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  4. 120/150
  5. Installation & Servicing

WarmFlow 120/150 Installation & Servicing

Summary of 120/150

  • Page 1

    50/70 – 70/90 – 90/120 – 120/150 – 150/200 bluebird boilerhouse models, goldbird kitchen models & whitebird utility room models 50/90 front servicing boilers goldbird kitchen model whitebird utility room model 200/250 bluebird boilerhouse model 50/70 – 70/90 whitebird utility room system boiler 50/7...

  • Page 2: Commissioning

    Issue 6.2 jan ’04 commissioning *this appliance must be commissioned *failure to commission the boiler will invalidate the warranty. After commissioning ensure that the pre-paid warranty registration card is completed and returned. Servicing to ensure continued reliable operation and fuel economy it...

  • Page 3

    Contents page 1.0 user instructions ............................................................................................................................................................ 2 1.1 goldbird models ........................................................................................

  • Page 4: 1.0 User Instructions

    1.0 user instructions 1.1 goldbird models thermostat control the recommended minimum thermostat setting is 65 ° c. Below this ‘cold water corrosion’ is likely to occur which can reduce the life of the heat exchanger and is not covered by the boiler warranty. The boiler thermostat is adjustable from ...

  • Page 5

    1 flue 2 system pressure gauge 3 spare bsp connection (x2) 4 boiler limit thermostat 5 thermostat pocket 6 12l expansion vessel 7 heating return (x2) 1” bsp 8 drain cock 9 heating flow 10 automatic air vent 11 pressure relief discharge 12 isolation gate valve (x2) 13 grundfoss pump 14 pressure relie...

  • Page 6

    1.6 components 50/90 front servicing boiler insulation retainer boiler test point external door insulation burner reset button/ lock out lamp rdb burner optional air intake spigot side casing flue ring top casing thermostat pocket whitebird thermostat goldbird control panel baffles insulation shield...

  • Page 7

    1.8 baffles 1.8.1 top servicing boilers 50/70 (3 in number) 70/90 & 120/150 (8 in number) 90/120, 150/200, 300, 400 & 500 have a similar arrangement (12, 12, 12, 16 and 16 baffles respectively) front front 50/90 (4 in number) heavy baffle to the bottom note: before firing make sure the baffles have ...

  • Page 8

    2.0 introduction the boilers are fired by a pressure jet oil burner which is covered by the manufacturer’s parts and labour warranty valid for one year (from boiler date stamp). Optional extended guarantees covering parts and labour are also available (although not applicable to the republic of irel...

  • Page 9

    H a b j f d e c = = g k 3.0 dimensions 3.1 goldbird kitchen, whitebird and whitebird system utility room models (including front servicing boilers) j 127 127 127 127 127 output (kw) 14.6-20.5 20.5-26.4 26.4-35.2 35.2-44.0 44.0-58.6 a 865 865 865 1168 1168 b 413 413 595 495 495 c 599 599 599 785 785 ...

  • Page 10

    B m e l n q p a d c k f g h j r 3.3 industrial bluebird models 3.4 kabin pak the kabin pak comes factory fitted with a warmflow bluebird boiler and insulated low level flue kit complete with a terminal guard. An adaptor is available to allow the low level flue to be extended using standard twin wall...

  • Page 11

    P k a f d e g i h b l c j m n q j b h c = = d k l m a g f e x n 3.5 kabin pak back outlet model 50-70 70-90 j 85 85 a 892 892 b 732 732 c 636 636 d 156 156 e 191 191 f 554 554 g 138 138 h 85 85 k 137 137 l 554 554 m 50 50 n 188 188 3.6 slimline kabin pak when installing a slimline kabin pak against ...

  • Page 12

    3.7 flue options 3.7.1 ‘easy fit’ low level balanced flue the horizontal dimension can be increased up to an additional 1200mm using a combination of long extension pieces (600mm) and short extension pieces (300mm). 102 712 max 225 max 175 min 490 min Ø125 3.7.2 ‘easy fit’ high level balanced flue t...

  • Page 13

    3.7.4 easy fit vertical balanced flue (vbf) extension kits as required (packs c or d) pack e or f pack e or f a 175 min 225 max 900 min 1400 max pack a pack h pitched roof flashing (22" – 45" adjustable) pack b vbf terminal section extension kits (pack c or d) as required max 2 no pack d pack a 675m...

  • Page 14

    4.0 installation the boiler installation must be in compliance with bs 5410 and the building regulations. Failure to install and commission in accordance with the instructions contained within this booklet will invalidate the warranty. 4.1 service access 24” (600mm) clearance should be provided abov...

  • Page 15

    4.5 air vents on the system boiler an automatic air vent complete with its own check valve is fitted to the top of the boiler heat exchanger. It is recommended that an air vent is fitted at the highest point in the system. However where the pipework comes off the boiler and drops down an automatic a...

  • Page 16

    To burner from power supply (switched live) 5.0 electricity supply 220 – 240v. 1ph, 50 hz the boiler/burner and other external electrical equipment should be wired with heat resistant cable via a fused double pole isolating switch which should be fitted with a 5 amp fuse. The appliance must be effec...

  • Page 17

    5.3 control panel wiring (goldbird boilers) page 15.

  • Page 18

    5.4 r40 burner control box (g10 & g20s burners) m ~ 2 3 1 4 5 6 7 8 9 n l green/yellow brown remote lock-out if required blue fan housing brown blue black blue 50v white brown motor capacitor black solenoid coil control panel blanking plate blanking plate/ programmer bracket opitional programmer 5.5...

  • Page 19

    L n e pump 1 2 3 4 5 6 7 8 9 10 2 1 3 l n e 240v 50hz 10 way junction box v4073a mid position zone valve blue g/yellow white l641a cylinder stat c 2 1 t6360b room stat orange grey 5.6 system wiring diagrams – goldbird boilers with internal programmer note: bluebirds and whitebirds should be treated ...

  • Page 20

    N e l pump 1 2 3 4 5 6 7 8 9 10 2 1 3 l n e 240v 50hz 10 way junction box l641a cylinder stat 1 c 2 t6360b room stat grey grey blue orange orange brown blue brown g/yellow g/yellow motor motor v4043h zone valve dhw v4043h zone valve htg 5.6.2 honeywell ‘s’ plan – independant ch&dhw (fully pumped) no...

  • Page 21

    6.0 technical data 6.1 domestic bluebirds, whitebirds and goldbirds model output range kw range setting nominal heat kw input btu nominal heat kw output btu bur ner head flue siz e m m dia in nfgt (max output) ° c max co 2 % smok e bacar ach nozzle mak e (k erosine) siz e pump bar pressure psi nozzl...

  • Page 22

    Model output range kw range setting nominal heat kw input btu nominal heat kw output btu burner f head position flue size mm dia in nfgt (max output) ° c co 2 % smoke bacarach nozzle make (kerosine) size pump bar pressure psi nozzle make (gas oil) size pump bar pressure psi approx fuel l/h flow rate...

  • Page 23

    6.2 industrial bluebirds 2.5 10 145 danfoss 60 ° s model output range kw nominal heat kw input btu nominal heat kw output btu burner head flue size mm dia in nfgt (max output) ° c co 2 smoke bacarach nozzle make (kerosine) size pump bar pressure psi nozzle make (gas oil) size pump bar pressure psi a...

  • Page 24

    7.0 air supply for combustion and ventilation (see bs 5410) 7.1 open flue boilers when the boiler is sited in a 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 7.2 balanced fl...

  • Page 25

    8.0 flues 8.1 conventional flues the flue should be designed in accordance with the local bye-laws and the clean air act. Draught stabilisers are not recommended for oil fired boilers. Sharp bends or horizontal runs should be avoided and the flue should terminate 2 feet (600mm) above the ridge of th...

  • Page 26

    Terminal position min distance a below gutters, soil pipes or drain pipes 1,000 b from a door, window or air vent 600 c above ground, flat roof or balcony level 600 d below eaves or balconies 1,000 e from an internal or external corner 600 f from a terminal facing the terminal 600 g from a surface f...

  • Page 27

    8.3 installation of flue air intake adapter spigot & gasket air intake cover riello rdb burner test hole plug flue gasket top panel optional flue dressing ring top panel blanking plate boiler lid conventional flue ring horizontal flue adapter optional extension pieces flue terminal easy fit balanced...

  • Page 28

    8.3.1 installation of a flue (bf-r, hlbf-r, vbf) 1. Make a suitable sized hole in the wall or ceiling for the flue kit. Add the dimensions given on pages 7 (dimension g) and 10 (flue vertical dimension). The cavities around the opening must be sealed and protected by a non-combustable sleeve. 2. Rem...

  • Page 29

    8.3.2 installation of high level balanced flue (hlbf) installation instructions as per the balanced flue except there are no seals involved as the flue is not telescopic. There are no extension pieces available for these units and only 2 rearward facing options are recommended for the 90/120 range o...

  • Page 30

    Front casing control thermostat boiler door left hand side casing top casing right hand side casing rear casing 9.2 installation of industrial bluebird casings remove the boiler door (8 bolts) and place the 2 side panels onto the boiler plinth locating the studs on the bottom edge of the casing into...

  • Page 31

    9.4 kabin pak installations 1. Although the standard and slimline kabin paks are manufactured from galvanised steel, it is recommended that after a period of weathering (approx 4-8 weeks) that the kabin pak is painted with a suitable primer and finish coat to prevent corrosion. 2. When using the kab...

  • Page 32

    9.6 fitting a standard kabin pak vertical flue adaptor 1. Remove the 2 screws connecting the flue main body to the kabin pak and lift off. It may be necessary to break the seal between the flue main body and the top of the flue pipe. 2. Ensure that the gap between the existing flue pipe and top of t...

  • Page 33

    9.8 fitting a slimline kabin pak vertical flue adaptor remove the flue terminal (4 screws) and fit the adaptor as shown (4 screws). Flue terminal vertical flue adaptor note: where there is a possibility of air being trapped in the boiler the installer must ensure that the automatic air vent is fitte...

  • Page 34

    10.0 oil supply 1. Oil tank steel tanks constructed to bs 799 part 5 1987 should be painted on the outside only and mounted on piers to prevent corrosion. Plastic oil tanks are also available and can be suitable for installation at ground level. However, kerosine should never be stored in translucen...

  • Page 35

    0.5 35 100 0.5 30 100 1 25 100 1.5 20 90 i.D. 8 mm i.D. 10 mm lift h (m) total maximum pipe length (m) 2 15 70 3 8 30 3.5 6 20 10.2 two pipe system 10.3 de-aerator system for maximum pipe length and lift contact de-aerator manufacturer. De-aerator may be above or below burner and must be positioned ...

  • Page 36

    10.4 one pipe lift 20mm per metre slope approved site gauge water separator 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 1.5 20 90 2 15 70 3 8 30 3.5...

  • Page 37

    11.0 burners 11.1 rdb burner the burner is fitted with the correct nozzle and the pressure set. All that is further required before commissioning, is to connect the oil and electricity supply. 1. Pump 5. Air damper adjustment screw 2. Control box 6. Air tube connection (b/f) or inlet cover 3. Reset ...

  • Page 38

    11.3 g20s burner 11.4 oil supply (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 as shown. 1. Return line 6. Hydraulic jack with air-damper 2. Suction line 7. Combustion head adjus...

  • Page 39

    Attention before assembling or removing the nozzle, loosen the screw (a) and move the electrodes away from the nozzle. 11.7 burner start-up cycle 11.5 air damper adjustment the setting is purely indicative. Each installation however, has its own unpredictable working conditions: actual nozzle output...

  • Page 40

    12.0 servicing and commissioning 12.1 commissioning note: it is recommended that an oftec trained and registered technician should be used. It is the responsibility of the installer to ensure that the boiler is properly commissioned. See bs 5410. Failure to do so may invalidate the warranty. Combust...

  • Page 41

    13.0 horstmann 626 electronic programmer user instructions (goldbirds only) the 626 boiler mounted programmer is an electronic, 7 day central heating and hot water control; extremely reliable and easy to operate. Properly programmed it will help you save energy and create a comfortable environment i...

  • Page 42

    Setting the time of day press the set button so that the set indicator is pointing to the clock position on the front of the programmer. The day of the week indicator will now flash. Use the plus(+) or minus(-) buttons to move the day of the week indicator to the current day of the week. Numbers rel...

  • Page 43

    The display will now show ‘1 on’ and the first on time for that day will flash. Adjust the flashing time as required by using the (+) and (-) buttons then press enter. The display will now show ‘1 off’ and the first programmed off time for the day will flash. This can be altered in the same way as t...

  • Page 44

    Press the advance button once and release. The word advance will appear in the display. If the programmer was originally on it will now switch off and stay off until the next programmed on time. The opposite will apply if the programmer was originally off. In both cases the unit will then revert to ...

  • Page 45

    Programme selection the following programmes can be selected for either hot water by itself, central heating by itself or hot water and heating together. Auto when auto is selected the programmer will switch on and off according to the switching times held in the memory, i.E. Up to three on/off peri...

  • Page 46

    14.0 fault finding is there a supply voltage to terminal 12 in the control panel or to the control thermostat. Expect 240v ± 10%. Page 44.

  • Page 47

    15.0 spares 15.1 riello rdb burners 1&2 no code 3748357 3748557 3748757 description 1 3005787 • • • gasket 2 3006384 • • • flange 3 3008768 • cup-shaped head 3 3008724 • cup-shaped head 3 3008769 • cup-shaped head 4 3007513 • • • electrode assembly 5 3006552 • • • electrode bracket 6 3008642 • • • n...

  • Page 48

    No code 3748950 3748850 description 1 3005795 • • gasket 2 3008637 • • flange 3 3006392 • end ring and diffuser disc 4 3006151 • blast tube assembly 5 3008538 • electrode assembly 6 3006552 • • electrode bracket 7 3008954 • nozzle holder 8 3008956 • high voltage lead 9 3008957 • • collar 10 3008876 ...

  • Page 49

    15.3 burner spares riello 40 – g10 no code description 1 3000879 air shutter assembly 2 3006913 tube 3 3005788 fan 4 3005798 condenser 5 3007355 motor 6 3007077 washer 7 3007450 pump 8 3002279 coil 9 3006553 cover 10 3007028 ‘o’ ring 11 3007162 ‘o’ ring 12 3005719 filter 13 3006925 valve stem 14 300...

  • Page 50

    15.4 riello 40 – g20s no code description 1 3005799 fan 2 3007156 ‘o’ ring 3 3007028 ‘o’ ring 4 3005801 washer 5 3005800 tube 6 3005802 condenser 7 3007077 washer 8 3005771 pivot 9 3005803 washer 10 3005804 pivot 11 3007079 washer 12 3005805 connector 13 3007162 ‘o’ ring 14 3005719 filter 15 3006925...

  • Page 51

    15.5 boiler parts list code dual immersion thermostat (bluebird, whitebird, kabin pak boilers) wds1 dual immersion thermostat (system boilers) wds2 boiler control thermostat (goldbird) 2131 boiler limit thermostat (goldbird) 281 automatic air vent c/w check valve 614 drain cock 618 pressure relief v...

  • Page 52: For Parts, Service

    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 992 cert. No. Fm 29884 iso 9001/2002 web: www.Warmflowboilers.Co.Uk for parts, service tech...