WarmFlow U Series User manual

Boiler Manual
Incorporating: Guarantee Registration
User Instructions
Installation Instructions
Service Instructions
Service Record
High Efficiency
Condensing Boilers
Models covered by this manual:
U-Series
Utility U70HE U90HE U120HE
Utility Pumped UP70HE UP90HE
Utility System US70HE US90HE
Utility Combi UC70HE UC90HE
K-Series
Kabin Pak K70HE K90HE K120HE
Kabin Pak Pumped KP70HE KP90HE
Kabin Pak System KS70HE KS90HE
Kabin Pak Combi KC70HE KC90HE
Leave this manuaL with the end user

Commissioning
This appliance must be commissioned. Failure to commission the
boiler will invalidate the warranty. After commissioning ensure that
the attached guarantee registration card is completed and returned.
Servicing
To ensure continued reliable operation and fuel economy
it is recommended that the boiler is serviced annually
by a Warmflow or an OFTEC registered technician.
NI Customers Only
Warmflow Engineering Service division (NI) provides an
excellent back-up service, operating a team of OFTEC trained
engineers who can meet all the servicing, commissioning
and breakdown requirements for your appliance.
Telephone: [phone]
Fax: [phone]
Email: service@warmflow.co.uk
Web: www.warmflow.co.uk
For Parts, Service Technical & Warranty Contact
Great Britain & N Ireland, Tel: [phone]
Republic of Ireland, Tel: [phone]
This manual is accurate at the date of printing (E&OE) but will be superseded and should be disregarded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
ISSUE 1
JAN 07
LISBURN
Lissue Industrial Estate, Moira Road,
Lisburn, Co Antrim, N Ireland, BT28 2RF
Tel: [phone]
Fax: [phone]
Email: sales@warmflow.co.uk
technical@warmflow.co.uk
service@warmflow.co.uk
MANCHESTER
144 Bradford Road,
Manchester, M40 7AS
Tel: [phone]
Fax: [phone]
Email: sales@warmflowgb.co.uk
technical@warmflowgb.co.uk
service@warmflowgb.co.uk

Page 1
Contents Page
User Instructions .....................................................................................................................................................................2
Condensing Boiler Installation Requirements ......................................................................................................................4
Condensing Combi Boiler Pre-Installation Requirements...................................................................................................5
1.0 General Information
1.1 Introduction .....................................................................................................................................................6
1.2 General Requirements.....................................................................................................................................6
1.3 Combi General Requirements..........................................................................................................................7
1.4 Baffle Positioning.............................................................................................................................................7
1.5 Components ...................................................................................................................................................8
2.0 Technical Details
2.1 Combi Sequence of Operation Flow Chart ....................................................................................................15
2.2 Dimensions ...................................................................................................................................................16
2.3 Flue Options, Components & Dimensions......................................................................................................18
2.4 Condensate Disposal ....................................................................................................................................21
2.5 Technical Data...............................................................................................................................................22
3.0 Electricity Supply & Wiring Details
3.1 Dual Immersion Thermostat...........................................................................................................................30
3.2 RDB Burner Control Box ...............................................................................................................................30
3.3 Combi Wiring Details .....................................................................................................................................31
3.4 Installation of a Combi Optional Programmer.................................................................................................34
3.5 Standard Timers for Combis..........................................................................................................................35
3.6 Standard/System Boiler Optional Programmer ..............................................................................................35
4.0 Oil Supply
4.1 One Pipe Gravity System...............................................................................................................................39
4.2 Two Pipe System...........................................................................................................................................40
4.3 De-aerator System ........................................................................................................................................40
4.4 One Pipe Lift System.....................................................................................................................................41
5.0 Flues
5.1 Installation of Balanced Flues.........................................................................................................................42
5.2 Conventional Flues ........................................................................................................................................44
5.3 Flue Terminal Positions ..................................................................................................................................44
6.0 Air Supply
6.1 Open Flue Boilers ..........................................................................................................................................46
6.2 Balanced Flue Boilers ....................................................................................................................................46
7.0 Installation Requirements
7.1 General Requirements...................................................................................................................................47
7.2 Sealed Systems ............................................................................................................................................48
7.3 Combi Domestic Hot Water...........................................................................................................................49
8.0 Burners
8.1 RDB Burner...................................................................................................................................................50
8.2 Oil Pump .......................................................................................................................................................50
8.3 Electrical Connections ...................................................................................................................................50
8.4 Electrode Setting...........................................................................................................................................51
8.5 Burner Start-Up Cycle ...................................................................................................................................51
8.6 Air Damper Adjustment .................................................................................................................................51
9.0 Commissioning & Servicing
9.1 Commissioning..............................................................................................................................................52
9.2 Servicing .......................................................................................................................................................52
10.0 Burner Fault Finding
10.1 Riello RDB.....................................................................................................................................................53
11.0 Combi Fault Finding
11.1 Central Heating .............................................................................................................................................54
11.2 Domestic Hot Water......................................................................................................................................55
12.0 Optional Boiler Mounted Digital Timer
12.1 Operational Instructions.................................................................................................................................56
13.0 Spares
13.1 RDB 2.2 Spares ............................................................................................................................................60
13.2 Pipe Spares...................................................................................................................................................61
13.3 Boiler Short Parts List....................................................................................................................................62
14.0 Guarantee Terms & Conditions...............................................................................................................................63
Commissioning/Service Record.............................................................................................................................64

Page 2
USER INSTRUCTIONS
Dual Thermostat
The radiator temperature is regulated via the
boiler control thermostat. The thermostat is user
adjustable from 55°C at its minimum setting (dial
‘0’) to 85°C at its maximum setting (dial ‘5’). In
order to provide an additional level of safety there
is a high limit thermostat which has a cut off point
of 110°C; this is factory set and is not adjustable.
If thermostat trips it needs to be reset manually.
High Limit Thermostat 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
reset button while the boiler is still 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 is a fault or there is no
fuel getting to the burner. The house holder should
only reset the burner twice in succession. If the
burner continues to lockout contact Warmflow or
your service engineer.
System Pressure – System & Combi Boilers
When the boiler is connected to a sealed system
the system pressure should be periodically
checked. The minimum pressure, as indicated by
the black needle, is 0.5 bar when the boiler is cold
and 2.5 bar when the boiler is at normal operating
temperature. If the pressure is outside this range
contact Warmflow or your installer.
Control Thermostat
High
Limit
Reset
Reset
Burner Lock Out Reset
System Pressure

Page 3
Filling Loop
If the system pressure falls below the minimum
(eg, removal of radiator for decorating purposes)
then the system should be topped up using the
filling loop valve. After the system has been topped
up the pressure gauge should read 1 bar when
the system is cold. The valve must be fully closed
and the filling loop flexible removed from the valve,
expect a small water loss from the pipe.
Combi Control Panel
The heating control thermostat is user adjustable
from 55°C to 85°C. In order to provide an
additional level of safety there is a high limit
thermostat 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 panel is fitted with two on/off
selector switches to control hot water and central
heating. These switches can be replaced by the optional two channel digital
programmer, instructions for use are provided in the main boiler handbook.
This boiler must be serviced annually. Contact Warmflow for further
details.
In the event of a breakdown please contact your commissioning engineer
who should then contact our service department whilst at your home, to
report the fault.
High Limit
Reset Button
Underneath
Filling
Loop
Valve
Flexible
Filling
Loop
Hose
Control Thermostat Knob

Page 4
CONDENSING BOILER INSTALLATION
REQUIREMENTS
The Warmflow condensing boiler can be fitted to most installations using
standard practices and techniques.
There are however a number of considerations that must be taken into
account.
1. All existing systems must be properly flushed to remove any sediment/
sludge in order to prevent any blockage or reduction in efficiency of the
boiler.
2. The system must be fully pumped.
3. The primary difference between an ordinary boiler and a condensing
boiler is the condensate drain. The drain can be plumbed from the
condensate trap in any 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 blocked flueways.
Where the boiler is fitted into a basement a condensate pump may be
required.
4. As an indicator of the increased efficiency of a condensing boiler there
may be a visible plume of ‘steam’ from the flue. Care needs to be
exercised when positioning the appliance and selecting the type of flue
to ensure that the plume does not cause a nuisance to the householder
or to surrounding properties.
As the water temperature in the system rises the pluming effect will
diminish. Even where pluming is not visible the boiler is still operating
more efficiently than a standard boiler.

Page 5
BEFORE FITTING A COMBI BOILER
THE INSTALLER MUST CHECK:
1. What the maximum hot water demand is likely to be placed on the
boiler. Not every installation is suitable for a Combi boiler. Systems
requiring very high hot water flow rates may be better suited with an
unvented cylinder.
2. That the mains are capable of supplying up to 24 litre/min with a
minimum dynamic pressure of 1.8 bar at the boiler. This is to ensure
that the boiler can achieve its maximum output. To prevent excessive
flow rates ie greater than 24 litre/min it is recommended that a pressure
reducing valve is fitted to the incoming mains water supply, set at 2 bar.
3. Where the mains water pressure is supplied via a borehole pump and
accumulator the pressure variation must not affect the thermostatic
mixer valve. (Contact Warmflow for further details).
4. The hardness of the mains water supply. Systems with hard water must
be fitted with a suitable chemical scale preventer (eg Fernox Quantomat
or Combimate alternatively contact Warmflow for further details).
5. That the flow from 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 restrict the flow to these taps by reducing the bore of the
supply pipework (eg 15mm) or by fitting a restrictor into the pipework.
6. That any outlet when opened does not starve all the other outlets of hot
water. If more than one outlet is open at the same time then the total
flow from all the outlets should not exceed the maximum flow rate of
the boiler.
7. That any showers being supplied with hot water by the boiler are
compatible with this type of appliance (contact Warmflow for further
details).
It should be noted that the boiler has been factory fitted with an
18 litre/min flow restrictor.
The manufacturers guarantees are void if the appliance is not installed
and commissioned in accordance with the recommendations made
herein.

Page 6
1.0 General Information
1.1 Introduction
Note: All our domestic appliances have been independently tested and
accredited as exceeding the minimum SEDBUK efficiency levels required for
its type, in compliance with the Building Regulations Approved Document
L1A, L1B for England and Wales, the Building Standards (Scotland)
Regulations Section 6, Part F northern Ireland and Part L Republic of
Ireland.
Warmflow oil fired condensing boilers are designed to burn Class C2 (28 sec
redwood) kerosine and to be used on a fully pumped system, and are suitable for
connection to sealed heating systems.
As standard the Combi and System boilers are fitted with a system expansion
vessel, circulating pumps, filling loop, pressure gauge and safety valve. An optional
7-day electronic programmer kit is also available.
The Combi can provide at mains pressure domestic hot water without the need for
a storage 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 boiler must be in accordance with the following regulations.
BS5410 : PART 1 Code of practice for oil firing.
BS5449 : PART 1 Forced circulation hot water systems.
BS7593 : Treatment of water in domestic hot water central heating systems.
Current Building Regulations: Part J England and Wales
Section 3 Scotland
Part L Northern Ireland
Part J Republic of Ireland
Current IEE Regulations:
BS7074 : PART 1 Application Selection & Installation of Expansion Vessels
The heating system should be installed by a competent installer in accordance
with the recommendations laid down by HVCA, OFTEC and a sound engineering
practice.
In order to comply with GB building regulations OFTEC forms CD10 for
installations and CD11 for commissioning should be left with the customer,
alternatively the installation can be inspected and approved by a building
control officer. CD10 and CD11 forms are available from OFTEC on
Tel: [phone], Fax: [phone].

Page 7
1.3 Combi General Requirements
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
been satisfied the entire output of the boiler is 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 to
be satisfied.
After a draw-off of 120L at 24L/min, with an average temperature rise of 32°C, the
thermal store has a recovery time of approximately 7 mins.
Note: If HW has not been selected no hot water can be produced even if the heat
store is up to temperature.
1.3.1 Pump Over-Run
Where there is a build up of excess heat in the boiler primary heat exchanger and
the central heating has not been selected then the pump over-run thermostat
will operate. The excess heat will then be pumped into the heat store. Once the
temperature has fallen in the boiler and the pump over-run stat is satisfied or the
central heating pump starts to operate, then the hot water pump will stop.
1.4 Baffle Positioning
Before firing make sure the baffles have not been dislodged in transit. To achieve
maximum efficiency push the primary heat exchanger baffles in the direction of
the arrows as shown. The secondary heat exchanger spring baffles must be fully
inserted into the heat exchanger tubes (narrow end first).

Page 8
1.5 Components
1.5.1 U-Series Utility – Casing Components
1. Boiler Assembly
2. Top Casing (removable)
3. Rear Casing
4. Side Casing
5. Front Casing (removable)
1.5.2 U-Series Utility – Pre-Wired (UHE) – Key Components
1. Heat Exchanger
2. Condensing Unit
3. Auto Air Vent
4. Service Door
5. ‘Dual-Safe’ Thermostat
6. Heat Exchanger Baffles
7. Service Door
8. Service Door Cover
9. Condensate Trap
10. Riello RDB 2.2 Burner
11. Heating Flow Connection
12. Heating Return Connection
1
2
3
45
1
2
12
4
5
6
7
8
9
11
3
10

Page 9
1.5.3 U-Series Utility – Pumped (UPHE) – Key Components
1. Heat Exchanger
2. Condensing Unit
3. Pipework Assembly
4. Pressure Relief Valve
5. Auto Air Vent
6. Circulating Pump
7. Auto Air Vent
8. Service Door
9. ‘Dual-Safe’ Thermostat
10. Heat Exchanger Baffles
11. Service Door
12. Service Door Cover
13. Condensate Trap
14. Riello RDB 2.2 Burner
15. Heating Flow Connection
16. Heating Return Connection
1.5.4 U-Series Utility – System (USHE) – Key Components
1. Pumped (UPHE) Boiler Assembly
2. System Kit (SK1)
3. Pressure Gauge
4. Expansion Vessel
5. Filling Loop
6. Heating Flow Connection
7. Heating Return Connection
1
11
12
10
2
8
9
16
4
6
5
15
13
14
7
3
1
6
7
3
4
2
5

Page 10
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 Head Pump
8. Condensate Trap
9. Service Door
10. Service Door Cover
11. Control Panel
12. Expansion Vessel
13. Riello RDB 2.2 Burner
14. Heat Exchanger Baffles
(see dimension drawing
for details of connections)
1.5.6 U-Series Utility – Combi (UCHE) – Control Panel
Control
Thermostat
Mains On
Lamp (Green)
High Limit Tripped
Lamp (Yellow)
Burner Lockout
Lamp (Red)
HW On/Off
Switch
CW On/Off
Switch
High Limit Thermostat Reset
(Underneath)
1
2
3
4
5
6
7
8
9
10
11
1213
14

Page 11
1.5.7 K-Series Kabin Pak – Casing Components
1. Boiler Assembly
2. Top Casing (removable)
3. Flue Assembly (removable)
4. Rear Flue Casing
5. Blanking Plug (removable)
6. Rear Casing (removable)
7. Side Casing
8. Front Casing (removable)
1
2
3
4
5
6
7
8

Page 12
1.5.8 K-Series Kabin Pak – Pre-Wired (KHE) – Key Components
1. Heat Exchanger
2. Condensing Unit
3. Auto Air Vent
4. Service Door
5. ‘Dual-Safe’ Thermostat
6. Heat Exchanger Baffles
7. Service Door
8. Service Door Cover
9. Condensate Trap
10. Riello RDB 2.2 Burner
11. Heating Flow Connection
12. Heating Return Connection
1.5.9 K-Series Kabin Pak – Pumped (KPHE) – Key Components
1. Heat Exchanger
2. Condensing Unit
3. Pipework Assembly
4. Pressure Relief Valve
5. Auto Air Vent
6. Circulating Pump
7. Auto Air Vent
8. Service Door
9. ‘Dual-Safe’ Thermostat
10. Heat Exchanger Baffles
11. Service Door
12. Service Door Cover
13. Condensate Trap
14. Riello RDB 2.2 Burner
15. Heating Flow Connection
16. Heating Return Connection
1
2
3
5
4
6
7
8
9
10
11
12
1
8 2
45
6
7
9
10
11
12
13
14
15
16
3

Page 13
1.5.10 K-Series Kabin Pak – System (KSHE) – Key Components
1. Pumped (KPHE) Boiler Assembly
2. System Kit (SK1)
3. Pressure Gauge
4. Expansion Vessel
5. Filling Loop
6. Heating Flow Connection
7. Heating Return Connection
1.5.11 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. Condensate Trap
9. Service Door
10. Service Door Cover
11. Control Panel
12. Expansion Vessel
13. Riello RDB 2.2 Burner
14. Heat Exchanger Baffles
(see dimension drawing
for details of connections)
6
7
4
2
3
5
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Page 14
1.5.12 K Series Kabin Pak – Combi (KCHE) – Control Panel
Control
Thermostat
Mains On
Lamp (Green)
High Limit Tripped
Lamp (Yellow)
Burner Lockout
Lamp (Red)
HW On/Off
Switch
CW On/Off
Switch
High Limit Thermostat Reset
(Underneath)

Page 15
2.0 Technical Details
2.1 Combi Sequence of Operation Flow Chart
Power
On
Timer Calling
For Heat
HW
Selected
Flow Switch
Closed
DHW Tank
Stat Satisfied
CH
Selected
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
Press
Reset Button
Press
Reset Button
Pump Overrun
Stat Satisfied
DHW Pump
Only Runs
YES
YES
YES
NO
YES
NO
YES
YES
YES
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES NO
NO
NO

Page 16
NMLKJHGFEDCBAMODEL
U~
UP~
US~
865 413 601 666 766 42 104 583 50 75 86 134 21
865 413 601 666 766 42 104 583 50 75 86 134 21
865 413 601 666 766 42 104 583 50 75 86 134 21
QPNMLKJHGFEDCBAMODEL R S
UC~ 596 865 601 766 134 207 390 841 817 840 845 74 115 167 205 310 666
2.2 Dimensions
2.2.1 U-Series Utility (UHE, UPHE & USHE Models)
2.2.2 U-Series Utility (UCHE Models)
1. Pressure Relief Discharge (15mm)
2. Heating Flow (22mm)
3. Domestic Hot Water (22mm)
4. Cold Water Mains (15mm)
5. Knock-Out for Heating
Return Connection

Page 17
2.2.3 K-Series Kabin Pak (KHE, KPHE & KSHE Models)
QPNMLKJHGFEDCBAMODEL
K~ 413 900 700 773 210 95 161 67 40 90 40 67 705 50 50
KP~ 413 900 700 773 210 95 161 67 40 90 40 67 705 50 50
KS~ 413 900 700 773 210 95 161 67 40 90 40 67 705 50 50
QPNMLKJHGFEDCBAMODEL R S
KC~ 600
2.2.4 K-Series Kabin Pak (KCHE Models)
900 700 772 210 95 161 67 40 90 40 67 705 50 50 396 209

Page 18
2.3 Flue Options, Components & Dimensions
2.3.1 HE Low Level Balanced Flue Kit (FBF)
Comprising the following four main components.