WarmFlow COMBI 70 Service Manual

INSTALLATION & SERVICINGMANUAL FOR70/90COMBI BOILER&70/90KABIN PAK COMBILEAVE THESE INSTRUCTIONS WITH THE END USERNATIONALACCREDITATIONOF CERT

2.2 BafflesFRONTBefore firing make sure the baffles have not been dislodged in transit and are correctlypositioned. To achieve maximum efficiency push

180458000813016201310460820REAR VIEW2 3 4562.4 Dimensions2.4.1 Combi Dimensions2.4.2 Combi Boiler ConnectionsAll dimensions are given in mm.1. Cold Ma

2.4.3 Kabin Pak Combi DimensionsMODEL70/90J371A892B732C636D373E188F191G376H172102712 MAX225 MAX175 MIN490 MINØ1252.5 Combi Flue Options (not applicabl

2.5.2 ‘Easy Fit’ High Level Balanced Flue (HLBF)The HLBF is available in 4 fixed horizontal lengths which are:Option 1 – 455mmOption 2 – 655mmOption 3

2.5.5 Easy Fit Telescopic High Level Balanced Flue (HLBF-R)2.5.6 Easy Fit Vertical Balanced Flue (VBF)EXTENSION KITSAS REQUIRED(PACKS C OR D)PA CK E O

2.6 Technical DataModelNominal heat KWInput Btu/hrNominal heat KWOutput Btu/hrEfficiency at max output (net) %BurnerHeadFlue mmSize inMax CO2%SmokeFGT

3.0 Electricity Supply220 - 240V. 1PH, 50 HzThe boiler/burner and other external electrical equipment should be wired via a fuseddouble pole isolating

3.3 Combi Wiring Details3.3.1 Wiring DiagramP– PurpleO– OrangeY– YellowR– RedW– WhiteBR – BrownBL – BlueB– BlackG/Y – Green/YellowPage 15

3.3.2 Combi Wiring SchematicBREAK INTO THE WHITEWIRE BETWEEN NO 16 ONTHE PCB AND THE LIMITSTAT AND CONNECT IN THEPRESSURE SWITCH WITH AWIRING BLOCK AS

3.4 Kabin Pak Combi Wiring Details3.4.1 Kabin Pak Combi Wiring DiagramP– PurpleO– OrangeY– YellowR– RedW– WhiteBR – BrownBL – BlueB– BlackG/Y – Green/

ISSUE 4MAR ’03SERVICINGTo ensure continued reliable operation andfuel economy it is recommended that theboiler is serviced annually.Warmflow Engineeri

3.4.2 Kabin Pak Combi Wiring SchematicBREAK INTO THE WHITEWIRE BETWEEN NO 16 ONTHE PCB AND THE LIMITSTAT AND CONNECT IN THEPRESSURE SWITCH WITH AWIRIN

3.5 Frost Thermostats3.5.1 Combi BoilersThe switched live from the frost thermostat (the frost thermostat must be supplied by apermanent live) should

3.6 Timers for Standard CombiNote: Single channel timers or programmers are not recommended.3.6.1 Installation of a remote two channel programmer (opt

3.6.3 Installation of Warmflow Optional Programmer (not applicable to the Kabin PakCombi)1. Disconnect the electrical supply.2. Remove top casing (4 s

3.7 Timers for Kabin Pak CombisNote: Single channel timers or programmers are not recommended.3.7.1 Installation of a Remote Two Channel ProgrammerONO

4.0 Oil Supply1. Oil TankSteel tanks constructed to BS 799 Part 5 1987 should be painted on the outside onlyand mounted on piers to prevent corrosion.

0.5351000.5301001251001.52090I.D.8 mmI.D.10 mmLift H(m)Total Maximum Pipe Length (m)2157038303.56204.2 Two Pipe System4.3 De-aerator SystemFor maximum

4.4 One Pipe Lift20mm PER METRE SLOPEAPPROVEDSITE GAUGEWATERSEPARATORNote: The pump vacuum shouldnot exceed a maximum of 0.4 bar.Above this gas is rel

5.0 Flues5.1 Conventional FluesThe flue should be designed inaccordance with the local bye-lawsand the Clean Air Act. Draughtstabilisers are not recom

Terminal Position Min DistanceA Below gutters, soil pipes or drain pipes 1000B From a door, window or air vent 600C Above ground, flat roof or balcony

BEFORE FITTING THIS BOILER THEINSTALLER MUST CHECK:1. What the maximum hot water demand is likely to be placed onthe boiler. Not every installation is

6.0 Air Supply for Combustion and Ventilation(see BS 5410)6.1 Open Flue BoilersWhen the boiler is sited in a cellar where the only access for combusti

6.3 Installation of FluesOPTIONALEXTENSION PIECESEasy Fit VerticalBalancedFlue (VBF)Easy Fit HighLevel BalancedFlue (HLBF)Standard LowLevel Convention

6.3.1 Installation of a Balanced Flue (BF-R, HLBF-R & VBF)1. Make a suitable sized hole in the wall or ceiling for the flue kit. Add the dimension

6.3.2 Installation of Telescopic Low Level Conventional FlueInstallation instructions as per the balanced flue except there is only an inner seal, the

8.0 InstallationThe boiler installation must be in compliance with BS 5410 Part 1 1997 and the BuildingRegulations.8.1 HearthThe boiler hearth tempera

8.3.4 Boiler ConnectionsAll connections to the appliance should be made with compression fittings.8.3.5 Additional Requirements for a Kabin Pak Combi1

8.4 Domestic Hot WaterThe mains water supply pressure must be less than 5 bar. If this pressure is exceededa pressure reducing valve must be fitted. T

8.6 Fitting a Vertical Flue Adaptor1. Remove the 2 self tappers connecting the flue main body to the Kabin Pak and lift off.It may be necessary to bre

9.0 Burners9.1 RDB BurnerThe burner is fitted with the correct nozzle and the pressure set. All that is furtherrequired before commissioning, is to co

AttentionBefore assembling or removing the nozzle,loosen the screw (A) and move the electrodesaway from the nozzle.9.3 Electrical ConnectionsThe boile

Contents Page1.0 User Instructions ... 3

10.0 Commissioning and Servicing10.1 CommissioningNote:IT IS RECOMMENDED THAT AN OFTEC TRAINED AND REGISTERED TECHNICIANSHOULD BE USED.IT IS THE RESPO

P123456LNHEATING SUPPLYWATERGHORSTMANN TIMERS & CONTROLS Ltd:NEWBRIDGE ROAD, BATH.626 OEM - WARMFLOW220-250V 50Hz 5(2)A T.5511.0 Horstmann 62

Setting the Time of DayPress the SET button so that the SET indicator is pointing tothe CLOCK position on the front of the programmer. The DAYOF THE W

Adjust the flashing time as required by using the (+) AND (-)BUTTONS THEN PRESS ENTER.The display will now show ‘1 OFF’ and the first programmedOFF ti

1. Hot water ON indicator.2. Central heating ON indicator.3. Advance button.4. Hot water programme select button.5. Central heating programme select b

Using the AdvanceThe ADVANCE facility allows you to bring forward the next ONor OFF period without having to alter the programmed ON/OFF times.Press t

12.0 Fault Finding12.1 Central HeatingNOSwitch on power,set selectors forCH on and DHWoff.Set all controls tocall for heat.Does the burnerfire?Is lock

12.2 Domestic Hot WaterSwitch on power, setselectors to CH off andDHW on.Is DHW pump working?Is there continuityacross connection 20and 21 on the PCB?

Does burner motor start?YESNOSTARTSwitch on electricity supply. Set all boilercontrols and external controls to call for heat.Burner operating satisfa

13.0 Spares13.1 Riello RDB BurnerNO CODE 3748757 DESCRIPTION16 3008654 • Pump17 3007162 • ‘O’ Ring18 3008653 • Filter ‘O’ Ring19 3003602 • Connector20

1.0 User Instructions1.0.1 Boiler Control ThermostatThe boiler control thermostat is located on the front of the boiler facia panel and maybe adjusted

13.2 Pipe SparesCH Pump to BoilerFlexible Pipe 2056Plate Heat Exchanger to BoilerFlexible Pipe 2057Boiler to Pressure VesselFlexible Pipe 2056Flow Swi

13.3 Short Parts ListPart Description CodeFlow Switch 1476Tank & Boiler Control Thermostat 2131Boiler Limit Thermostat 281Tank Limit Thermostat 21

This manual is accurate at the date of printing but will be superseded and should be disregarded if specificationsand/or appearances are changed in th

1.1 IntroductionNote: All our domestic appliances have been independently tested and accreditedas exceeding the minimum SEDBUK efficiency levels requi

1234567891011121314151617181.3 Components1.3.1 Combi Assembly1. Automatic Air Vents2. Boiler Heat Exchanger3. Boiler Control and Limit Stat4. 12 Litre

1234567891011 12 13 16 17 1820192221242314 151.3.3 Kabin Combi Assembly1. Flue Terminal Guard2. Low Level Flue3. Service Access Hatch4. Control Panel

2.0 Technical Details2.1 Sequence of Operation Flow ChartYESNOYESDHWTank StatSatisfiedFlowSwitchClosedTimerCalling ForHeatPowerOnDHWPump OnlyRunsHWLim