Halstead Eden CBX, Eden SBX Installation And Servicing Instructions

EDEN X TYPE
COMBINATION AND SEALED SYSTEM CONDENSING BOILERS
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE GIVEN TO THE USER
CBX 24, 32 & 38
SBX 30
0086
G.C. Appliance No. 47-260-05 (Eden CBX 24) G.C. Appliance No. 47-260-04 (Eden CBX 32) G.C. Appliance No. 47-260-14 (Eden CBX 38)
G.C. Appliance No. 41-260-13 (Eden SBX 30) G.C. Appliance No. 47-260-07 (Eden CBX 24 Propane) G.C. Appliance No. 47-260-06 (Eden CBX 32 Propane) G.C. Appliance No. 47-260-15 (Eden CBX 38 Propane) G.C. Appliance No. 41-260-16 (Eden SBX 30 Propane)
CNTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 2
2.1 Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Overall Dimensions & Minimum Clearances . . . . . . . . . . . . . . . . . 4
2.5 Concentric Air / Flue Duct Specifications . . . . . . . . . . . . . . . . . . . 4
2.6 Specification for Open Flued B33 Applications . . . . . . . . . . . . . . . 6
2.7 Specification for Twin Flued (Type C53) Applications . . . . . . . . . . . 7
2.8 Additional Concentric Flue Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.9 Appliance Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . 10
3.1 Statutory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Appliance Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Flue Terminal Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Central Heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.8 Domestic Hot Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.9 Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.10 External Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 APPLIANCE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 15
4.1 Unpacking The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.2 Preparing The Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.3 Mounting The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.4 Central Heating & Domestic Hot Water Service Connections . . . . .16
4.5 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Condensate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Pressure Relief Valve Connection . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Air / Flue Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.9 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.10 Optional Cylinder/Tank Temperature Sensor
(SBX Appliances Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.1 Filling the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5.2 Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.3 DHW Flow Rate (Cbx Appliances Only) . . . . . . . . . . . . . . . . . . . 21
5.4 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.5 Location Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.6 Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.7 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5.8 Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.9 Users Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.10 Appliance Log Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.11 Gas Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 ROUTINE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Combustion Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Gas Control Valve, Fan & Burner Assembly . . . . . . . . . . . . . . . . . 23
6.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.4 Ignition & Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.5 Combustion Chamber & Heat Exchanger . . . . . . . . . . . . . . . . . . 25
6.6 Condensate Drain
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 Domestic Cold Water Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.8 Sealed Water System
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.9 Re-assembly & Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . 26
6.10 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 INTERNAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . 27
7.1 Functional Flow Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 27
8 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.2 Diagnostic LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.3 Faulting Finding Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
8.4 Domestic Hot Water Fault Finding . . . . . . . . . . . . . . . . . . . . . . . 28
8.5 Central Heating Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . 28
9 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . 30
9.1 Ignition and Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . 30
9.2 Igniter Unit and Ignition Leads . . . . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 Gas Control Valve including Air Inlet Cowl . . . . . . . . . . . . . . . . . 31
9.4 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.6 Combustion Chamber Front Insulation . . . . . . . . . . . . . . . . . . . . . 33
9.7 Combustion Chamber Rear Insulation . . . . . . . . . . . . . . . . . . . . . 33
9.8 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.9 Flue Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.10 Pump (Head Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.11 Diverter Valve Motorised Head . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.12 Hydroblock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.13 Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.14 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.15 Water Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.16 Flue Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.17 Plate Heat Exchanger and Filter
(CBX Appliances Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.18 Condensate Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.19 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.20 Auto Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.21 Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.22 Time Clock (CBX Appliances Only) . . . . . . . . . . . . . . . . . . . . . . . 38
9.23 DHW Flow Turbine, Flow Regulator and Filter
(CBX Appliances Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
9.24 Draining The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Introduction
The Halstead, Eden CBX, and Eden SBX range are, high efficiency condensing, fully automatic, wall mounted gas appliances suitable for either room sealed or opened flued applications, for use with natural gas (G20), and LPG (G31). The Eden CBX combination appliances provide the user with both central heating (CH) and domestic hot water (DHW) on demand, with DHW pre-heat feature. The Eden SBX models are suitable for a sealed central heating system, with the facility to heat and control a hot water cylinder directly.
The appliances feature an attractive white stove enamelled casing, with inset control panels. The flue systems are in white stove enamel to give a clean attractive appearance to the installation.
A standard horizontal concentric air/flue duct terminal is available, (maximum duct length of 755 mm (29in)), suitable for room sealed applications. The duct assembly is connected to the appliance via a turret, which can be orientated to provide different horizontal duct directions. Extension ducts may be fitted in accordance with and up to the maximum dimensions stated in these instructions.
A vertical concentric outlet kit is also available for installations where an outside wall is not accessible or where it is desired to fit the duct 'through the roof'. Installation using the horizontal duct is described in the main text of these instructions and additional information is provided in the vertical outlet kit for the vertical installation option. (Note: If the vertical outlet kit is to be used, access to the roof is necessary).
Other flue kits are available for open flued (B
23
), split flued (C53),
and special (C
13
) applications, contact Halstead Boilers Ltd
Service Help Line: 08450 710780, for further details,
ONLY HALSTEAD APPROVED FLUE KITS OR EXTENSIONS MAY BE USED WITH THESE APPLIANCES.
CONTENTS INTRODUCTION
1
1
IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, (I.E. CORGI REGISTERED INSTALLERS) IN ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). FAILURE TO COMPLY WITH THESE REGULATIONS MAY LEAD TO PROSECUTION.
These appliances have been tested and certified in order to satisfy the necessary European Directives and comply with the latest Building Regulations, including the efficiency requirements of the SEDBUK scheme.
Gas Appliance Directive 90/396/EEC Efficiency of Hot Water Boilers Directive 92/42/EEC Low Voltage Directive 93/68/EEC Electromagnetic Compatibility Directive 92/31/EEC No modifications to these appliances should be made unless they
are fully approved by the manufacturer. Appliance installation must be carried out by a competent person
and must be in accordance with the current legislation in force at the time of installation, in the country of destination.
The manufacturer's instructions must not be taken as overriding any statutory requirements.
GAS LEAKS. DO NOT OPERATE ANY ELECTRICAL SWITCHES, OR USE A NAKED
FLAME. TURN OFF THE GAS SUPPLY. VENTILATE THE AREA BY OPENING DOORS AND WINDOWS. CALL OUT YOUR LOCAL GAS SUPPLIER.
Control of Substances Hazardous to Health
Under Section 6 of the Health and Safety at Work Act 1974, it is required to provide information on substances hazardous to health.
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
Insulation Pads - These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaints you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
Gas and Electricity Consumer Council (Energywatch)
Energywatch is an independent organisation, which protects the interests of gas users. If you need advice concerning energy issues, they may be contacted on their consumer help line number: 08459 060708, or via their web site;
http://www.energywatch.org.uk.
The appliances incorporate a microprocessor based, fully modulating air/gas ratio control system with direct burner ignition, which provides a modulated heat output to either central heating (CH) or domestic hot water (DHW) demands, and with internal frost protection provided as standard across the range. The heat exchanger is constructed from stainless steel.
A combined circulating pump, diverter valve and automatic air vent assembly, pressure gauge, safety valve and system expansion vessel are included. Isolation valves are fitted to the service connections. The CBX appliances have a DHW flow detection device, which gives priority to DHW demand and proportions the required heating load to the DHW flow rate, an electro­mechanical 24 hour time clock is also fitted as standard to the CBX appliances.
The appliances may be used with any certified mains voltage room thermostat, (or programmer/ room thermostat SBX appliances), and can operate without the need for an automatic bypass valve, however if thermostatic radiator valves are installed it is recommended that one radiator is fitted with lockshield valves, (normally in the bathroom), to allow the pump overrun facility to operate correctly. A separate CH expansion vessel is not required if the total CH system content is less than 84 litres, but one is required for systems with volumes greater than 84 litres; refer to section 3.7. A separate DHW expansion vessel is not required for the CBX appliances.
1.1
IMPORTANT INFORMATION
1.2
GENERAL DESCRIPTION
!
2
Eden CBX 38 Propane, Eden CBX 32 Propane, Eden CBX 24 Propane, Eden SBX 30 Propane:
II
2H3P
(G31 (Propane) with a regulated gas supply at 37 mbar
(14.9 in.wg) inlet pressure). The appliance classification (as defined in EN 483) may be any of
the following depending on the chosen flue option: C
13
, C33, C53,
or B
23
These appliances are certified to comply with the requirements of EN 483, EN 677, and EN 625 for use in GB and IE (Great Britain and Ireland) using the following gas categories:
Eden CBX 38, Eden CBX 32, Eden CBX 24, Eden SBX 30:
II
2H3P
(G20 with a governed gas supply at 20 mbar (8 in.wg) inlet
pressure).
TECHNICAL SPECIFICATIONS
2
2.1
GAS CATEGORIES
Appliance CBX38 CBX32 CBX24 SBX30 CBX38 CBX32 CBX24 SBX30
Propane Propane Propane Propane
Mode Rate Central Heating Output Max
kW 30.0 24.0 18.0 30.0 30.0 24.0 18.0 30.0
(non-condensing)
(Btu/h) (102400) (81900) (61400) (102400) (102400) (81900) (61400) (102400)
(80 - 60 °C) Min
kW 9.0 7.9 5.9 8.2 9.0 7.9 5.9 8.2
(Btu/h) (30700) (27000) (20100) (28000) (30700) (27000) (20100) (28000)
Central Heating Output
Max
kW 32.1 25.7 19.3 32.1 32.1 25.7 19.3 32.1
(condensing) (50 - 30 °C) (Btu/h) (109500) (87700) (65900) (109500) (109500) (87700) (65900) (109500)
Net
kW 30.6 24.5 18.4 30.4 30.6 24.5 18.4 30.4
Central Heating Input (Btu/h) (104440) (83600) (62800) (103700) (10440) (83600) (62800) (103700) Max Rate
Gross
kW 34.0 27.2 20.4 33.8 33.2 26.6 20.0 33.0
(Btu/h) (116000) (92800) (69600) (115300) (113400) (91000) (68300) (112700)
Net
kW 9.2 7.3 5.5 7.6 9.2 7.3 5.5 7.6|
Central Heating Input (Btu/h) (31400) (24900) (18800) (26000) (31400) (24900) (18800) (26000) Min Rate
Gross
kW 10.2 8.2 6.1 8.4 10.0 7.9 6.0 8.3
(Btu/h) (34800) (28000) (20800) (28600) (34000) (27000) (20500) (28300)
Max
kW 38.0 32.0 24.0 38.0 32.0 24.0
Domestic Hot Water Output
(Btu/h) (129600) (109200) (81900) (129600) (109200) (81900)
Min
kW 9.0 7.9 5.9 9.0 7.9 5.9
(Btu/h) (30700) (27000) (20100) (30700) (27000) (20100)
Net
kW 38.8 32.7 24.5 38.8 32.7 24.5
Domestic Hot Water Input (Btu/h) (132300) (111600) (83600) (132300) (111600) (83600) Max rate
Gross
kW 43.1 36.2 27.2 42.1 35.5 26.6
(Btu/h) (146900) (123500) (92800) (143600) (121000) (90800)
Net
kW 9.2 7.3 5.5 9.2 7.3 5.5
Domestic Hot Water Input (Btu/h) (31400) (24900) (18800) (31400) (24900) (18800) Min rate
Gross
kW 10.2 8.2 6.1 10.0 7.9 6.0
(Btu/h) (34800) (28000) (20800) (34000) (27000) (20500)
Central Heating Gas Rate
m3/h 3.24 2.59 1.95 3.22
(after 10 min operation - hot)
Max (ft3/h) (114.4) (91.5) (68.9) (113.7)
kg/h 2.2 1.9 1.43 2.36
Domestic Hot Water Gas Rate
m3/h 41.0 3.46 2.59
(after 10 min operation - hot)
Max (ft3/h) (144.8) (122.2) (91.5)
kg/h 2.8 2.55 1.9
Seasonal Efficiency % 90.2 90.8 90.2 90.4 92.3 92.2 92.2 92.4 Seasonal Efficiency (SEDBUK) Band “A” Nox Classification Class “5”
PERFORMANCE DATA
2.2
Appliance CBX38 CBX32 CBX24 SBX30 CBX38 CBX32 CBX24 SBX30
Propane Propane Propane Propane
Design Domestic Hot Water l/min 15.6 13.1 9.8 15.6 13.1 9.8 Performance raised 35 °C (gpm) (3.4) (2.8) (2.2) (3.4) (2.8) (2.2)
DHW Specific Rate (D) EN 625 l/min 18.1 15.3 11.5 18.1 15.3 11.5 Min Mains Water Inlet Pressure Bar 1.0 1.0
for Max Heat Output (psi) (14.5) (14.5) Min Mains Water Inlet Pressure Bar 0.1 0.1
for Operation (psi) (1.5) (1.5) Max Mains Water Inlet Pressure
Bar 10 10
(psi) (145) (145)
Min Domestic Hot Water Flow l/min 2.5 2.5 Rate for Operation (gpm) (0.5) (0.5)
Min Central Heating System Pressure
Bar 0.7
Max Central Heating System Pressure
Bar 2.5
Max Domestic Hot Water Temp. °C 60 60 Min Domestic Hot Water Temp. °C 40 40 Max Central Heating Flow Temp. °C 80 Min Central Heating Flow Temp. °C 30
3
Natural Gas and Propane versions
Appliance CBX38 CBX32 CBX24 SBX30 Total weight (full) kg 55.4 54.9 51.7 55.2 Total weight (empty) kg 52.8 52.8 49.9 52.8 Max lift weight kg 42.2 42.0 39.0 41.0 Total water capacity l 2.4 2.1 1.8 2.4 Integral expansion vessel capacity l8 Maximum heating system water content using
l84
fitted expansion vessel, @ 0.75 bar Electrical supply 230V 50Hz Fuse at 3A Internal fuse T4H 4A 250V Maximum power consumption W 148 IP Rating IP33 Flue gas temperature Nat Gas 80/60(Propane) °C 80 79 (77) 74 (72) 73 (76) Flue gas temperature Nat Gas 50/30 62 41 43 41
CO
2
value max rate (Nat Gas)
% 9.2 ± 0.3 case on
9.0 ± 0.2 case off
CO2value min rate (Nat Gas) ref only % 8.4 ± 0.3 8.9 ± 0.3 CO value max rate (Nat Gas) % 0.01 ± 0.005
CO
2
value max rate (Propane)
% 10.7 ± 0.3 case on
10.5 ± 0.2 case off
CO2value min rate (Propane) ref only % 9.7 ± 0.3 10.0± 0.3 CO value max rate (Propane) % 0.019 ± 0.005 Flue products mass flow rate (Nat Gas) g/s 17.4 14.7 11.0 13.7 Flue products mass flow rate (Propane) g/s 17.4 14.7 11.0 13.7 Gas Valve Offset @ min rate Pa -3.0
GENERAL SPECIFICATIONS
2.3
4
2.4
OVERALL DIMENSIONS AND MINIMUM CLEARANCES
1
200mm
200mm
366mm
760mm
455mm
914mm
150mm
97mm
228mm
100mm Ø
5mm
SEE NOTE
5mm
NOTE: 10mm for normal operation. 450mm for installation and servicing.
The EDEN 'x-type' range can be installed to a number of different concentric flue systems. The different flue applications as shown in Figure 2 are available as kits usually comprising the connecting parts to the appliance and end terminal. Flue extension ducts and extension elbows are available as accessories.
2.5
CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS
Connections
CBX32 CBX24 SBX30 CBX38
Gas 15 mm compression 22 mm compression CH flow 22 mm compression CH return 22 mm compression DHW inlet CBX appliance only 15 mm compression DHW outlet CBX appliance only 15 mm compression DHW return SBX appliance only 22 mm compression Pressure relief valve outlet 15 mm tail Condensate Drain 21.5 - 22 mm plastic overflow pipe
5
8
FLUE OPTIONS
Vertical flue kit - Part no. 956081
with flat roof flashing plate
Vertical flue kit - Part no. 956081
Flue system application
Vertical flue kit - Part no. 956081
Split pipe vertical flue outlet kit
- Part no. 956080
with flat roof flashing plate
Raised external flue outlet kit
- Part no. 956084
Chimney flue liner kit
- Part no. 956082
External vertical flue kit
- Part no. 956085
Telescopic horizontal flue kit
- Part no. 956120
The following systems are available for the EDEN ‘x-type’ range. For full fitting instructions refer to the leaflet supplied with the flue kit.
2
Traditional concentric flue system, Figure 3a, with a maximum length of 10m*. The flanged flue elbow is designed with 3° slope towards the appliance so that the condensate can easily drain off. It has to be considered that for every metre horizontal flue length the terminal exit centreline is approx. 45 mm higher than the elbow’s centreline. The standard telescopic terminal is 615mm max length and 430mm min length, but can be cut to a minimum flue length of 250mm, which is suitable for single, 100mm (4"), brick walls.
3a
TERMINAL (C13) - PART NO.956120
2.5.1
KIT A + TELESCOPIC HORIZONTAL WALL
* Note: Flues which exceed 7mtrs in length will be subject to a small percentage decrease in heat input (below the standard tolerance) as shown in graph ‘A’ on the following page.
TERMINAL (C33) - HBL PART 956081
2.5.2
KIT B VERTICAL CONCENTRIC FLUE
3b
Standard concentric (ø100/60) vertical flue application, Figures 3b, 3c, through roof attics with a maximum length of 12m*. The kit comprises of the roof terminal, vertical adaptor with sampling point and bracket. The maximum length is measured from the top of the appliance casing to the underside of the air cowl.
6
If the standard horizontal terminal is likely to cause nuisance to a neighbour or buildings, because of excess pluming, then this particular flue kit raises the flue gas outlet point to a higher elevation with the minimum amount of changes. The flue gas duct is teed-off from the concentric part and covered by an 80mm outer tube to protect the flue duct from freezing. The air in-take remains at the lower level (see Figure 3d).
If choosing this option then the external flue duct length should be taken into account when calculating equivalent flue length.
For installation details refer to the flue kit instructions.
FLUE KIT (C13) – PART NO. 956084
2.5.3
2.5.3 KIT C: HORIZONTAL ANTI-PLUME
Dimensions from vertical terminals to opening windows should be in line with Figure 5.
3c
Roof terminal with rain cover and pitched roof flashing kit.
b
a
Fig 3(c) Offset vertical flue.
‘a’ measured from boiler flue outlet centre line to the centre line of the extension elbow. ‘b’ measured from the top of the boiler to the underside of the air cowl. Maximum allowable length of a + b = 8900mm
P AR T NO: 956085
2.5.4
KIT D EXTERNAL VERTICAL FLUE - (C33)
3e
Suitable for installations if the appliance can’t be repositioned and where other horizontal flue options may cause some nuisance to neighbours or buildings. The flue kit contains some additional 45° elbows and extension ducts as well as a special wall bracket to pass the guttering (see Figure 3e). The concentric
3d
Horizontal flues (
C33) up to 10m in length, or equivalent, may be used, however a reduction in the heat input will occur. The graph shows details.
GRAPH A
102.0
101.0
100.0
99.0
98.0
97.0
96.0
95.0
94.0
93.0
92.0
01234567891011
Flue Length (m)
Heat input (%)
Reduction in heat input as flue length increases
77
Maximum flue resistive length = 30m.
3f
A flue system can be built up from the components detailed in the table, but the total flue resistance must not exceed the maximum stated.
flue will be routed vertically alongside the outside wall to above the roofline. Special seals are required to prevent rainwater penetrating the pipe joints. For installation details refer to the flue kit instructions.
This kit is suitable for open flue application in accordance with BS5440 where a room sealed flue installation is impractical. The kit comprises of a flue adaptor from the appliance to the chimney , a flexible plastic flue liner with connection parts and chimney terminal (see Figure 3f). Where an open flue system is used, then an air vent must be provided in the same room or internal space as the flue duct air inlet, see section 3.4.
For installation details refer to the flue kit instructions.
(B23) – PART NO. 956082
2.6
KIT E CHIMNEY FLUE LINER KIT
It has to be noted that the flue duct is under pressure when the appliance is in operation and the duct can leak poisonous carbon monoxide if the duct components are not correctly assembled. It is not recommended to route the flue duct through living space areas, i.e. bed rooms, living rooms etc.
For installation details refer to the instructions provided with the twin flued kit.
For C53 flue systems the terminal for the supply of combustion air and for the evacuation of combustion products shall not be installed on opposite walls of the building.
Maximum flue resistance permitted for a twin flued system = 52 Pa
Minimum flue resistance permitted for a twin flued system = 23.5 Pa
Flue Component Flue Resistance (Pa) Part Number
Twin Flue Adaptor (required) 9.5 ­Air Inlet Terminal (required) 3 ­Chimney Terminal (required) 0.5 ­80 mm dia straight duct 1 metre 1 956101 80 mm dia straight duct 2 metre 2 956102 90° Elbow (80/80) 8 956100 45° Elbow (80/80) 4 956099
3g
A flue system can be built up from the components detailed in the table, but the total flue resistance must not exceed the maximum stated.
PART NO. 956080
2.7
KIT F: TWIN FLUE SYSTEM (C53) –
This flue system kit is designed for installations where the air intake position is different than the flue duct exit point. The kit comprises of a twin adaptor from which the air intake is taken from the adjacent outside wall (see example Figure 3g) and the flue duct is routed vertically through the roof.
8
FLUE LENGTHS
Length supplied in standard kit - horizontal 815mm Max horizontal length
(from boiler to chimney - 60/100mm)
2000mm
Min horizontal length
(from boiler to chimney - 60/100mm)
100mm
Max vertical length
(from boiler to chimney - 60/100mm)
2000mm
Min vertical length
(from boiler to chimney - 60/100mm)
200mm
Length supplied in standard kit - vertical
(available in 10m, 20m and 30m length)
N/A
FLEXITUBE MUST BE PURCHASED AS AN ACCESSORY TO COMPLETE THE KIT
(See below)
Flexi tube min length 5m Flexi tube max length 30m
ACCESSORIES
Description Part No. Resistive Length
HORIZONTAL - 60/100 Accessories
Flue extension duct - 500mm 956092 450mm Flue extension duct - 1000mm (Incl. 1 x support bracket) 956093 950mm 93°extension elbow 956091 1550mm 45°extension elbow (pair) 956090 775mm Air inlet duct - included in kit N/A N/A Straight adapter (60/80) - included in kit N/A N/A
91.5°adapter elbow (80/80) - included in kit N/A N/A Support bracket - 100mm 840517 N/A 93°flanged elbow - included in kit 956082 N/A Vertical turret socket 956087 N/A
VERTICAL - Accessories
Flexi tube - 10m 956110 10m Flexi tube - 20m 956111 20m Flexi tube - 30m 956112 30m Straight duct (80) - included in kit N/A N/A Chimney terminal - included in kit N/A N/A
NOTE:
RESISTIVE LENGTH INFORMATION ONLY REQUIRED FOR COAXIAL FLUE PARTS. THE CORRUGATED (FLEXI TUBE) FLUE PARTS ARE FIXED AND ALL PARTS ARE REQUIRED FOR EVERY APPLICATION.
9
The following additional concentric kits are available as optional extras.
Flue Extension Ducts - 1000 mm and 500 mm long, (each duct extends the flue length by up to 950 mm and 450 mm respectively).
93° Extension Elbow - Allows an additional bend in the flue, and has an 'equivalent length' of 1550 mm. This elbow is mechanically different from the flanged elbow supplied as standard with the appliance, but has the same equivalent length.
45° Extension Elbow - Allows an additional bend in the flue and has an 'equivalent length' of 775 mm.
Vertical Turret Socket - For use with elevated horizontal flues and vertical terminals.
Vertical Roof Terminal - For use where an external wall is not available, or where it is desirable to route the ducts vertically.
For installation details refer to the instructions provided with the individual flue kits.
These optional kits may be used with the standard flue kits to produce an extensive range of flue options, providing that the following rules are strictly obeyed.
a) The maximum/minimum permissible length of the room sealed flue system are:
2.8
ADDITIONAL CONCENTRIC FLUE KITS
The 'equivalent' flue length must not exceed the maximum values stated.
Horizontal flue terminal (all orientations) maximum 10000 mm (394 in) Horizontal flue terminal (rear exit) minimum 250 mm (10 in) V ertical flue terminal maximum 12000 mm (472 in) V ertical flue terminal minimum 600 mm (23
1
/2 in)
Refer to Figures 2 and 3 to determine which option kits are required before commencing the installation. Instructions for installing the appliance with a horizontal flue and straight extension ducts are included in the main text of these instructions (section 4.8).
b) The standard terminal must always be fitted horizontally; horizontal ducts must have a continuous fall towards the appliance of 2.5°. This ensures condensate runs back into the appliance from the flue system. The vertical terminal must always be used if a vertical outlet is required.
c) The concentric flue system must use either a flanged elbow or a vertical flue turret socket at the entry/exit to the appliance.
d) All joints must be correctly made and secured in accordance with the installation instructions. When cutting ducts, avoid swarf, uneven and sharp edges to maintain duct integrity.
The resistance of the diverter is equivalent to 0.5 metre of flue length. Ensure this is used when calculating the maximum allowable flue length. (maximum horizontal flue length restricted to 4.5 metres when using the plume diverter).
Plume Diverter Kit Part No: 956103
(For use with Standard horizontal telescopic flue kit - Part no 956120 - only)
This kit is provided to assist in fitting a condensing boiler with reduced clearances when fitted in good practice according to the Guide to Condensing Boiler Installation published by DEFRA/HMSO.
This kit allows the boiler flue outlet to be directed to the left or to the right only.
Under certain operating conditions condensing appliances have a tendency to form a plume of water vapour at the terminal. Therefore consideration should be given when fitting the Plume Diverter in terms of plume dispersal onto adjacent surfaces and neighbouring properties.
a) Refer to section 2.5 for instructions on fitting the flue system.
Also see Figure 5 for all other clearances.
INSTALLATION
PLUME DIVERTER TERMINAL
INSTALLATION INSTRUCTIONS
2.8.1
3h
10
Note. The Plume Diver ter terminal must not under any circumstances deflect flue products downwards.
3i
The diverter allows the terminal clearance to be reduced as follows (see diagrams below):
Clearance H – From a surface facing the terminal - 600mm. Clearance F – From internal or external clearances - 300mm.
b) Choose the direction required to deflect the flue products (left or right only)
c) Push the diverter elbow onto the angled outlet of the flue
terminal in the desired rotational position and ensure the diverter is pushed up to the shoulder to fully engage the rubber seal.
d) Fix the diverter to the flue terminal with the self drilling screw provided. Do not use a power tool to fit screw.
2.9
APPLIANCE HYDRAULIC CIRCUITS
4a
Central Heating Mode (CBX)
4b
Domestic Hot Water Mode (CBX)
4c
Central Heating Mode (SBX)
11
12
INSTALLATION REQUIREMENTS
3
3.1
STATUTORY REQUIREMENTS
GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1996 (AS AMENDED)
The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.
In GB, a CORGI Registered Installer must carry out the installation. It must be carried out in accordance with the relevant requirements of the:
Gas Safety (Installation and Use) Regulations
The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).
The Water Fitting Regulations or W ater Byelaws in Scotland. The Current I.E.E Wiring Regulations.
Where no specific instructions are given, reference should be made to the relevant British Standard code of Practice.
In IE, the installation must be carried out by a Competent Person and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.
It should also be in accordance with the relevant recommendations in the current editions of the following British Standards and Codes of Practice: BS 5449, BS 5546, BS 5440-1, BS 5440-2, BS 6798, BS 6891, Institute of Gas Engineer document IGE/UP-7, BS 7074 (expansion vessel), BS 5482 (propane installations) and IS813 for IE.
IMPORTANT NOTE: Manufacturer's instruction must NOT be taken in any way as overriding statutory obligations.
3.3
FLUE TERMINAL POSITION
DETAILED RECOMMENDATIONS FOR FLUE INSTALLATION ARE GIVEN IN BS 5440-1. THE FOLLOWING NOTES ARE FOR GENERAL GUIDANCE.
a) The appliance MUST be installed so that the terminal is
exposed to the external air. b) It is important that the position of the terminal allows free
passage of air across it at all times. c) It is ESSENTIAL TO ENSURE that products of combustion
discharging from the terminal cannot re-enter the building or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation / air conditioning.
d) The minimum acceptable dimensions from the terminal to obstructions and ventilation openings are specified in Figure 6.
e) If the terminal discharges into a pathway or passageway check that combustion products will not cause nuisance and that the terminal will not obstruct the passageway.
f) Where the lowest part of the terminal is fitted less than 2000 mm (78 in) above the ground, above a balcony or above a flat roof to which people have access, the terminal MUST be protected by a purpose designed K6 terminal guard (optional extra: Part No. 951507).
g) The air inlet / flue outlet MUST NOT be closer than 25 mm (1 in) to combustible material.
h) Condensing appliances have a tendency to form a plume of water vapour at the terminal under certain operating conditions. This is normal but positions where this would cause damage or a nuisance should be avoided. Consideration should be given to the dispersal of the plume in terms of adjacent surfaces and neighbouring properties. A special flue terminal, (Kit C), is available to raise the flue discharge point; use of this terminal will limit the maximum flue length available. For further information contact: Halstead Boiler Ltd, Service Help Line: 08450 710780.
3.2
APPLIANCE LOCATION
THE FOLLOWING LIMITATIONS MUST BE OBSERVED WHEN SITING THE APPLIANCE:
a) The appliance is not suitable for external installations. The
position selected for installation should be within the building, unless otherwise protected by a suitable enclosure and MUST allow adequate space for installation, servicing and operation of the appliance and for air circulation around it (Section 2.4 and 3.4).
b) This position MUST allow for a suitable flue system and terminal position. The appliance must be installed on a flat vertical wall, which is capable of supporting the weight of the appliance and any ancillary equipment.
c) If the appliance is to be fitted in a timber framed building it should be fitted in accordance with the British Gas publication 'Guide for Gas Installations In Timber Frame Housing', Institute of Gas Engineers document IGE/UP-7. If in doubt, advice must be sought from the Local Gas Supplier.
d) The appliance is approved to a protection rating of IP33. Therefore if the appliance is to be installed in a room containing a bath or a shower, any electrical switch or control utilising mains electricity must be so situated that it cannot be touched by a person using the bath or shower. Attention is drawn to the requirements of the current BS 7671 (I.E.E Wiring Regulations)
and in Scotland the electrical provisions of the Building Regulations applicable in Scotland.
3.4
VENTILATION REQUIREMENTS
Detailed recommendations for air supply are given in BS 5440-2. The following notes are for general guidance.
a) It is not necessary to have a purpose provided air vent in the room or internal space in which a room-sealed appliance is installed.
b) Cupboard or compartment ventilation is not necessary for a room-sealed appliance providing that the minimum clearances are maintained.
c) Where an open flued, (B23), system is used, then an air vent must be provided in the same room or internal space as the flue duct air inlet, with a minimum free-area of at least:
CBX 38 159 cm
2
CBX 32 128.5 cm
2
CBX 24 87.5 cm
2
SBX 30 117 cm
2
13
5
FLUE TERMINAL POSITION
Position Minimum spacing
A Directly below an openable window, 300mm 12in
air vent, or any other ventilation opening
B Below gutter, drain/soil pipe 75mm 3in C Below eaves 200mm 8in D Below a balcony 200mm 8in
*2500mm 98in
E From vertical drain pipes and 150mm 6in
soil pipes
F From internal or external corners 300mm 12in
*internal corners *1000mm 40in
G Above adjacent ground or
balcony level 300mm 12in
H From a surface facing the terminal 600mm 24in
*2500mm 98in
I Facing terminals 1200mm 48in
*2500mm 98in
J From opening (door/window) in 1200mm 48in
carpo r t in to dw el li ng *not recommended
K Vertically from a terminal on the 1500mm 60in
same wall
L Horizontally from a terminal on the 300mm 12in
same wall
M Adjacent to opening 300mm 12in N Below carpor t 600mm 24in
*not recommended
O From adjacent wall 300mm 12in P From adjacent opening window 1000mm 40in Q From another term inal 600mm 24in R Minimum height 300mm 12in
A
B,C
G
K
M
A
E
F
F
K
B,C
G
G
K
K
L
L
J
F
H,I
D,N
C
Q
O
O
P
R
SPECIAL REQUIREMENTS FOR A VERTICALLY BALANCED FLUE
300mm Min
430mm Min
d) If the appliance is installed in a room or internal space with other
opened flued appliances, then the size of the air vent necessary should be calculated in accordance with BS 5440-2 Table 2.
e) Where an open flued system is used, and the flue duct air inlet is within a compartment then high and low level air vents are necessary in the compartment, the size of the vents should be calculated in accordance with BS 5440-2 Table 2.
3.5
CONDENSATE DISPOSAL
The condensate drain connection is suitable for either 21.5 mm or 22 mm plastic push fit or adhesive overflow pipes and fittings. It should be piped to drain, preferably within the building, maintaining a continuous 2.5° fall away from the appliance. If the drain is routed to outside it should be to a drain or soak away, and any external pipe work should be in 32 mm. Insulation to protect from freezing in cold weather conditions is also advisable. Note if the appliance is installed in a garage all pipe work should be in 32 mm. Ensure that the condensate discharge system complies with any local regulations in force.
3.6
GAS SUPPLY
a) The Gas Supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas.
b) An existing service pipe MUST NOT be used without prior consultation with the Gas Supplier.
c) A gas meter can only be connected by the Gas Supplier or by their contractor.
d) An existing meter and/or pipe work should be of sufficient size to carry the maximum appliance input plus the demand of any other installed appliance. (BS 6891: 1988).
A minimum of 22 mm diameter pipe work is recommended within 1000 mm of the appliance gas cock.
e) Natural gas appliances: The governor at the meter must
give a constant outlet pressure of 20 mbar (8 in.wg) when all appliances on the system are running.
Propane appliances: The regulator must give a constant outlet pressure of 37 mbar (14.9 in.wg) when all appliances on the system are running.
f) The gas supply line should be purged. WARNING: Before purging open all doors and windows, also extinguish any cigarettes, pipes, and any other naked lights.
g) The complete installation must be tested for gas tightness.
3.7
CENTRAL HEATING SYSTEM
a) The appliances incorporate all the components necessary to allow them to be connected to a sealed central heating system. Refer to Figure 7a for a typical system design, which incorporates radiators, and a drain facility that must be provided at the lowest point in the system to allow complete drain down.
b) The installation should be designed to operate with a flow temperature of up to 95 °C.
c) A sealed system must only be filled by a competent person. d) The available pump head for the appliances are given in Figure 6.
*Recommended by the boiler manufacturing industry to prevent pluming nuisance and damage to buildings.
14
e) If thermostatic radiator valves are fitted, a radiator must be fitted with two lock shield valves, to enable correct operation of the pump-overrun facility.
f) The following paragraphs outline the specifications of the items fitted to the appliances.
PUMP - The available pump head shown in Figure 6 is that in excess of the appliance hydraulic resistance, i.e. that available for the system.
7
AVAILABLE PUMP HEADS
1
0123456789101112131415161718
2
3
4
5
6
7
Flow Rate ltr/min
Pump Head (m H
2
0)
SBX 30 & CBX 38 CBX 32 CBX 24
6
EXPANSION VESSEL - The integral expansion vessel is pre-
charged to a pressure of between 0.5 and 1.0 bar. This should be checked before the water system is filled. Details below show the water system volume that is acceptable for this vessel. If the system water volume is larger then an additional vessel must be fitted to the system. BS 5449 and BS 6798 give further details regarding expansion vessel sizing and sealed systems.
Expansion Vessel Requirements
V essel charge and
bar 0.5 0.75 1.0 1.5
initial system pressure Total water content of system
using 8 L (1.54 gal) capacity
L 96847350
expansion vessel supplied with appliance.
For systems having a larger capacity multiply the total system capacity in litres (gallons) by
0.0833 0.093 0.109 0.156
these factors to obtain the total minimum expansion vessel capacity required in litres.
PRESSURE GAUGE - A pressure gauge is situated on the appliance control panel. This can be viewed by lowering the bottom front panel.
PRESSURE RELIEF V ALVE - A pressure relief valve set to 3 bar (43.5 psi) is supplied with the appliance, however it will start to open at approximately 2.7 bar. It should not be used to flush the system.
FILLING LOOP
A filling loop is supplied loose with the appliance for connecting the mains water supply to the CH system so that the system can be filled on installation or whenever water pressure has been removed for system modifications, etc. The filling loop complies with the current water supply (water fittings) regulations.
Methods of filling a sealed system are shown in Figure 8.
WATER TREATMENT, CLEANSING AND FLUSHING THE HEATING SYSTEM
NOTE:
British Standard BS7593: 1992 stresses the importance of cleansing and flushing of the system to ensure it continues to run efficiently with the minimum of maintenance necessary. Halstead Boilers fully support this professional approach and recommend that the system is cleansed with an effective chemical cleanser and protected long term with a suitable inhibitor. Such products are available from Fernox and Sentinal.
CONTROLS. As a minimum it is recommended that a room thermostat be installed to control the appliance. Thermostatic radiator valves may be fitted to the system, however they must not be fitted in the room where the room thermostat is fitted. There must be at least one radiator installed with lock shield valves that should not be closed. Further guidance can be obtained from the Domestic Heating and Hot W ater Guide to the building regulations.
a) Check that the mains water pressure is sufficient (as stated in
2.2 “Performance Data”) to produce the required DHW flow rate, but does not exceed the maximum DHW pressure (10 bar). If necessary, a pressure-reducing valve must be fitted to the mains supply before the DHW inlet connection.
b) The final 600 mm (24 in) of the mains supply pipe to the boiler must be copper.
c) Avoid long DHW pipe runs and several hot water draw off points. d) Insulate the hot water pipes if accessible to minimise the heat
losses within the pipes to keep the water hot longer. e) A domestic hot water regulator is fitted within the appliance to
control the maximum water flow rate. This may be removed to obtain higher flow rates. Higher flow rates will not damage the appliance but may reduce the water temperature below an acceptable level.
DOMESTIC HOT / COLD WATER SUPPLY TAPS AND MIXING TAPS. All equipment designed for use at mains water
pressure is suitable. SHOWERS & BIDETS. Any mains pressure shower or bidet
complying with the Local Water Undertaking byelaws is suitable.
(CBX APPLIANCES ONLY)
3.8
DOMESTIC HOT WATER SYSTEM
15
TYPICAL SYSTEM DESIGN FOR EDEN CBX
7a
APPLIANCE
TIME CLOCK
PRESSURE RELIEF OUTLET TO DRAIN
DOMESTIC HOT WATER OUT
DOMESTIC HOT WATER
DOMESTIC COLD WATER
CH RETURN
CH FLOW
MAINS WATER IN
ROOM THERMOSTAT
DRAIN COCK AT LOWEST POINT IN SYSTEM
RADIATOR WITH
2 LOCKSHIELD
VALVES IN OPEN
POSITION
GAS SUPPLY
PRESSURE REDUCING VALVE (if required)
BS STOP VALVE (Fixed Spindle)
MAINS WATER
For information please contact Halstead Boilers Technical Helpline under 08450 710780
OPTIONAL SYSTEM DESIGN WITH UNVENTED STORAGE CYLINDER FOR EDEN SBX
NOTE (CBX circuit): No automatic by-pass required. However it is
recommended to leave one radiator open to ensure pump over-run function. It is also recommended to fit TRV’s on all radiators except in rooms with a room thermostat
NOTE (SBX circuit): For detailed system designs see the seperate booklet supplied with the boiler.
7B
16
8
ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM
MAINS WATER SUPPLY
DOUBLE CHECK VALVE ASSEMBLY
STOP VALVE
STOP VALVE
HEATING SYSTEM RETURN
CISTERN & OVERFLOW
MAINS WATER SUPPLY
PRESSURE PUMP & REDUCING VALVE IF REQUIRED
STOP VALVE
HEATING SYSTEM RETURN
FLEXIBLE HOSE UNION TEMPORARY CONNECTION To be removed immediately after filling
RECOMMENDED AND APPROVED METHOD FOR FILLING A CLOSED CIRCUIT IN A HOUSE. (R24-2a WATER REGULATIONS GUIDE)
Note: The appliance has a built in
filling loop
METHOD B
3.9
ELECTRICITY SUPPLY
a) Wiring external to the appliance must be in accordance with the current I.E.E Wiring regulations (BS 7671) for electrical installation and any local regulations, which apply.
b) The mains cable must be at least 0.75 mm2 (24/0.2 mm) PVC insulated to BS 6500 table 16.
c) THIS APPLIANCE MUST BE EARTHED. Failure to provide a satisfactory earth connection will result in appliance malfunction.
d) The method of connection to the mains supply must facilitate complete electrical isolation of the appliance. Either a 3A fused three pin plug and un-switched shuttered socket outlet, both complying with BS 1363, or a 3A fused double pole switch having a 3 mm contact separation in both poles and serving only the boiler (and its external controls) may be used.
3.10
EXTERNAL CONTROLS
The CBX appliances may be used with any certified mains voltage room thermostat, and the SBX appliances with any certified programmer/room thermostat, as described in section 4. A low voltage DHW cylinder / tank sensor is available as a kit, for use with SBX appliances. For further information contact: Halstead Boilers Ltd, Service Helpline: 08450 710780.
METHOD A
17
APPLIANCE INSTALLATION
4
4.1
UNPACKING THE APPLIANCE
The appliance is supplied in one box. Flue kits are provided separately, the various flue kits available as described in sections
2.5 - 2.7. If the appliance is to be installed without access to an external wall, a wall liner kit is also required.
Unpack the boxes and check the contents:
G Complete appliance G Paper wall mounting template G Wall mounting plate G Plumbing jig G Installation and Servicing Instruction G User's Instructions G Benchmark book G Hardware pack containing:
50 mm x No 10 wood screws - 4 off Wall plugs - 4 off 22 mm copper street elbows ­2 off (3 off SBX appliance)
Before installing the appliance, check that the chosen location is suitable (section 3.2) and that the requirements for flue position (section 3.3) and minimum clearances (Figure 1b) are satisfied.
Manual Handling Note: During the appliance installation it will be necessary to employ caution and assistance whilst lifting, as the appliance exceeds the recommended weight for a one-man lift. Take care to avoid trip hazards, slippery or wet surfaces.
4.2
PREPARING THE WALL
a) Fix the paper template in the required position (ensuring that the necessary clearances are achieved). Ensure squareness by hanging a plumb line.
b) Mark the position of the wall mounting plate-fixing holes (4). Select one from each group. Refer to Figure 10.
c) Mark the position of the flue outlet. For side flue installation extend the flue centre line on to the sidewall, where the flue length exceeds 775 mm, a flue slope angle of 2.5° needs to be taken into account. Refer to Figure 10. Remove the paper template.
d) Cut the hole in the wall for the air/flue duct (preferably with a core-boring tool). The hole must be horizontal and not be less than 100 mm in diameter. If the hole is not accessible from outside, its minimum diameter must be sufficient to allow insertion of the wall liner (130 mm, 5in). The wall liner is available as an optional extra and must be sealed in position with mortar (or equivalent).
e) Drill the four fixing holes using a 6mm drill and insert the wall plugs provided.
f) Hang the wall mounting plate using two fixing screws in the top, ensuring that it is level. Hook the plumbing jig onto the two bottom locating tabs of the wall mounting plate. Refer to Figure 9.
g) Enter the bottom two fixing screws into the wall plugs and tighten up all four screws.
If required, service connections may be made now before mounting the appliance - Refer to section 5.
Pipe work may be routed from above or below the appliance as required.
9
CBX
SBX
18
10
11
4.3
MOUNTING THE APPLIANCE
Refer to Figure 11 a) Lift the appliance into position approximately 10 mm above the
top of the wall mounting plate and use the side wings on the plate to locate the appliance horizontally . Then carefully lower the appliance, ensuring that the top locating tabs are securely engaged.
b) Connect the central heating system pipes to the central heating flow and return pipes on the boiler.
Refer to Figure 12
Commission the central heating system and domestic hot water system, for CBX appliances as described in section 5.1, and then proceed to Section 4.5.
MOUNTING THE APPLIANCE
12a
CBX SERVICE CONNECTIONS
WATER SERVICE CONNECTIONS
4.4
CENTRAL HEATING & DOMESTIC HOT
12b
SBX SERVICE CONNECTIONS
Pipe work may be routed from above or below the appliance as required.
CENTRAL HEATING
RETURN
MAINS WATER
IN & FLOW
TURBINE
GAS
SUPPLY
DOMESTIC
HOT WATER
OUT
SERVICE
CONNECTION
PIPES NOT SUPPLIED
FILLING
LOOP
DRAIN POINT
PRESSURE
RELIEF
CONDENSATE
OUTLET
CENTRAL HEATING
FLOW
43mm 108mm 169mm 240mm 305mm
351.5mm
411.5mm 448mm
43mm 169mm 240mm 305mm
351.5mm
411.5mm 448mm
SERVICE
CONNECTION
PIPES NOT SUPPLIED
CENTRAL HEATING
RETURN
GAS
SUPPLY
SECONDARY
RETURN FROM
TANK
(OPTIONAL)
PRESSURE
RELIEF
CENTRAL HEATING
FLOW
DRAIN
POINT
CONDENSATE
OUTLET
Refer to Figure 12 Connect the gas supply pipe to the gas service cock. It is
recommended that a minimum of 22 mm diameter OD copper pipe be used to within 1000 mm of the gas service cock. For full rate, operate CBX appliances in DHW mode.
13
CONDENSATE CONNECTIONS
4.5
GAS CONNECTION
4.6
CONDENSATE CONNECTION
Refer to Figure 13 Connect preferably a 22 mm plastic push fit or adhesive overflow pipe to
the condensate outlet. It should be piped to drain, preferably within the building, maintaining a continuous 2° fall away from the appliance. Note; if an additional “U” trap is fitted between the appliance and the discharge point, then a visible air break is necessary between the appliance and trap, because a trap is already provided within the appliance. 32 mm pipe should be used for external pipe work, or if the appliance is installed in a garage. If the drain is routed externally to a drain or soak away , then the external length should be kept as short as possible and not exceed 3000 mm. Protection from freezing in cold weather conditions is also advisable. Ensure that the condensate discharge system complies with any local regulations in force.
In exceptional circumstances, such as when a boiler is installed in a basement without drainage, it may be necessary to install a condensate pump to carry condensate up to ground/drain level. Such products are available from Grundfos Pumps Ltd on:01525 850000 and Pump House on: 0115 922 2211.
4.7
PRESSURE RELIEF VALVE CONNECTION
The safety valve is located at the bottom RHS of the appliance. Connect the copper tail provided, to the safety valve outlet, and then connect a discharge pipe of not less than 15 mm diameter copper to the tail. The pipe should be positioned so that the discharge of water or steam can be noticed, but cannot create a hazard to the occupants of the premises or damage electrical components or wiring.
4.8
AIR / FLUE DUCT INSTALLATION
The flue length is measured from the centreline of the appliance flue outlet to the inside of the external wall-sealing ring. In most cases it will be possible to achieve the required flue length without cutting the ducts, however where necessary the plain ends of the extension ducts may be cut. Never cut the swaged end, and always ensure that the cut is square and free of burrs or debris.
NOTE IT IS ESSENTIAL THAT THE TERMINAL IS FITTED THE CORRECT WAY UP
See flue kit Instructions (i.e. rain shield at the top).
MEASURING THE EXACT FLUE LENGTH
FAN OUTLET EXTERNAL Dia. 60mm
TOTAL FLUE LENGTH FROM FLUE OUTLET CENTRE TO OUTSIDE WALL FACE:
= LENGTH
L
WALL
L
14
19
For correct flue installation please refer to the installation instructions that are provided with the individual flue kit as described in sections
2.5 - 2.7. a) Measure the required flue length as shown in Figure 14. Refer to
section 2.5 to determine whether any extension kits are required. Installations using only the standard ducts or standard ducts with straight extensions are described in this section. Installation instructions for all other flue systems are included in the various flue kits.
b) Ensure that all (inner and outer tube) sealing rings are provided and assemble the air/flue ducts as shown in the flue instructions.
c) Construct the correct flue length by building the flue out from the appliance.
Ensure that the flue and air seals are correctly fitted before assembly and that each section is fully engaged.
20
4.9
ELECTRICAL CONNECTIONS
Connect the electricity supply and external controls (using suitable mains cable) as follows:
Wire the cable(s) into the appropriate connections in the electrical plug provided, referring to Figure 16. Live supply to L1, Neutral and Earth as indicated. Check that L2 and L3 are linked.
To provide correct cable retention, fit the piece of tubing supplied over the cable as it passes through the clamping arrangement. The cable will be held in position as the plug cover is fitted.
If a programmer/room thermostat is to be fitted remove the red link between L2 and L3 and connect the device across these terminals. Any external controls fitted must be rated at 230V 50Hz and have volt free contacts.
16
If this sensor kit is used, refer to the separate kit for instructions for installation and wiring details.
SENSOR (SBX APPLIANCES ONLY)
4.10
OPTIONAL CYLINDER / TANK TEMPERATURE
15
2 ALIGN ASSEMBLED FLUE
SYSTEM ELBOW TO APPLIANCE AND SECURE
3 SLIDE INTERNAL WALL
SEALING RING TO WALL TO FORM A GOOD SEAL
1 INSERT
ASSEMBLED FLUE SYSTEM FROM INSIDE THE ROOM. EXTERNAL WALL SEALING RING OPENS
EXTERNAL WALL SEALING RING
130mm Dia. HOLE WITH WALL LINER
INTERNAL WALL
SEALING RING
TOP
FIBRE SEAL FITTED
INSTALLING THE FLUE SYSTEM FROM INSIDE THE ROOM
Wall thickness up to 800 mm (31 in) only. a) Push the terminal through the wall liner taking care to ensure
that the terminal is the correct way round and the external wall­sealing ring does not become dislodged.
b) Assemble the flue system extension ducts as necessary, referring to Figure 15.
c) Pull the flue system towards the appliance to seat the external sealing ring against the outside wall, ensuring that the duct joints are not disturbed.
D) Use the internal sealing ring to make good the internal hole, and check that the terminal is correctly located on the outside wall (Where possible this should be visually checked from outside the building.) Figure 16 shows a view of the flue system, correctly installed.
e) Finally locate and secure the elbow to the appliance using the four screws provided.
FROM OUTSIDE THE ROOM
4.8.2
INSTALLING THE AIR/FLUE DUCT
(Flue hole diameter 100 mm - wall liner not necessary)
a) Secure the flue elbow with seal to the appliance using 4 screws. b) Fit external wall sealing ring over flue and then from outside
the building, push the flue system through the wall taking care to ensure that the terminal is the correct way around.
c) Loosely fit the internal wall sealing ring over the inside end of the flue.
d) Assemble the flue system extension ducts as necessary, referring to the flue kit instructions, and fit to the flue elbow.
e) Fit the flue terminal to the flue system, ensuring that the duct joints are not disturbed, and that the external sealing ring is seated against the outside wall.
f) Finally use the internal sealing ring to make good the internal hole. Check that the external wall sealing ring and the terminal is correctly located, on the outside wall from outside the building.
FROM INSIDE THE ROOM
4.8.1
INSTALLING THE AIR/FLUE DUCT
Note: If room thermostat is to be fitted remove the link and connect room thermostat across L2 and L3.
21
COMMISSIONING & TESTING
5
5.1
FILLING THE WATER SYSTEM
Before commissioning the appliance, the whole gas installation including the meter MUST be purged and tested for gas tightness in accordance with BS 6891: 1988.
Open all doors and windows, extinguish naked lights, and DO NOT SMOKE whilst purging the gas line.
It is recommended, where possible, to flush the CH system without the appliance fitted, to avoid debris and flux blocking the waterways within the appliance.
Do not use the pressure relief valve to drain the system, because dirt or debris could prevent the valve seating correctly. If the valve leaks or sticks closed, then replace it.
Before commencing the commissioning procedure, ensure that the gas service cock is turned on, the electricity supply is isolated, and that the CH and DHW pipe-work (where fitted) is complete. A special feature of the CBX appliances is that the water systems can be completely filled prior to fitting the appliance. It is recommended that this procedure be followed even when the appliance is to be fitted immediately after filling the system. Fill the water systems by following the procedure detailed below steps 1 to 5, and referring to Figure 17.
17
COMMISSIONING THE WATER SYSTEM
1) Check that the CH flow, return, (and DHW return on SBX appliance if used), isolating valves are in the open position.
2) Fill the system with water using one of the approved methods described in section 3.7 to about 2.0 bar, (filling loop provided on CBX appliances). Vent the system via the radiator valves and system air vents in accordance with normal practice. Ensure that all system air vents are closed.
To aid venting, a manual air vent is provided on the LHS of the heat exchanger, and an automatic air vent on the pump assembly.
3) Check the system for soundness.
4) Check the operation of the pressure relief valve (Figure 18) by lifting the lever on the valve gently to ease the valve of its seat. Checking that water is discharged, release the lever and ensure that the valve seats correctly and does not leak.
18
5) Drain the entire system to flush out any debris, and refill to 0.2
bar above the system design pressure (between 0.5 and 1.5 bar) by repeating the above procedure. Follow the commissioning procedure described below, and then repeat this instruction with the system hot. It is recommended that the system be cleaned with a recognised system cleaner such as Fernox or Sentinel.
6) On CBX appliances, open the DHW inlet valve and operate each hot water tap in turn to clear all the air from the pipes and the appliance.
7) Remove the pump cap; use a screwdriver to rotate the pump shaft. Replace the cap.
8) Disconnect the filling loop from the system.
9) Prior to lighting the appliance to check the gas rates, the
central heating system should be checked for circulation by operating the appliance with the gas turned off, this is to ensure that no air locks occur. The appliance may go into ignition lockout and require resetting.
!
CH
RETURN
FILLING
LOOP VALVE
DHW FLOW
CH
FLOW
FILLING
LOOP VALVE
COLD
WATER IN
GAS SUPPLY
CH
DRAIN
FILLING
LOOP
CONDENSATE WASTE OUTLET
(NOTE: TRAP PARTS FITTED
INSIDE BOILER NOT ON
PLUMBING JIG)
CH
RETURN
CH
FLOW
SECONDARY
RETURN FROM
TANK (OPTIONAL)
GAS
SUPPLY
CH
DRAIN
CONDENSATE WASTE OUTLET
(NOTE: TRAP PARTS FITTED
INSIDE BOILER NOT ON
PLUMBING JIG)
PRESSURE GAUGE
CAPILLARY
PRESSURE RELIEF VALVE
22
5.2
COMMISSIONING THE APPLIANCE
Refer to Figure 19
If, at any time during the commissioning procedure, it is required to prevent the appliance from modulating, set the CH temperature control knob to the Service position.
To select Comfort DHW control, i.e. with pre-heat, turn the DHW temperature control knob fully clockwise and then back to the desired temperature setting. LED 2 will then illuminate and LED 1 extinguish.
With the CH temperature control knob in the Service position, the appliance will fire continuously at minimum heat input and LEDs 4 and 5 will flash. This setting is for the convenience of the Service Engineer ONLY.
If the Reset LED shows RED, to establish the cause press and hold the Reset button for three seconds. The Reset LED will flash RED and the error code will be displayed via the LED's 1-4. Refer to 'fault finding' Section 8.
a) Check that the gas supply is turned ON and the gas service cock is OPEN.
b) Slacken the screw in the appliance inlet pressure test point and connect a suitable manometer. Refer to Figure 20.
c) Set the CH and DHW temperature control knobs fully anticlockwise to the standby positions.
d) Switch on the electrical supply and set the ON/OFF switch to ON (I). The Reset LED will briefly show red, then blue, then extinguish. The fan will start briefly and then stop. The LEDs 1-4 (yellow) will illuminate briefly.
For CBX appliances e) T urn the DHW temperature control knob to the desired
temperature position and fully open any DHW tap. LED 1 will show yellow (Economy mode). The ignition sequence will commence and when flame is detected the Reset LED will show blue. If the burner fails to light after five attempts, ignition lockout occurs. In this event the Reset LED will show RED. To re-set the appliance and initiate a further ignition sequence, press the Reset button.
f) After ignition, allow the appliance to run for at least 10 minutes and check that the gas supply pressure measured at the appliance inlet pressure test point is: 20 ± 1 mbar for natural gas, and 37 ± 1 mbar for propane appliances.
g) Close the DHW tap and ensure that the burner goes out (BLUE light off) and the pump stops after an over-run period of 5 minutes.
g) Ensure that the room thermostat (if fitted) is calling for heat. Turn the clock override switch to the 'I' position. Turn the CH temperature control knob to the '+' position. The ignition sequence will commence and when flame is detected the Reset LED will show blue. The Reset LED will show BLUE and LEDs 3 and 4 will show YELLOW.
h) Set the clock to the desired times by setting the tabs. i) Slide the clock override switch to the 'timed' position _and
check the operation of the clock and room thermostat (If fitted).
For SBX appliances: j) Ensure that the programmer and room thermostat (if fitted) are
calling for heat. Turn the CH temperature control knob to the '+' position. The ignition sequence will commence and when flame is detected the Reset LED will show BLUE and LEDs 3 and 4 will show YELLOW. Check the gas supply pressure; see item 'f' above.
k) Turn off the demand from the programmer/room thermostat, or turn the CH temperature control knob to the 'standby' position, and ensure that the burner goes out (BLUE light off) and the pump stops after an over-run period of 2 minutes.
l) If the optional cylinder/tank sensor is fitted, check that the appliance operates when the programmer is calling for heat and the cylinder is cold.
Mains ON/OFF Switch
CH Error Code Indicator (3&4)
CH Temp. Control
DHW Economy/
Comfort Switch
Economy/Comfort
Error Code LED (1&2)
Service Function
24hr Clock
BURNER (Blue) LOCK-OUT (Red) LED and Reset Button
Pressure
Gauge
DHW
Temperature
Control
ARROW
INDICATES
CURRENT TIME
TABS OUT = ON PERIOD
TABS IN = OFF PERIOD
CLOCK OVERRIDE SWITCH (Heating only)
= Continuous ON = Timed =OFF
19
FASCIA PANEL AND CONTROLS (CBX model shown)
!
A flow regulator is supplied factory fitted to the appliance to ensure that no adjustment is necessary. Should the mains flow rate be below the minimum required, it is possible to remove the flow regulator from the appliance as instructed in section 9. The nominal pre-adjusted flow rate may vary by ± 5 % due to factory tolerances and mains water pressure fluctuation.
5.4
FINAL CHECKS
a) Turn both the DHW and CH temperature control knobs to standby. b) Turn the appliance on/off switch to the off ('O') position,
remove the manometer and tighten the appliance inlet pressure test point screw. Re-light the burner and test for gas tightness.
c) Fit the appliance casing as described and illustrated in Figure 21: Fit each side panel with two screws at the top and bottom of each panel. Position and fit controls cover in place using screws provided. Ensure it hinges correctly. Fit the front panel in position using locating studs and ensure it’s correctly seated by pressing.
d) Set the heating and hot water controls to the required settings. For CBX appliances ensure that the clock override switch is in the timed position and check that the time clock is set at the desired time periods. Set the room thermostat (if fitted) to the required setting.
e) For SBX appliances if the cylinder / tank sensor if fitted set the hot water sensor to the required setting. Refer to separate cylinder / tank sensor instructions.
5.3
DHW FLOW RA TE (CBX APPLIANCES ONLY)
21
CASING
5.5
LOCKOUT INDICATION
In the event of failure during an ignition sequence, (5 attempts) the
Reset LED will show steady RED. By pressing and holding the Reset button for 3 seconds the Reset LED will flash RED and LEDs
1 to 4 will display the error code (0011). To Reset the appliance and initiate a further ignition attempt, press the Reset button.
NOTE:
In the event of failure during normal running, the Reset
LED will show steady RED.
To access the relevant error codes, press the Reset button for three seconds. The Reset LED will flash RED. To reset the appliance press the Reset button.
Refer to 'fault finding' Section 8.
5.6
FROST PROTECTION
5.7
OVERHEAT PROTECTION
The appliance is fitted with a frost protection device. In the event of very cold conditions, the pump may operate and the appliance light for a few minutes to protect the appliance and system from potential frost damage. This can only function if the gas and electricity supplies are maintained and the ON/OFF switch on the appliance is left ON. (‘l’) On CBX appliances the time clock can be switched to the OFF setting.
The appliance incorporates flow and return thermostats, which monitor the appliance's operating temperature. Abnormal temperatures such as overheating will cause the appliance to go to lockout and the Reset button will show steady RED, if the error codes are accessed the LED 4 (code 0001) will illuminate. Allow the appliance to cool, and then press the Reset button to clear.
20
INLET PRESSURE TEST POINT
23
Note: On the CBX 38 the inlet pressure test point is situated on the gas service cock.
24
5.8
OTHER FEATURES
The following additional features are included in the appliance specification:
ANTI-CYCLE DEVICE:
When the appliance cycles on its central heating control thermostat, a slow cycle device operates. The timer (set to 5 minutes) is activated after the end of each burn cycle to prevent rapid cycling of the burner.
ANTI PUMP SEIZURE DEVICE:
Providing that a power supply is maintained and the appliance ON/OFF switch is ON, the pump will operate for at least 20 seconds in every 23 hours (regardless of heat demand) to prevent pump seizure during periods where the appliance is not used.
CH SOFT START DEVICE:
After every burner start, in CH mode, the burner output stays at low for 3 minutes, to ensure smooth heat up of the system and maximum efficiency.
DHW PRE-HEAT: (CBX appliances only)
DHW Comfort selected: With no demand for DHW the appliance will fire periodically for a few seconds to maintain the DHW plate heat exchanger in a heated condition. This feature will automatically adjust to the user's habitual requirements. Thus during long periods of no DHW draw-off, e.g. overnight, no pre-heat is provided. With DHW
Economy selected, no pre-heat is provided. KEEP-HOT FACILITY (EDEN CBX appliances only)
This feature is designed to provide hot water very quickly without wasting too much water. Therefore you may notice that after EVER Y hot water draw-off the burner may stay on for a short period of a few seconds. This is to pre-heat the hot water circuit and prepare the appliance for the next hot water draw-off.
This feature applies in both the 'Comfort' and 'Economy' modes.
OPTIONAL - HOT W ATER DELAY PERIOD (EDEN CBX appliances only)
After every hot water draw-off the appliance may stay in this mode for a few minutes, (if selected), even though a central heating demand is present (LED 3 & 4, as shown in the user manual, will be off during this period). This feature reduces the hot water outlet temperature fluctuations between draw-offs. This feature is particularly handy when having a shower.
In households with many hot water taps or larger families this feature could cause some unwanted delays in providing central heating. To override the few minute delay , briefly turn the CH control knob or room thermostat (if fitted) and the appliance will change over to CH almost immediately , (at least 1 minute after last burner cycle).
SERVICE MODE:
The appliance enters the SERVICE mode by turning the control knob to 'SERVICE' (full clockwise). The two LED's above the knob are now flashing. In this mode the appliance runs at the minimum CH output. This mode allows the gas valve offset and CO
2
emissions to
be measured.
5.9
USERS INSTRUCTIONS
Upon completion of commissioning and testing the system, the installer must instruct the user in how to operate the appliance by drawing the user's attention to the following.
a) Give the 'Users Instructions' to the householder and emphasise their responsibilities under the 'Gas Safety (Installation and Use) Regulations or rules in force.
5.10
APPLIANCE LOG BOOK
A logbook is supplied with this appliance to record installation and commissioning details and to make future servicing of the appliance easier.
This logbook forms part of the industry's Benchmark code of practice for the installation, commissioning and servicing of central heating systems.
Please ensure that the logbook is fully completed and left with the customer for future reference, along with Users Instructions and this Installation and Servicing Instruction manual.
b) Explain and demonstrate the lighting and shutdown procedures.
c) Advise the householder on the efficient use of the system, including the use and adjustment of all system controls for both CH and DHW.
d) Advise the user of the precautions necessary to prevent damage to the system, and to the building, in the event of the system remaining inoperative during frost conditions.
e) Explain the function of the Reset button, and how to reset the appliance. Emphasise that if cutouts persists, the appliance should be turned off and the installer or service engineer consulted.
f) Stress the importance of an annual service by a registered heating engineer.
g) The electrical mains supply to the appliance must remain ON and the ON/OFF switch must be left ON for the frost protection circuit to operate.
5.11
GAS CONVERSION
Appliances may be converted from one gas group to another. It is possible to convert between Propane and Natural gas by use of conversion kits. The kits comprise the following:
Propane to Natural Gas
Kit Numbers 955123 - Eden CBX 32
955124 - Eden CBX 24 955125 - Eden SBX 30 988642 - Eden CBX 38 Conversion Instructions Gas Control Valve Data Badge (Natural Gas) Boiler Chip Card Nat Gas Cork Gasket Polydome Badge (Natural Gas)
Natural Gas to Propane
Kit Numbers 955120 - Eden CBX 32
955121 - Eden CBX 24 955122 - Eden SBX 30 988641 - Eden CBX 38 Conversion Instructions Gas Control Valve Data Badge (Propane) Boiler Chip Card Propane Cork Gasket Polydome Badge (Propane)
Instruction on how to convert the appliance is given in the conversion instructions supplied with these kits. However, particular attention should be given to the fitting of the gas valve and the use of the Boiler Chip Card (BCC).
For further information contact: Halstead Boilers Ltd, Service Help Line: 08450 710780.
ROUTINE SERVICING
6
6.1
COMBUSTION CHECK
The appliance incorporates a flue sampling point on the appliance flue elbow, or appliance vertical flue adaptor. If the service engineer has suitable equipment to analyse the flue gas, the plastic cap may be removed and a 6 mm inside diameter sample tube fitted. For CBX appliances operate in DHW mode, at full rate, for SBX appliances operate the appliance in Service mode, (see section 5.2). After ten minutes operation check the CO
2
/CO values and compare with those figures stated in section 2.3. Do not forget to replace the cap after use.
When the appliance is operating at maximum output check that the gas supply pressure is 20.0 mbar, using the inlet pressure test point located on the gas supply pipe.
Before commencing any service operation, ISOLATE the mains electrical supply, and TURN OFF the gas supply at the main service cock.
To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be adequate. It is the law that a competent person, such as British Gas or other CORGI registered personnel, must carry out any service work.
Service the appliance by following the full procedure detailed below:
22
CONTROL PANEL
23
COMBUSTION CASE PANELS
e) Unscrew the screw holding the gas valve lead plug, and
disconnect the plug.
f) Disconnect the electrical leads from the fan (2 plugs). g) Undo the nut holding the gas valve feed pipe to the gas
isolating cock, and disconnect. h) Disengage the gas valve feed pipe grommet from the casing
by pushing it up. i) Remove the 6 nuts holding the combustion chamber front cover
in place. j) Remove the gas control valve, fan & burner assembly, by
carefully pulling forward the combustion chamber front and rotating the assembly anticlockwise so that the burner points forward, then disengage the gas valve feed pipe from the casing, by lifting up the assembly. Take care not to damage the insulation.
k) The assembly may then be inspected. l) Re-assemble in reverse order.
VALVE, FAN & BURNER ASSEMBLY
6.2
GAS CONTROL
Refer to Figures 22, 23, 24, and 25 a) Remove the casing front panel, pulls off. b) Lower the controls panel (2 screws). c) Remove the sealed chamber front panels (11 screws). d) Disconnect the igniter plug, earth lead and detection plug from
the igniter and detection electrodes.
6.4
IGNITION & DETECTION ELECTRODES
a) Inspect the ignition and detection electrodes in situ. If necessary, clean using a soft brush. If either the electrode or the ceramic insulation shows signs of damage or wear, replace the electrode(s) and their gasket.
b) Check that the alignments of the ignition and detection electrodes are correct. Refer to Figure 26. Adjust by carefully bending the tip of the electrode rod whilst supporting the base of the rod. Do not put any pressure on the ceramic insulation.
6.3
BURNER
Inspect, and if necessary clean the main burner ports using a soft brush or vacuum cleaner. Do not use a wire brush or any abrasive material.
25
26
24
CBX
SBX
HEAT EXCHANGER
6.5
COMBUSTION CHAMBER &
Inspect the inside of the combustion chamber for debris. If necessary, clean the inside of the tubes with a soft brush. Do not brush the insulation at the rear, check the integrity of the combustion chamber insulation panels, if damaged they will require replacement.
6.6
CONDENSATE DRAIN
The condensate Drain has a removable cap, Figure 27, which allows the removal of debris that may be caught within it. Place a bowl under the cap to catch the condensate and remove the cap. Any debris inside will be expelled at this point. Replace the cap ensuring a good seal is made. Discard the condensate and debris.
25
GAS CONTROL VALVE, FAN & BURNER ASSEMBLY
26
26A SPARK ELECTRODE
26B DETECTOR ELECTRODE
FILTER (CBX APPLIANCES ONLY)
6.7
DOMESTIC COLD WATER INLET
Close the water inlet isolating cock, open a domestic hot water tap at the lowest point in the system and allow the pressure to dissipate. Close this tap again. Undo the nut holding DHW turbine to the water inlet isolating cock. The filter inside the isolating cock can now be carefully removed, and cleaned as necessary by flushing with water. Re-assemble in reverse order, ensuring all seals are replaced correctly. Refer to Figure 28
27
28
6.8
SEALED WATER SYSTEM
a) Check the operation of the pressure relief valve as described in section 5.1.
b) Check the correct operation of the pressure gauge by noting the reading when cold and check that the pressure increases with temperature. Replace the gauge if readings are suspect.
c) Check that the system is at its original (cold) design pressure. If necessary, re-pressurise the system as described in section 5.1 and search for and rectify any leaks causing loss of water.
d) In case of heavy pressure fluctuations during the heat and cool down cycle, check the pre-charge pressure of the expansion vessel. If the air pressure is less than 0.75 bar recharge vessel with an air pump.
27
CONDENSATE DRAIN
28
6.9
RE-ASSEMBLY & RE-COMMISSIONING
a) Re-assemble all components in reverse order. b) Check that all joints and seals are correctly fitted. c) Turn on the gas and electricity supply and light the appliance,
as described in section 5.2.
d) Re-perform a combustion check, as described in section 6.1. e) Check the operation of the appliance in both CH and DHW
modes as applicable. f) Remove the manometer and tighten the inlet pressure test point
sealing screw.
g) Test for gas tightness.
6.10
FINAL CHECKS
a) Ensure the fascia panel into the upright position and secure with the two screws.
b) Re-fit the front casing panel. c) Return all appliance and external controls (if fitted) to their
original settings.
INTERNAL WIRING DIAGRAMS
7
7.1 : FUNCTIONAL FLOW WIRING DIAGRAM
29
29
30
FAULT FINDING
8
8.1
GENERAL
Before looking for a fault condition, check that:
G The mains electrical supply is turned on. G The clock, room or cylinder/tank thermostat (where fitted) are
calling for heat.
G The gas service cock is open. G The CH and DHW isolation cocks are open. G The system is at design pressure.
Before attempting any electrical fault finding, always conduct the preliminary electrical system checks as described in the Instructions for the British Gas Multimeter, or other similar instrument.
On completion of any service or fault finding operation involving making or breaking electrical connections, always check for EARTH CONTINUITY, POLARITY and RESISTANCE TO EARTH.
Detailed procedures for replacing faulty components are described in section 9 (Parts Replacement).
8.2
DIAGNOSTIC LED INDICATORS
FASCIA PANEL, Figure 30
The Reset LED shows steady RED in a lockout condition and the error code will be displayed by the 4 yellow lights above the two control knobs.
For fault finding, refer to the diagnostic chart shown below, together with the notes given in sections 8.3, 8.4 and 8.5.
Depending on the fault condition, the boiler can be reset by pressing the RED Reset light.
8.3
FAULT FINDING CODES
In the event of the appliance failing to light, refer to the Diagnostics Chart.
LED 1
CLOCK
PRESSURE GAUGE
DHW TEMP CONTROL
CH TEMP CONTROL
ON/OFF SWITCH
LED 3LED 2 LED 4
RESET & burner/ lock-out LED
FACIA PANEL
30
When the hot water tap is turned on, the control should perform a series of checks followed by an ignition sequence. Refer to section 5.2.
If the control has powered up correctly but does not respond to a DHW demand, check the following:
a) Check that the DHW flow rate at the tap is greater than 2.5 litre/minute.
b) Check the operation of the DHW flow turbine, Figure 28. c) Check the wires to the DHW flow turbine. d) Check connector X8 is correctly connected to the PCB.
If the above items are ok, replace the PCB. If DHW temperature fluctuates heavily during a long draw off,
check the secondary plate heat exchanger filter for debris, clean and replace, (refer to section 9.19).
FINDING (CBX APPLIANCES ONLY)
8.4
DOMESTIC HOT WATER FAULT
Upon a demand for Central Heating, (closure of the time switch and room thermostat, where fitted), the controls should carry out a set of start up checks, followed by an ignition sequence. Refer to Section 5.2.
If the control has powered up correctly but does not respond to a CH demand. Check voltage between pin 2 connector X1A (orange wire) and pin 2 connector X1B (blue wire). If 0 V ac, check room thermostat and clock. If 230 V ac, check control for lockout or blocking codes, (refer to section 8.3), check operation of the pump.
Note: Whenever a CH demand is removed, either by the timer, the room thermostat or by the appliance's internal temperature control, an anti cycle mode is initiated which prevents the appliance from firing in CH mode for 5 minutes. Ensure that the control is not in this mode by removing power from the control and restoring it after a delay of 10 seconds.
If room thermostat and clock are OK and no lockout or blocking code exists and the control is not in anti cycle mode, then replace PCB.
8.5
CENTRAL HEATING FAULT FINDING
For further information contact: Halstead Boilers Ltd. Service Help line: 08450 710780.
LED CODE
FAUL T/EFFECT REASON ACTION
1 2 3 4
G Check no air is in heat exchanger/CH system G Check pump operation
HHHG Overheated appliance Water temperature greater than 105 °C
G Check diverter valve operation G Check PCB/X1C connector G Check mains lead to pump G Check flow thermistor
G Check gas supply
HHGH No gas/No flame Low gas pressure
G Check gas service cock G Check gas valve and lead
G Check detection electrode/lead
HHGG Lockout flame signal/ No flame signal on ignition, or loss
G Check gas supply
Lockout after 5 ignition of signal during operation
G Check gas valve and lead
attempts
G Check PCB/X2A & X2B connectors G Check spark generator/spark electrode G Check mains earth lead continuity
G Check flue sensor
HGHH Flue gas sensor/ Flue gas temperature greater than 95 °C
G Check flue system
No flame
G Check no air is in heat exchanger/CH system G Check pump G Check PCB/PCB connectors
HGHG Defective sensor/ Defective flow, return or flue sensor
G Check flow, return and flue sensors
No flame
G Check wiring to sensors G Check PCB/X6 & X8 connectors
HGGH Defective gas valve/
5 sec flame signal after
G
Check gas valve and lead
Flame continues after
burner is switched off
G
Check PCB
demand ends
G Check fan G Check mains fan lead & connector
HGGG Defective fan/No flame Missing or Erroneous RPM signal
G Check low voltage fan lead & connector G Check PCB/X3 connector G Check pump operation G Check diverter valve operation
GHHH CRC error/No flame Internal Eprom data error G Check PCB GHHG Error in power supply/
Low mains voltage
G Check mains voltage
No flame G Check PCB connectors
G Check water pressure
GHGH Water flow failure/
G Check pump
Flame for a short Sensor temperature differential incorrect
G Check no air is in heat exchanger/CH system
period only
G Check flow, and return sensors G Check wires to sensors not crossed
GHGG PCB error/No flame Internal error G Check PCB GGHH BCC error/No flame Incorrect /missing BCC G Reseat or replace BCC
GGHG Differential check faulty/
G Check flow, and return sensors
Flame for 15 seconds
Zero check faulty DHW or CH
G Check wires to sensors not crossed G Check PCB
GGGH Activate BCC/No flame New BCC G Press reset to activate GGGG Safety system failure/
Failure of internal self checking system
G
Check PCB
No flame
G Check DHW turbine & lead
HHHH DHW cold Defective DHW turbine or Diverter valve
G Check Diverter valve & lead G Check PCB/X4 connector G Check filter in plate heat exchanger
G Check power supply
HHHH No light indication Defective power supply
G Check PCB/X1B connector G Check PCB fuse
HHHH No flame Faulty connector
G Check PCB/X1A connector
31
32
REPLACEMENT OF PARTS
9
Before commencing any service operation, ISOLATE the mains electrical supply and TURN OFF the gas supply at the main service cock.
Replacement of most parts first requires the removal of the sealed chamber front panels; refer to section 6.2.
There may be some slight water spillage; so electrical components should be protected.
It is the law that any service work must be carried out by a registered person.
Refer to Figure 31 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2. c) Unscrew the two screws holding the electrode, remove
electrode, and used gasket.
ELECTRODES
9.1
IGNITION AND DETECTION
Refer to Figure 32 a) Ensure supply voltage is isolated. b) Remove the plug and earth lead from the ignition electrode. c) Remove the electrical supply leads. d) Unscrew the two screws holding the igniter unit, remove igniter
unit.
e) Fit the new igniter unit. f) Re-assemble in reverse order; ensure that the igniter unit is
orientated as shown in Figure 32, and that the brown electric supply lead is fitted to position 1 on the igniter unit.
g) Ensure that all joints and seals are correctly re-fitted.
9.2
IGNITER UNIT AND IGNITION LEADS
31
32
IGNITOR UNIT AND IGNITION LEADS
d) Fit the new electrode, and new gasket. e) Check that electrode is aligned as detailed in Figures 26(a) or 26(b). f) Re-assemble in reverse order. Ensure that all joints and seals
are correctly re-fitted.
INCLUDING AIR INLET COWL
9.3
GAS CONTROL VALVE
Refer to Figures 33, 34 & 35 a) Ensure supply voltage is isolated, and that the gas supply is isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2. c) Unscrew four screws holding the gas feed pipe, and remove gas
feed pipe, refer to Figure 33.
Note: Newer versions may have a single flange nut securing the gas feed pipe.
d) Unscrew three tork screws (T -20), and remove gas control valve,
refer to Figure 34 e) Unclip the top section of the black plastic air inlet cowl from the fan
assembly , and remove white plastic insert, clean or replace as necessary, refer to Figure 35.
f) Refit or replace the top section of the black plastic air inlet cowl, ensuring that it is clipped into place and that the holes in the white plastic insert are aligned with the fixing holes.
g) Attach and secure the gas feed pipe to the replacement gas valve, using a new gasket.
h) Attach and secure the replacement gas control valve to the fan assembly .
i) Re-assemble in reverse order; ensure that all joints and seals are correctly re-fitted.
Note: The gas control valve is factory set and sealed and is not adjustable. If the gas control valve is changed, then when the appliance is running, the flue gas CO
2
should be measured, refer to section 6.1, and compared to the values stated in Performance Data, section 2.2. If the measured value does not correspond to the Performance Data, then contact: Halstead Boilers Ltd. Service Help line: 08450 710780.
33
GAS FEED PIPE CONNECTION TO GAS CONTROL VALVE
34
GAS CONTROL VALVE
35
AIR INLET COWL
33
If a new gas valve is fitted it must be adjusted as per the instructions that are supplied with the new gas valve.
A suitable, calibrated flue gas analyser is required to measure the CO
2
.
9.3.2
COMBUSTION CHECK SET-UP
When installing, commissioning or servicing a gas appliance that incorporates a pre-mix burner and zero-set governor, because it is
not possible to measure an operating pressure the engineer should first check that the gas supply is metered and ascertain whether it is possible to measure the gas rate. If the gas input rate can be measured then the requirements of GSIUR 26(9) can be met, including any specific requirements in manufacturers’ instructions.
If gas input rate cannot be measured then, to satisfy the intent of GSIUR 26(9), the engineer shall measure the combustion quality of the appliance in accordance with BS 7967 or the manufacturers’ instructions.
If the engineer does not have the required equipment and no alternative test is specified by the manufacturer then the appliance shall be turned off and disconnected as an un-commissioned appliance until such time that equipment is available to undertake such tests.
!
34
40
BURNER GASKET
38
MANIFOLD MOUNTING SCREWS
39
WITHDRAWING BURNER
If the gas control valve is changed, then when the appliance is running, the flue gas CO
2
should be measured, refer to section 6.1, and compared to the values stated section 2.3. If the measured value does not correspond to the Performance Data, then contact: Halstead Boilers Ltd. Service Help line: 08450 710780.
Always seal the gas valve adjustment screw with paint after adjustment
Refer to Figures 35, 36, & 37 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2. c) Remove the gas control valve including air inlet cowl; refer to
section 9.3. d) Unscrew the three screws holding the lower section of the black
plastic air inlet cowl and gas valve mounting plate, remove plate and cowl; refer to Figures 35 and 36.
e) Unscrew the four screws holding the fan to the burner manifold, and remove fan; refer to Figure 37.
f) Attach and secure the replacement fan, replace the gasket. g) Re-assemble in reverse order; ensure that all joints and seals are
correctly re-fitted.
9.4
FAN
36
GAS VALVE MOUNTING PLATE
37
FAN MOUNTING SCREWS
35
FRONT INSULATION
9.6
COMBUSTION CHAMBER
The design of the appliance is such that the combustion chamber insulation should not require replacement unless mechanically damaged. It is recommended that to prevent dust, the insulation be dampened prior to removal, and that a protective mask is worn when changing or handling the insulation material.
Refer to Figure 41 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2.
c) Remove the electrodes; refer to section 9.1. d) Remove the burner: refer to section 9.5. E) Replace the combustion chamber front insulation. f) Re-assemble the burner and electrodes, using new gaskets. g) Check the position of the electrodes: refer to section 6.4. h) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted.
41
COMBUSTION CHAMBER FRONT INSULATION
INSULATION
9.7
COMBUSTION CHAMBER REAR
Refer to Figure 42 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2. c) Use an Allen key to undo the central screw holding the rear
insulation in place. d) Remove old insulation and fit replacement, ensuring locating
washer is in front. e) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted.
42
COMBUSTION CHAMBER REAR INSULATION
9.8
HEAT EXCHANGER
Refer to Figures 15, & 43 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2. c) Disconnect the electrical leads to the flue sensor, flow sensor
and return sensor.
d) Drain down the appliance; refer to section 9.24. e) Disconnect the flue system from the appliance, 4 screws, and
lift up to disengage the flue from the flue hood; refer to Figure 15. f) Remove the retaining clip from the heat exchanger flow outlet,
and undo the nut connecting the flow pipe to the plate-to-plate heat exchanger. On SBX appliances undo the nut connecting the flow pipe to the CH flow isolating cock; refer to Figure 43.
g) Rotate the flow pipe anticlockwise and gently pull down to disengage the flow pipe from the heat exchanger.
h) Remove the retaining clip from the heat exchanger return inlet, and undo the nut connecting the flow pipe to the hydroblock adaptor fitting.
i) Rotate the return pipe clockwise and gently pull down to disengage the return pipe from the heat exchanger.
Refer to Figures 38, 39 & 40 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2. c) Unscrew the three tork screws, (T-25), holding the manifold to
the combustion chamber front cover, and remove the manifold; refer to Figure 38.
d) Remove the gasket, and withdraw the burner; refer to Figure 39 e) Fit replacement burner, taking care not to damage the
insulation, and ensure burner is correctly located by lining up the locating tab.
f) Fit new gasket; refer to Figure 40. g) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted.
9.5
BURNER
36
j) Disconnect the condensate drainpipe from the condensate drainpipe sump adaptor; refer to section 9.18.
k) Unscrew the three nuts holding the heat exchanger to the back panel; refer to Figure 43.
l) Remove the heat exchanger. m) Disconnect the condensate drainpipe sump adaptor from the
heat exchanger. n) Remove the flue hood from the heat exchanger, two screws,
and fit the flue hood onto the new heat exchanger, Check integrity of the flue hood seals and replace as necessary. Remove the manual air vent and vent tube from the heat exchanger and fit onto to new heat exchanger; refer to Figure 43.
o) Fit the condensate drainpipe sump adaptor to the heat exchanger and flue hood.
p) Re-assemble in reverse order; check integrity of the flow and return pipe 'O' rings and fibre washers and replace as necessary. Ensure that all joints and seals are correctly re-fitted.
q) Open the isolating cocks and vent air from the system using the manual air vent. Re-pressurise the system as necessary and check for water leaks.
Note: It is likely that the heat exchanger will still contain water.
43
HEAT EXCHANGER
Refer to Figures 44 a) Ensure supply voltage is isolated, and that the gas supply is
isolated. b) Remove the gas control valve, fan & burner assembly; refer to
section 6.2.
c) Remove the heat exchanger: refer to section 9.8. d) Disconnect the condensate drainpipe sump adaptor from the
heat exchanger; refer to section 9.18. e) Remove the existing flue hood from the heat exchanger, two
screws, and fit the replacement flue hood onto the heat exchanger; use new flue hood seals; refer to Figure 44.
f) Fit the condensate drainpipe sump adaptor to the heat exchanger and flue hood.
g) Unscrew the flue sensor from the existing flue hood and fit onto the new flue hood; refer to section 9.16.
h) Re-assemble in reverse order; check integrity of the flow and return pipe 'O' rings and fibre washers and replace as necessary. Ensure that all joints and seals are correctly re-fitted.
i) Open the isolating cocks and vent air from the system using the manual air vent. Re-pressurise the system as necessary and check for water leaks.
9.9
FLUE HOOD
44
FLUE HOOD
Refer to Figures 45 a) Ensure supply voltage is isolated. b) Disconnect the electrical lead to the pump head. c) Drain down the appliance; refer to section 9.24. d) Using a long Allen key unscrew the four screws holding the
pump head; refer to Figure 45. e) Remove the pump head, and fit replacement pump head,
using a new 'O' ring seal. f) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted. g) Open the isolating cocks and vent air from the system using
the manual air vent. Re-pressurise the system as necessary and check for water leaks.
Note: It is likely that there will still be some water spillage when the head is removed.
9.10
PUMP (HEAD ONLY)
45
PUMP HEAD
Refer to Figure 46 a) Ensure supply voltage is isolated. b) Disconnect the electrical lead to the diverter valve motorised
head.
c) Unscrew the locating screw; refer to Figure 46. d) Unclip the diverter valve motorised head and slide it down to
disengage it from the hydroblock body.
e) Fit the replacement diverter valve motorised head. f) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted.
9.11
DIVERTER VALVE MOTORISED HEAD
46
DIVERTER VALVE MOTORISED HEAD
Refer to Figure 47 a) Ensure supply voltage is isolated. b) Disconnect the electrical leads to the pump head and diverter
valve motorised head.
c) Drain down the appliance; refer to section 9.24. d) Remove the flow and return pipes from the heat exchanger;
refer to section 9.8. e) Remove the clip holding the hydroblock adaptor fitting in
place, and remove fitting.
f) Remove the two clips holding the return pipes in place. g) Undo the nut connecting the CH return pipe to the CH return
isolating cock, and disengage the CH return pipe from the hydroblock.
h) On CBX appliances, undo the nut connecting the DHW return pipe to the plate heat exchanger and disengage the DHW return pipe from the hydroblock.
i) On SBX appliances, undo the nut connecting the secondary return pipe to the secondary return isolating cock and disengage the secondary return pipe from the hydroblock.
j) Remove the clip holding the flexible hose in place, and remove hose.
k) Unscrew the three screws holding the hydroblock onto the mounting studs, and remove the hydroblock.
l) Align the replacement hydroblock against the mounting studs and secure using the three screws.
m) Re-assemble in reverse order; ensure that all joints and seals are correctly re-fitted.
n) Open the isolating cocks and vent air from the system using the manual air vent. Re-pressurise the system as necessary and check for water leaks.
Note: It is likely that there will still be some water spillage when the Hydroblock is removed.
9.12
HYDROBLOCK ASSEMBLY
47
HYDROBLOCK ASSEMBLY
37
38
Refer to Figure 48 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. c) Remove the spire nut on the case in front of the expansion
vessel. d) Undo the nut connecting the flexible hose to the expansion
vessel and remove hose.
e) Slide the expansion vessel forward and remove. f) Slide the replacement expansion vessel in place. g) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted. h) Open the isolating cocks and vent air from the system using
the manual air vent. Re-pressurise the system as necessary and check for water leaks.
9.13
EXPANSION VESSEL
48
EXPANSION VESSEL
Refer to Figures 18 & 24 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. c) Undo the nut securing the discharge tail pipe to the pressure
relief valve and remove. Undo the nut securing the pressure gauge capillary, and remove.
d) Undo the nut securing the pressure relief valve to the CH flow pipe and remove the pressure relief valve.
e) Fit the replacement pressure relief valve, using new fibre washers.
f) Re-assemble in reverse order; ensure that all joints and seals are correctly re-fitted.
i) Open the isolating cocks and vent air from the system using the manual air vent. Re-pressurise the system as necessary and check for water leaks.
Note: the pressure relief valve should not be used to drain the system.
9.14
PRESSURE RELIEF VALVE
Refer to Figure 49 a) Ensure supply voltage is isolated. b) Disconnect the electrical lead from the sensor to be changed. c) Unclip the sensor from the pipe and remove. d) Clip the replacement sensor onto the pipe and position as
shown in Figure 51.
e) Reconnect the electrical lead.
9.15
WATER TEMPERATURE SENSORS
49
49a FLOW SENSOR
49b RETURN SENSOR
Refer to Figure 50 a) Ensure supply voltage is isolated. b) Disconnect the electrical lead from the flue sensor. c) Unscrew the flue sensor and remove from the flue hood. d) Fit the replacement flue sensor and reconnect the electrical
lead (blue plug).
9.16
FLUE SENSOR
39
50
FLUE SENSOR
51
PLATE HEAT EXCHANGER
FILTER (CBX APPLIANCES ONLY)
9.17
PLATE HEAT EXCHANGER AND
Refer to Figure 51 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. c) Close the DHW inlet isolating cock, open a DHW tap at the
lowest point in the system and allow the pressure to dissipate. Close this tap again.
d) Undo the nut connecting the flow pipe from the main heat exchanger to the plate heat exchanger, and rotate in an anticlockwise direction to give access to the filter.
e) Lift out the filter and clean under a tap. g) Refit the filter, or replace as necessary, and re-assemble in
reverse order; ensure that all joints and seals are correctly re-fitted. h) If it is suspected that the plate heat exchanger is blocked or is
leaking then proceed as follows: i) Undo the nut connecting the pipe from the hydroblock to the
plate heat exchanger, and rotate out of the way. j) Undo the nut connecting the plate heat exchanger to the CH
flow water isolating cock pipe. k) Undo the nut connecting the plate heat exchanger to the DHW
outlet pipe. l) Undo the nut connecting the plate heat exchanger to the DHW
water isolating cock pipe.
m) Lift up the plate heat exchanger and remove. n) Fit the replacement plate heat exchanger, using new case
seals as necessary, ensuring the filter is fitted. o) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted. p) Open the isolating cocks and vent air from the system using
the manual air vent. Re-pressurise the system as necessary and check for water leaks.
Refer to Figure 27 a) Ensure supply voltage is isolated. b) Open the drain sump cap, while holding a receptacle beneath
to capture any condensate.
c) Disconnect the condensate drainpipe from the appliance. d) Undo the two locknuts holding the system in place. e) Unclip the hose from the support bracket. f) Detach the condensate drainpipe sump adaptor, by gently
pulling down. g) Remove the condensate drain system, clean or replace as
necessary. h) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted.
9.18
CONDENSATE DRAIN SYSTEM
Refer to Figure 24 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. c) Disconnect the pressure gauge capillary from the pressure
relief valve. d) Disengage the pressure gauge from the fascia panel, and
remove the gauge.
e) Fit the new pressure gauge and re-assemble in reverse order. f) Open the isolating cocks and vent air from the system using
the manual air vent. Re-pressurise the system as necessary and check for water leaks.
9.19
PRESSURE GAUGE
Refer to Figure 47 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. c) Disconnect the vent tube from the auto air vent and check that
it is free from blockage.
d) Unscrew the auto air vent, and fit replacement. e) Re-assemble in reverse order; ensure that all joints and seals
are correctly re-fitted.
f) Open the isolating cocks and vent air from the system using
9.20
AUTO AIR VENT
40
53
DRAIN POINT
Refer to Figures 19, 24 & 52 a) Ensure supply voltage is isolated. b) Lower the controls front panel and lower the control fascia panel. c) Unplug the electrical leads from the PCB. Refer to section 7. d) Unplug the BCC if fitted. e) Remove the PCB plastic cover. f) Unclip the PCB and withdraw. g) Carefully remove the three control knobs, noting their position
and fit onto new PCB.
h) Fit the new PCB and plug in the BCC if previously used. i) Re-assemble in reverse order, ensuring control knobs are free to
move and reset button operates. j) Turn ON the electrical supply and set the ON/OFF switch to ON,
if the Reset LED, (Refer to section 8.3), shows steady red proceed as follows:
a) Press the Reset button. The Reset LED and LED 1 should flash once. b) Wait approximately 5 seconds, while the control is re-
programmed and then press the Reset button, to initialise the control.
9.21
CONTROL PCB
a) Ensure supply voltage is isolated. b) Lower the controls front panel and lower the control fascia panel. c) Unplug the electrical leads from the PCB. Refer to section 7. d) Unplug the four electrical leads from the back of the clock. e) Remove the four retaining screws and withdraw the clock from
the control panel.
f) Fit the new clock and re-assemble in reverse order.
9.22
TIME CLOCK (CBX APPLIANCES ONLY)
FLOW REGULATOR AND DHW FILTER (CBX APPLIANCES ONLY)
9.23
DHW FLOW TURBINE, DHW
Refer to Figure 28 a) Ensure supply voltage is isolated. b) Remove the electrical lead to the DHW flow turbine. a) Close the DHW inlet isolating cock, open a DHW tap at the lowest
point in the system and allow the pressure to dissipate. Close this tap again. c) Undo the nut connecting the DHW flow turbine to the DHW inlet
isolating cock. d) Undo the nut connecting the DHW flow turbine to the water feed pipe,
and remove the DHW flow turbine, (containing the DHW Flow Regulator). e) The DHW filter is located inside the flow cock. To remove it, first remove
the top hat washer and then prise the filter out with a pointed tool. e) The assembly can now be flushed clean using water, and parts replaced
as necessary. g) Re-assemble in reverse order, using a new fibre washer; ensure that all
joints and seals are correctly re-fitted. f) Open the DHW inlet isolating cock and vent air from the system by
opening each hot water tap in the house in turn.
There may be some slight water spillage; so electrical components should be protected.
Refer to Figures 43 & 53
a) Before draining, give the appliance a brief CH demand, to ensure the diverter valve is in the CH position.
b) Ensure supply voltage is isolated. c) If not draining the entire CH system, close the CH flow, CH
return water isolating cocks. d) Close the DHW return water-isolating cock, (where fitted). e) Drain down the system from the external drain point, and
drain the appliance using the drain tap on the CH flow water isolating cock, in conjunction with the manual air vent located on the LHS of the heat exchanger; refer to Figures 43 and 53.
f) Where the DHW circuit is to be worked on, close the DHW inlet isolating cock, open a DHW tap at the lowest point in the system and allow the pressure to dissipate. Close this tap again.
Note: the pressure relief valve should not be used to drain the system.
9.24
DRAINING THE APPLIANCE
the manual air vent. Re-pressurise the system as necessary and check for water leaks.
52
PCB HOUSING
NG/Propane chip card
Electrical Connectors
Securing Screws
41
Refer to Figure 54
Key G C Part No. Description No off Makers Pt No. 1 Ignition Electrode 1 988526 2 Detection Electrode 1 988527 3 Spark generator Unit incl. spark leads 1 500665 4a Gas Control Valve - NG/LPG (CBX24/32 SBX30) 1 988315 4b Gas Control Valve - NG/LPG (CBX38) 1 TBA 5 Fan Assembly 1 601015 6a Burner (CBX32) 1 700601 6b Burner (CBX24) 1 700600 6c Burner (CBX38/SBX30) 1 700602 7a Heat Exchanger (CBX32) 1 451031 7b Heat Exchanger (CBX24) 1 451032 7c Heat Exchanger (CBX38/SBX30) 1 451030 8 Pump Head (6 metre) 1 500672 9 Diverter Valve Motorised Head 1 500673 10 Hydroblock Assembly 1 500650 11 Expansion Vessel 1 451020 12 Pressure Relief Valve 1 300734 13 Water Temperature Sensor 2 500661 14 Flue Sensor 1 500660 15a Plate Heat Exchanger (CBX24/32) 1 451015 15b Plate Heat Exchanger (CBX38) 1 451018 16 Plate Heat Exchanger Filter 1 500498 17 Pressure Gauge 1 450961 18 Auto Air Vent 1 500674 19 Control PCB incl cover 1 988488 20 Time Clock 1 600520 21 DHW Flow Turbine 1 300733 22a DHW Flow Regulator (CBX32) 1 300715 22b DHW Flow Regulator (CBX24) 1 300717 22c DHW Flow Regulator (CBX 38) 1 300719 23 DHW Filter 1 500497 24 Manual Bleed valve 1 300730
Heat Exchanger o-ring kit 988489 Hydroblock o-ring kit 988490
SHORT PARTS LIST
10
42
54
123 4
5678
9 10 11 12
13 14 15 16
17 18 19 20
21 22 23
24
SERVICE HELPLINE: 08450 710780 TRAINING: 01926 834838
Halstead Boilers Limited, 20/22 First Avenue, Bluebridge Industrial Estate, Halstead, Essex C09 2EX.
Telephone: 01787 272800. Sales Direct Line: 01787 475557. Fax: 01787 474588.
Service Helpline: 08450 710780. Training: 01926 834838.
Email: sales@halsteadboilers.co.uk or service@halsteadboilers.co.uk or training@halsteadboilers.co.uk
Website: www.halsteadboilers.co.uk
Halstead Boilers is continuously improving its products and may therefore change specifications without prior notice.
The statutory rights of the consumer are not affected.
01/08 751030 Issue 2
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