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Boiler Manual

Incorporating:

Guarantee Registration

User Instructions

Installation Instructions

Service Instructions

Service Record

High Efficiency

Condensing Boilers

For use with kerosene 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

Kabin Pak

K70HE

K90HE

K120HE

K150HE

Kabin Pak Pumped

KP70HE

KP90HE

KP120HE

KP150HE

Kabin Pak System

KS70HE

KS90HE

KS120HE

Kabin Pak Combi

KC70HE

KC90HE

Leave this manuaL with the end user

Содержание Utility U70HE

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 76: ...Page 74 Notes...

Страница 77: ...Page 75 Notes...

Страница 78: ...Page 76 Notes...

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

Страница 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...

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