domestic Hot Water 78...

Page 5: ...rmostat Reset If the high level thermostat trip has operated remove the reset cover by using a coin or screwdriver turning anti clockwise and press the small red button now exposed Do not press the re...

Page 6: ...itor manufacturers recommendations and monitored going forward Frequent or routine topping up of the system should not be necessary and may prove harmful to the appliance Should topping up prove neces...

Page 7: ...ordinary 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 bloc...

Page 8: ...water supply Systems with hard water must be fitted with a suitable chemical scale preventer e g Fernox Quantomat or Combimate 5 That the flow from any one hot water outlet does not exceed the maximu...

Page 9: ...ating pumps filling loop pressure gauge and safety valve An optional 7 day electronic programmer kit is also available for all Utility boiler models The Combi can provide at mains pressure domestic ho...

Page 10: ...directed to DHW before the boiler will switch over to CH When fully cold it can take up to 20 minutes for the heat store of a 90 000 Btu h combi to be satisfied and slightly longer for a 70 000 Btu h...

Page 11: ...s shown The secondary heat exchanger spring baffles must be fully inserted into the heat exchanger tubes narrow end first 150 HE Models The primary heat exchanger baffles consist of two half width baf...

Page 12: ...Top Rear Casing removable 4 Sides Rear Casing 5 Front Casing removable 6 Bottom Front Casing 1 Heat Exchanger 2 Condensing Unit 3 Auto Air Vent 4 Service Door 5 Dual Safe Thermostat 6 Heat Exchanger...

Page 13: ...4 5 2 U Series Utility Casing Components Models up to 120 HE 150 HE Models Page 11...

Page 14: ...4 5 3 U Series Utility Pre Wired UHE Key Components Models up to 120 HE 150 HE Models Page 12...

Page 15: ...4 5 4 U Series Utility Pumped UPHE Key Components Models up to 120 HE 150 HE Models Page 13...

Page 16: ...Page 14 4 5 5 U Series Utility System USHE Key Components 4 5 6 U Series Utility Combi UCHE Key Components...

Page 17: ...4 5 7 K Series Kabin Pak Casing Components Models up to 120 HE 150 HE Models Page 15...

Page 18: ...4 5 8 K Series Kabin Pak Pre Wired KHE Key Components Models up to 120 HE 150 HE Models Page 16...

Page 19: ...4 5 9 K Series Kabin Pak Pumped KPHE Key Components Models up to 120 HE 150 HE Models Page 17...

Page 20: ...Page 18 4 5 10 K Series Kabin Pak System KSHE Key Components 4 5 11 K Series Kabin Pak Combi KCHE Key Components...

Page 21: ...ng On Off Switch Heating and Hot Water modes are controlled via the on off switches unless a remote time clock has been fitted Consult your installer 5 Mains On Lamp If this lamp is not lit there may...

Page 22: ...Page 20 4 5 13 Combi Pipe Layout UCHE KCHE Models...

Page 23: ...Page 21 5 TECHNICAL DETAILS 5 1 Combi Sequence of Operation Flow Chart...

Page 24: ...2 Dimensions 5 2 1 B Series Boilerhouse B70HE B90HE B120HE Models A 395 B 600 C 685 D 332 E 118 F 34 G 664 H 97 J 77 K 197 L 371 M 85 N 35 P 30 Q 50 R 80 5 2 2 U Series Utility UHE UPHE USHE Models up...

Page 25: ...Page 23 5 2 3 U Series Utility 150HE Models 5 2 4 U Series Utility UCHE Models...

Page 26: ...Page 24 5 2 5 K Series Kabin Pak KHE KPHE KSHE Models up to 120HE 5 2 6 K Series Kabin Pak Base Tray KHE KPHE KSHE Models up to 120HE...

Page 27: ...Page 25 5 2 7 K Series Kabin Pak 150HE Models 5 2 8 K Series Kabin Pak Base Tray 150HE Models...

Page 28: ...Page 26 5 2 9 K Series Kabin Pak KCHE Models 5 2 10 K Series Kabin Pak Base Tray KCHE Models...

Page 29: ...th 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 an internal soil stack or waste pipe an external gulley hop...

Page 30: ...s Temp 0 C 86 88 90 90 93 95 95 98 110 Smoke Bacarach 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 Oil Pump Pressure bar...

Page 31: ...3 95 95 98 110 75 90 105 Smoke Bacarach 0 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES Danfoss 80 H size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 0 85 1 00 1 25 Oil Pu...

Page 32: ...90 90 93 95 95 98 110 75 90 105 Smoke Bacarach 0 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES Danfoss 80 H size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 0 85 1 00 1 25...

Page 33: ...C 86 88 90 90 93 95 95 98 110 Smoke Bacarach 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 Oil Pump Pressure bar psi 7 0 1...

Page 34: ...2 35 0 52 2 65 0 58 2 98 0 65 2 98 0 65 3 40 0 75 3 81 0 84 Water Content litres gals 74 16 3 74 16 3 74 16 3 Boiler Weight Dry kg 140 140 140 Boiler Weight Wet kg 214 214 214 Domestic Hot Water DHW P...

Page 35: ...93 95 95 98 110 75 90 105 Smoke Bacarach 0 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES Danfoss 80 H size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 0 85 1 00 1 25 Oil P...

Page 36: ...90 90 93 95 95 98 110 75 90 105 Smoke Bacarach 0 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES Danfoss 80 H size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 0 85 1 00 1 2...

Page 37: ...C 86 88 90 90 93 95 95 98 110 Smoke Bacarach 0 0 0 Kerosene Settings Nozzle make Danfoss 60 ES Danfoss 60 ES Danfoss 60 ES size 0 5 0 5 0 6 0 6 0 65 0 75 0 75 0 85 0 85 Oil Pump Pressure bar psi 7 0...

Page 38: ...2 35 0 52 2 65 0 58 2 98 0 65 2 98 0 65 3 40 0 75 3 81 0 84 Water Content litres gals 74 16 3 74 16 3 74 16 3 Boiler Weight Dry kg 140 140 140 Boiler Weight Wet kg 214 214 214 Domestic Hot Water DHW...

Page 39: ...e via a fused double pole isolating switch which should be fitted with a 5 amp fuse The appliance must be effectively earthed and all external wiring should comply with current IEE Regulations 6 1 Dua...

Page 40: ...Page 38 6 3 Combi Wiring Details 6 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...

Page 41: ...Page 39 6 3 2 Wiring Schematic...

Page 42: ...lding a frost thermostat should be fitted in the coldest room in the house To prevent over heating of the property a pipe thermostat should be fitted on the return pipe close to the boiler The Kabin P...

Page 43: ...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 44: ...l panel remove the purple white and brown wires connecting the CH and HW switches to the 6 pin connector of the terminal block Connect the programmer to the 6 pin connector via a 5 core cable as shown...

Page 45: ...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 46: ...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 47: ...Page 45 6 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 48: ...Page 46 6 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 49: ...sed 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 p...

Page 50: ...e System Total Maximum Pipe Length m Head H m 0 0 0 5 1 0 1 5 2 0 3 0 3 5 ID 8mm 35 30 25 20 15 8 6 ID 10mm 100 100 100 90 70 30 20 7 3 De aerator System For maximum pipe length and lift contact de ae...

Page 51: ...mum Pipe Length m Head H m 0 0 0 5 1 0 1 5 2 0 3 0 3 5 ID 8mm 35 30 25 20 15 8 6 ID 10mm 100 100 100 90 70 30 20 Note The pump vacuum should not exceed a maximum of 0 4 bar Above this gas is released...

Page 52: ...quipment failure that is not covered by the manufacturer s warranty 3 Depending on the capacity of the oil storage tank and oil usage fuels may remain static within the tank for some considerable time...

Page 53: ...o fuel is introduced Contact the tank manufacturer or oil supplier for further advice If these recommendations are not respected this will increase the risk of contamination and possible equipment fai...

Page 54: ...hould be designed in accordance with local bye laws and the Building Regulations Draught stabilisers are not recommended for oil fired boilers Sharp bends or horizontal runs should be avoided and the...

Page 55: ...for detailed guidance In general a dwelling such as a private household will not be compartmentalised and the use of a plastic flue system is no different from that of a metal flue system If in doubt...

Page 56: ...The kit comprises FIT FLUE THERMOSTAT 1 Fit the flue thermostat BEFORE fitting the flue kit FIT STARTER PIECE 2 Remove the appropriate casing panel cut out using snips Fit the boiler adapter A 3 Lubri...

Page 57: ...hen X mm from the inner pipe CONNECT TERMINAL AND AIR HOSE 7 Lubricate then refit the terminal then secure with the locking band 8 Fit the air inlet spigot and gasket to the burner Attach the flexible...

Page 58: ...HBF The kit comprises FIT FLUE THERMOSTAT 1 Fit the flue thermostat BEFORE fitting the flue kit FIT STARTER PIECE 2 Remove the top panel casing cut out using snips Fit the boiler adapter A 3 Lubricate...

Page 59: ...starter assembly and secure with the jubilee clips MEASURE AND CUT FLUE TERMINAL i Cut a hole through the wall and fit a non combustible sleeve ii Fit the flue terminal E and measure the excess lengt...

Page 60: ...BF The kit comprises FIT FLUE THERMOSTAT 1 Fit the flue thermostat BEFORE fitting the flue kit FIT STARTER PIECE 2 Remove the top panel casing cut out using snips Fit the boiler adapter A 3 Lubricate...

Page 61: ...ir hose to the burner and starter assembly and secure with the jubilee clips MEASURE AND CUT TERMINAL 6 Fit the flashing and assemble the flue up through the roof lubricating all seals Measure the exc...

Page 62: ...itting kit required 2 If the terminal is less than 2 metres above ground level a terminal guard must be fitted 3 Extension pipes and flue adapter lengths quoted are effective lengths and not the actua...

Page 63: ...maximum equivalent length depending upon boiler output as illustrated in the above table Example Calculation Boiler Output 20kW Length of Flue distance from boiler to terminal 8 0m Example 1 No bends...

Page 64: ...Page 62 8 1 8 Plume Management Kits Plume Management Kits are available for our range of appliances 8 1 9 Utility Plume Management Kit UPMK...

Page 65: ...FIT DIVERTER ELBOW 3 Lubricate and insert one of the Elbows C into the end of the Terminal Assembly A Elbow C can be pointed at any angle up to 87 from the vertical It must not be pointed horizontally...

Page 66: ...Page 64 8 1 10 Kabin Pak Plume Management Kit KPMK The kit comprises...

Page 67: ...nsuring the assembly is tight onto the end of the pipe and that the seals are well compressed The Diverter Assembly should be firmly attached to the pipe when complete 4 ADJUST DIVERTER ASSEMBLY Turn...

Page 68: ...kits F16 or F18 contain Installation instructions FIT FLUE THERMOSTAT 1 Fit the flue thermostat BEFORE fitting the flue FIT STARTER PIECE 2 Remove the top casing panel cut out using snips Fit the boi...

Page 69: ...and secure with the jubilee clips CONNECT TO CLOSURE PLATE Install the chimney components and closure plate as instructed in the separate instruction leaflet Run the flue from the boiler to the chimne...

Page 70: ...al on the same wall 1500 L Horizontally from a terminal on the same wall 750 M Above the highest point of an intersection with the roof 600 N From a vertical structure on the side of the terminal 750...

Page 71: ...ir is at high level then the combustion air should be ducted to low level Combustion Air Supply Boiler in Room OPEN FLUE Boiler in Compartment OPEN FLUE VENTILATED FROM OUTSIDE OPEN FLUE VENTILATED FR...

Page 72: ...e heat exchangers and non return valves due to corrosion product in the system will not be covered by warranty 10 1 4 Air Vents The plastic plugs of the auto air vent s factory fitted to the boiler mu...

Page 73: ...tem and Combi boilers a filling point complete with a filling loop is supplied fitted to the expansion vessel The filling loop must be disconnected from the mains supply after filling A system pressur...

Page 74: ...tic hot water pipework Note that the flow rate from individual taps is dependant on the number of outlets being operated together as well as the length and size of pipework and the mains supply pressu...

Page 75: ...11 BURNERS 11 1 RDB Burner 11 2 Oil Pump The burner is supplied for use with a one pipe system For use on a two pipe system it is necessary to remove the return port plug and fit a small by pass plug...

Page 76: ...has its own 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 A...

Page 77: ...rmflow or OFTEC trained and registered technician and the commissioning certificate of the OFTEC Boiler Passport completed and returned to Warmflow within 30 days from the date of installation and 90...

Page 78: ...Page 76 13 BURNER FAULT FINDING 13 1 Riello RDB...

Page 79: ...Page 77 14 COMBI FAULT FINDING 14 1 Central Heating...

Page 80: ...Page 78 14 2 Domestic Hot Water...

Page 81: ...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 differe...

Page 82: ...CH2 CH CH1 HW CH2 PERIOD 1 ON 06 30 06 30 07 30 07 30 PERIOD 1 OFF 08 30 08 30 10 30 10 30 PERIOD 2 ON 12 00 12 00 12 00 12 00 PERIOD 2 OFF 14 00 14 00 14 00 14 00 PERIOD 3 ON 16 30 16 30 16 30 16 30...

Page 83: ...10 30 10 30 PERIOD 2 ON 16 30 16 30 16 30 16 30 PERIOD 2 OFF 22 30 22 30 22 30 22 30 Set Day Programme Period 3 On Off Switching Mon Fri Time Schedule Sat Sun Time Schedule CH CH1 HW CH2 CH CH1 HW CH...

Page 84: ...ADV and the AUTO will stop flash 15 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 key...

Page 85: ...Assembly 9 3008839 Air Damper Assembly 10 3005788 Fan 11 3008646 PE Cell 12 3002837 Capacitor 4 5 F 13 3007871 Needle Valve 14 20032135 Regulator No CODE 3514157 3514257 3514557 DESCRIPTION 15 300887...

Page 86: ...Air Damper Assembly 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 300572...

Page 87: ...odels KP70HE KP90HE KP120HE KS70HE KS90HE KS120HE 150HE Pumped Models UP150HE KP150HE From Boiler to Pump 22mm 3017 Pump Flow Pipe 22mm 3015 Expansion Vessel Pressure Hose 3020 From Boiler to Pump 22m...

Page 88: ...lve to Pump 3098 Ch Flow from Pump 3100 From Plate Heat Exchanger to Boiler Return 3096 Expansion Vessel Pressure Hose 3020 From Heat Store to Plate Heat Exchanger 1997 From Flowswitch to Mixing Valve...

Page 89: ...Valve Pressure Relief Valve Filling Loop Pressure Gauge Mixer Valve PCB Controller MK4 12 Litre Pressure Vessel Single Pole Relay Base Dual Safe Thermostat for Non Combi Models Optional Programmer fo...

Page 90: ...nd serviced in accordance with the installation instructions supplied with the boiler Additionally The Boiler Passport must be fully completed and the commissioning certificate returned to Warmflow wi...

Page 91: ......

Page 92: ...accurate at the date of printing E OE but will be superseded and should be disregarded if specifications and or appearances are changed in the interests of continued product improvement CODE 3307 ISS...

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