Halstead EDEN X Type VBX 18, EDEN X Type VBX 30 Installation And Servicing Instructions

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EDEN X TYPE

OPEN VENT CONDENSING BOILER

INSTALLATION AND SERVICING INSTRUCTIONS

TO BE GIVEN TO THE USER

0086

EC 87/BP/35

G.C. Appliance No. 41-260-15 (Eden VBX 18)

G.C. Appliance No. 41-260-14 (Eden VBX 30) G.C. Appliance No. 41-260-18 (Eden VBX 18 Propane) G.C. Appliance No. 41-260-17 (Eden VBX 30 Propane)

VBX 18 & 30

SERVICE HELPLINE: 01926 834834 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: 01926 834834. 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.

09/04 751053

SECTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE NO

1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . 5

2.7 Specification for Twin Flued (Type C53) Applications. . . . . . . . . . . 7

2.8 Additional Concentric Flue Kits . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.9 Appliance Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3INSTALLATION REQUIREMENTS. . . . . . . . . . . . . . . . . . . . 9

3.1

Statutory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.2 Appliance Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.3 Flue Terminal Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.4 Ventilation Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.5 Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.6 Gas Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.7 Central Heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.8 Draining Tap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.9 Safety Valve Open Vented System . . . . . . . . . . . . . . . . . . . . . . . 11

3.10 Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.11 Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.12 Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.13 Open Vented Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.14 Domestic Hot Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.15 Sealed Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.16 Safety Valve Sealed System . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.17 Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.18 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.19 Water Makeup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.20 Filling a Sealed Water System. . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.21 Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.22 External Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 APPLIANCE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 14

4.1

Unpacking The Appliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2 Preparing The Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.3 Mounting The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.4 Central Heating Service Connections . . . . . . . . . . . . . . . . . . . . . 15

4.5 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.6 Condensate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.7 Air / Flue Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5 COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.1

Filling the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.2 Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.3 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.4 Lockout / Reset Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.5 Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.6 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.7 Other Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.8 Users Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.9 Appliance Log Book. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.10 Gas Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6 ROUTINE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.1

Combustion Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.2 Gas Control Valve, Fan & Burner Assembly . . . . . . . . . . . . . . . . 22

6.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.4 Ignition & Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.5 Combustion Chamber & Heat Exchanger . . . . . . . . . . . . . . . . . . 23

6.6 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.7 Sealed Water System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.8 Re-assembly & Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . 24

6.9 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

7 INTERNAL WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . 25

7.1

Functional Flow Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 25

8FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8.2 Diagnostic LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8.3 Faulting Finding Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

8.4 Central Heating Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . 26

9 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . 28

9.1

Ignition and Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . 28

9.2 Igniter Unit and Ignition Leads . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.3 Gas Control Valve including Air Inlet Cowl . . . . . . . . . . . . . . . . . 29

9.4 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

9.6 Combustion Chamber Front Insulation . . . . . . . . . . . . . . . . . . . . 31

9.7 Combustion Chamber Rear Insulation. . . . . . . . . . . . . . . . . . . . . 31

9.8 Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

9.9 Flue Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9.10 Water Temperature Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

9.11 Flue Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9.12 Condensate Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

9.13 Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

The Halstead Eden VBX 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). They are designed for use with either sealed or open vented central heating systems.

The appliances feature an attractive white stove enamelled casing, with inset control panels. The flue system 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 (29 in)), 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

), split flued (C53),

and special (C

) applications, contact Halstead Boiler Ltd Service

Help Line: 01926 834834, for further details,

ONLY HALSTEAD APPROVED FLUE KITS OR EXTENSIONS MAY BE USED WITH THESE APPLIANCES.

CONTENTS INTRODUCTION

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 central heating (CH) demand, and with internal frost protection provided as standard.

The heat exchanger is constructed from stainless steel, and there is the option for routing the flow and return connections either via top or bottom connections.

The appliances may be used with any certified mains voltage room thermostat, 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.

1.1

IMPORTANT INFORMATION

1.2

GENERAL DESCRIPTION

Appliance VBX30 VBX18 VBX30 VBX18

Propane Propane

Mode Rate Central Heating Output

Max

kW 30.0 18.0 30.0 18.0

(non-condensing)

(Btu/h) (102400) (61400) (102400) (61400)

(80 - 60 °C)

Min

kW 8.2 5.9 8.2 5.9

(Btu/h) (28000) (20100) (28000) (20100)

Central Heating Output (condensing)

Max

kW 32.1 19.3 32.1 19.3

(50 - 30 °C) (Btu/h) (109500) (65900) (109500) (65900)

Net

kW 30.4 18.4 30.4 18.4

Central Heating Input

(Btu/h) (103700) (62800) (103700) (62800)

Max Rate

Gross

kW 33.8 20.4 33.0 20.0

(Btu/h) (115300) (69600) (112700) (68300)

Net

kW 7.6 5.5 7.6 5.5

Central Heating Input

(Btu/h) (26000) (18800) (26000) (18800)

Min Rate

Gross

kW 8.4 6.1 8.3 6.0

(Btu/h) (28600) (20800) (28300) (20500)

Central Heating Gas Rate

m3/h 3.22 1.95

(after 10 min operation - hot)

Max ft3/h (113.7) (68.9)

kg/h 2.36 1.43

Seasonal Efficiency % 90.4 91.0 92.4 93.1 Seasonal Efficiency (SEDBUK) Band “A” Nox Classification Class “5” Min Central Heating System Pressure Bar 0.1 (1 m H2O) Max Central Heating System Pressure Bar 3.0 Max Central Heating Flow Temperature °C 80 Min Central Heating Flow Temperature °C 30

Eden VBX 30 Propane, Eden VBX 18 Propane:

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

, C33,

, or B23.

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 VBX 30, Eden VBX 18:

2H3P

(G20 with a governed gas supply at 20 mbar (8 in.wg)

inlet pressure).

TECHNICAL SPECIFICATIONS

2.1

GAS CATEGORIES

2.2

PERFORMANCE DATA

Natural Gas and Propane versions

Appliance VBX30 VBX18 Total weight (full) kg 38.1 32.6 Total weight (empty) kg 36.1 31.3 Max lift weight kg 28.1 24.7 Total water capacity l 2.0 1.3 Electrical supply 230V 50Hz Fuse at 3A Internal fuse T4H 4A 250V Maximum power consumption W 110 IP Rating XXXX Flue gas temperature Nat Gas 80/60(Propane) °C 73 (76) 74 (72) Flue gas temperature Nat Gas 50/30 41 43

CO2value max rate (Nat Gas) %

9.2 ± 0.3 case on

9.0 ± 0.2 case off

CO2value min rate (Nat Gas) ref only % 8.9 ± 0.1 8.4 ± 0.1 CO value max rate (Nat Gas) % 0.01 ± 0.005

CO2value max rate (Propane) %

10.7 ± 0.3 case on

10.5 ± 0.2 case off

CO2value min rate (Propane) ref only % 10.0± 0.1 9.7 ± 0.1 CO value max rate (Propane) % 0.019 ± 0.005 Flue products mass flow rate (Nat Gas) g/s 13.7 8.3 Flue products mass flow rate (Propane) g/s 13.7 8.3 Gas Valve Offset @ min rate Pa -3.0

Connections

Gas 15 mm compression CH flow 22 mm tail CH return 22 mm tail Condensate Drain 21.5 - 22 mm plastic overflow pipe

2.3

GENERAL SPECIFICATIONS

Refer to Figure 49.

Key G C Part No. Description No off Makers Pt No.

1 Ignition Electrode 500680 2 Detection Electrode 500681 3 Spark Generator Unit 500665 4 Gas Control Valve 500655

5 Fan Assembly 601015 6a Burner VBX 30/SBX 30 700602 6b Burner VBX 18/CBX 24 700600 7a Heat Exchanger (VBX 30) 451033 7b Heat Exchanger (VBX 18) 451034

8Water Temperature Sensor 500661

9Flue Sensor 500660 10 Manual Bleed Valve 300730 11 Control PCB 988491 12 User Interface 988492

Heat Exchanger Seal Kit 988489

SHORT PARTS LIST

123 4

5678

2.4

OVERALL DIMENSIONS AND MINIMUM CLEARANCES

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

2.5

CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS

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

Standard horizontal flue kit

- Part no. 956083

The following flue systems are available for the EDEN 'x-type' range

parts to the appliance and end terminal. Flue extension ducts and extension elbows are available as accessories.

ABCDE FGHI JKLM

EDEN VBX 18 320 280 150 97 100 694 200 540 400 200 5 5 200

EDEN VBX 30 360 320 150 97 100 694 200 540 400 200 5 5 200

Refer to Figures 22 & 27 a)

Ensure supply voltage is isolated.

b) Unclip the user interface from its housing (see figure 22). c) Lower the controls front. d) Unplug the electrical leads from the PCB. Refer to section 7. e) Unplug the BCC (boiler chip card) if fitted. f) Remove the PCB plastic cover. g) Unclip the PCB and withdraw. h) Fit the new PCB and plug in the BCC if previously used. i) Re-assemble in reverse order. j) If the boiler requires resetting turn the CH Temperature Control

knob anti-clockwise to 'STANDBY' position and then back to 'ON' within two seconds. Refer to section 5.4.

9.13

CONTROL PCB

Refer to Figure 48 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).

9.11

FLUE SENSOR

Refer to Figure 30 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.

9.12

CONDENSATE DRAIN SYSTEM

Traditional concentric flue system, Figure 3a, with a maximum length of 5000 mm. 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 terminal is 755 mm long but can be cut to a minimum flue length of 250 mm, which is suitable for single, 100 mm (4”), brick walls.

Ø60/100mm concentric standard horizontal wall terminal. Max. length 5000mm. Min. length 250mm.

The pluming from the flue may cause nuisance to neighbours or other buildings.

Horizontal terminal has a built-in fall in the flue to allow condensate to drain away.

If horizontal flue requires extension pipe, the flue should be installed such that there is no section less than

2.5º – 3º to the horizontal.

93 flanged elbow (concentric) with sampling point

Standard horizontal flue kit - Part no. 956083

Kit A

60/100 flue accessories:

0.5m flue extension duct - 956092 1m flue extension duct - 956093 93 flue extension elbow - 956091 45 flue extension elbow (2x) - 956090 Vertical flue turret - 956087

(C13) - PART NO.956083

2.5.1

KIT A HORIZONTAL WALL TERMINAL

TERMINAL (C33) - HBL PART 956081

2.5.2

KIT B VERTICAL CONCENTRIC FLUE

Roof terminal with rain cover and pitched roof flashing kit.

Vertical flue socket with sampling point.

60/100 flue accessories:

0.5m flue extension duct - 956092 1m flue extension duct - 956093 93 flue extension elbow - 956091 45 flue extension elbow (2x) - 956090 Flat roof flashing plate - 956088 93 flanged flue elbow - 956086 Max. length12m. Min. length 0.6m.

Kit B

Vertical flue kit - Part no. 956081

Standard concentric (ø100/60) vertical flue application, Figures 3b, 3c, through roof attics with a maximum length of 12000 mm. The kit comprises of the roof terminal, flashing kit, 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.

For installation details refer to the flue kit instructions.

Fig 3(c) Offset vertical flue.

‘a’ measured from the boiler centre line to the centre line of the extension elbow.

‘b’ measured from the centre line of the extension elbow to the underside of the air cowl.

Maximum allowable length of a + b = 8900 mm.

Roof terminal with rain cover and pitched roof flashing kit.

If the standard horizontal terminal is likely to cause nuisance to neighbours 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 80 mm 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.

OUTLET (C53)

2.5.3

KIT C: RAISED EXTERNAL FLUE

HEAT EXCHANGER

Refer to Figure 46 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 9.12. 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 46.

f) Fit the condensate drainpipe sump adaptor to the heat exchanger and flue hood.

9.9

FLUE HOOD

Refer to Figure 47 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 47. e) Reconnect the electrical lead.

9.10

WATER TEMPERATURE SENSORS

return pipe 'O' rings and fibre washers and replace as necessary. Ensure that all joints and seals are correctly re-fitted. If required re-solder flow and return pipes.

q) Re-fill central heating system 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.

FLOW SENSOR

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) Re-fill central heating system and vent air from the system using the manual air vent. Re-pressurise the system as necessary and check for water leaks.

(B23) - PART NO. 956062

OUTSIDE WALL (C33) PART NO: 956085

2.5.4

KIT D VERTICAL CONCENTRIC -

Roof terminal with rain cover.

For outside installations the pipe joints have to be covered with special 'Lip-seal' to prevent rain ingress.

Max. lengths (from top of boiler to terminal) 8m. Min. length 1m.

Ø60/100mm concentric air/flue pipe Part no. 956093 (1m extension) and Part no. 956092 (0.5m extension)

93 flanged elbow (concentric) with sampling point

All horizontally fitted pipes are routed with a 2.5 – 3 fall towards the boiler.

Kit D

External vertical flue kit - Part no. 956085

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 flue will be

2.6

KIT E CHIMNEY FLUE LINER KIT

Maximum flue resistance permitted for an opened flued system = 100 Pa. Minimum flue resistance permitted for an opened flued system = 38 Pa.

Flue Component Flue Resistance Part

(Pa) Number

Air inlet Assembly (required) 9 60/80 Adaptor (required) 12 Ter minal (required) 9 -

91.5° Elbow (80) (required) 8 80 diameter Corrugated (required) 2/metre 80 mm diameter straight duct 2/metre Horizontal Flue Adaptor 15 956086 Ver tical Flue Adaptor 0 956087 93° Elbow (60/100) 15 956091 45° Elbow (60/100) 7 956090

Centralising brackets

Chimney terminal

93 flanged elbow (concentric) with sampling point

Ø60/100mm concentric chimney adaptor pipe.

In replacement installations, the chimney has to be cleared of debris and all flue parts.

Chimney plate

Flexible corrugated plastic flue liner Ø80mm according to EN 14471 Max. length 30m. Min. length 5m.

KIT E

Chimney flue liner kit - Part no. 956082

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.

Raised Ø60mm flue outlet duct with Ø80mm anti-freeze pipe. Max. height of raised flue from centre of air intake 4m. Min. height 1m.

93 flanged elbow (concentric) with sampling point

Standard horizontal flue adaptor has an already built-in fall in the flue to allow the condensate to drain away.

Kit C

Raised external flue outlet kit Part no. 956084

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.

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 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) 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.

COMBUSTION CHAMBER FRONT INSULATION

INSULATION

9.7

COMBUSTION CHAMBER REAR

Refer to Figure 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) 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.

COMBUSTION CHAMBER REAR INSULATION

9.8

HEAT EXCHANGER

Refer to Figures 14, & 45 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 lead to the flue sensor, remove both

flow and return sensors noting which goes where.

d) Drain down central heating system. e) Disconnect the flue system from the appliance, 4 screws, and

lift up to disengage the flue from the flue hood; refer to Figure 14. f) Remove the retaining clip from the heat exchanger flow outlet;

refer to Figure 45. g) Gently pull up (or down, depending on installation) to

disengage the flow pipe from the heat exchanger. h) Remove the retaining clip from the heat exchanger return

inlet. i) Gently pull up (or down, depending on installation) to

disengage the return pipe from the heat exchanger.

It may be necessary to cut both flow and return pipes to disengage them from the heat exchanger.

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 45.

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 45.

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

OUTLET (C53) - PART NO. 956080

2.7

KIT F: SPLIT PIPE VERTICAL FLUE

This flue system kit is designed for installations where the air intake position is different from the flue duct exit point. The kit comprises 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.

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 C5 flue systems the terminals for the supply of combustion air and for the evacuation of combustion products shall not be installed on opposite walls of the building.

For installation details refer to the instructions provided with the twin flued kit.

Maximum flue resistance permitted for a twin flued system = 100 Pa

Minimum flue resistance permitted for a twin flued system = 74 Pa

Flue Component Flue Resistance (Pa) Part Number Twin Flue Adaptor (required) 30 Air Inlet Terminal (required) 9 Flue Outlet Terminal (required) 27 80 mm diameter straight duct 2/metre 956102 90° Elbow (80/80) (Required) 8 956100 45° Elbow (80/80) 4 956099

Ø80mm air intake

Split flue system

Roof terminal with pitched roof flashing kit.

If the flue pipe passes through compartment from wall/floors, the requirements set out in Building Regulations Part B must be followed.

Ø80mm twin adaptor with sampling point.

If the flue pipe passes through habitable rooms within the same dwelling, the flue pipe must be routed through vented air ducts.

Max. flue length 30m.

The flue resistance for the following accessories has to be considered. Ø80mm flue extension 90 elbow 45 elbow

Split pipe vertical flue outlet kit Part no. 956080

Kit F

Aflue system can be built up from the components detailed in the table, but the total flue resistance must not exceed the maximum stated.

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.

Ver tical Turret Socket - For use with elevated horizontal flues and vertical terminals.

Ver tical 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.

The 'equivalent' flue length must not exceed the maximum values stated.

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:

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.

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 4.7).

Horizontal flue terminal (all orientations) maximum 5000 mm (197 in) Horizontal flue terminal (rear exit) minimum 250 mm (10 in) Ver tical flue terminal maximum 12000 mm (472 in) Ver tical flue terminal minimum 600 mm (23

/2 in)

2.8

ADDITIONAL CONCENTRIC FLUE KITS

GAS VALVE MOUNTING PLATE

FAN MOUNTING SCREWS

Refer to Figures 40, 41 & 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) Unscrew the three tork screws, (T-25), holding the manifold to

the combustion chamber front cover, and remove the manifold; refer to Figure 40.

d) Remove the gasket, and withdraw the burner; refer to Figure 41 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 42. g) Re-assemble in reverse order; ensure that all joints and seals

are correctly re-fitted.

9.5

BURNER

BURNER GASKET

MANIFOLD MOUNTING SCREWS

WITHDRAWING BURNER

2.9

APPLIANCE HYDRAULIC CIRCUITS

INCLUDING AIR INLET COWL

9.3

GAS CONTROL VALVE

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) Unscrew four screws holding the gas feed pipe, and remove

gas feed pipe, refer to Figure 35. d) Unscrew three tork screws (T-20), and remove gas control

valve, refer to Figure 36. 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 37.

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

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: 01926 834834

AIR INLET COWL

GAS FEED PIPE

GAS CONTROL VALVE

Refer to Figures 37, 38, & 39 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 37 and 38.

e) Unscrew the four screws holding the fan to the burner manifold, and remove fan; refer to Figure 39.

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

INSTALLATION REQUIREMENTS

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 Water 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 54401, 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 instructions 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.

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 5.

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 Boilers Ltd, Service Help Line: 01926 834834.

3.2

APPLIANCE LOCATION

The following limitations MUST be observed when siting the appliance:

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 XXXX. 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. (This section under review!)

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:

VBX 30 117 cm

VBX 18 57 cm

REPLACEMENT OF PARTS

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 33 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 34 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. g) Re-assemble in reverse order; ensure that the igniter unit is

orientated as shown in Figure 34, and that the brown electric supply lead is fitted to position 1 on the igniter unit.

h) Ensure that all joints and seals are correctly re-fitted.

9.2

IGNITER UNIT AND IGNITION LEADS

IGNITOR UNIT AND IGNITION LEADS

IGNITION AND DETECTION ELECTRODES

d) Fit the new electrode, and new gasket. e) Check that electrode is aligned as detailed in Figures 29(a) or

29(b). f) Re-assemble in reverse order. Ensure that all joints and seals

are correctly re-fitted.

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

carport into dwelling *not recommended

K Ve rtically 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 carport 600mm 24in

*not recommended

O From adjacent wall 300mm 12in P From adjacent opening window 1000mm 40in Q From another terminal 600mm 24in R Minimum height 300mm 12in

•

B,C

H,I

D,N

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, the aggregate maximum rated input shall be used to determine the air vent free-area. (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.

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.

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 are designed for open vented central heating water systems, but may be fitted to a sealed central heating system provided the necessary components, such as expansion vessel and pressure safety relief valve are fitted to the system. Refer to Figure 8 for a typical open vented 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.

*Recommended by the boiler manufacturing industry to prevent pluming nuisance and damage to buildings.

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.

LED CODE FAULT/EFFECT REASON ACTION

● Check no air is in heat exchanger/CH system

1 Overheated appliance Water temperature greater than 105 °C

● Check external pump operation

● Check PCB/X1C connector

● Check flow thermistor

Water flow failure or

● Check water pressure

Differential check faulty/

● Check external pump/ CH system blockage

Flame for a short

Sensor temperature differential incorrect

● Check no air is in heat exchanger/CH system

period only

● Check flow, and return sensors

● Check wires to sensors not crossed

● Check gas supply

● Check gas service cock

● Check gas valve and lead

No gas or Lockout flame Low gas pressure.

● Check detection electrode/lead

3signal/ No flame, Lockout No flame signal on ignition,

● Check gas supply

after 5 ignition attempts or loss of signal during operation

● Check gas valve and lead

● Check PCB/X2A & X2B connectors

● Check spark generator/spark electrode

● Check mains earth lead continuity

● Check flue sensor

● Check flue system

4Flue gas sensor/No flame Flue gas temperature greater than 95 °C

● Check no air is in heat exchanger/CH system

● Check external pump

● Check PCB/PCB connectors

● Check flow, return and flue sensors

5 Defective sensor/No flame Defective flow, return or flue sensor

● Check wiring to sensors

● Check PCB/X6 & X8 connectors

Defective gas valve/

5 sec flame signal after burner

●

Check gas valve and lead

6Flame continues after

is switched off

●

Check PCB

demand ends

● Check fan

7 Defective fan/No flame Missing or Erroneous RPM signal

● Check mains fan lead & connector

● Check low voltage fan lead & connector

● Check PCB/X3 connector

APCB error/No flame Internal error ● Check PCB b Activate BCC/No flame New BCC ● Turn CH control knob to reset twice to activate

Safety system failure/

Failure of internal self checking system

● Check PCB

No flame ● Check BCC is initialised E BCC error/No flame Incorrect /missing BCC ● Reseat or replace BCC hNo flame Faulty connector ● Check PCB/X1A connector

● Check water pressure

Differential check faulty/

● Check external pump/ CH system blockage

Flame for 15 seconds

Wat er flow rate too low

● Check no air is in heat exchanger/CH system

● Check flow, and return sensors

● Check wires to sensors not crossed

Error in power supply/

Low mains voltage

● Check mains voltage

No flame ● Check PCB connectors

● Check power supply

No light indication Defective power supply

● Check PCB/X1B connector

● Check PCB fuse

c) If a sealed system is to be used then only a competent person must fill it.

d) The hydraulic resistance curves for the appliances are given in Figure 6.

e) If thermostatic radiator valves are fitted, one 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.

APPLIANCE HYDRAULIC RESISTANCE

56789101112 13 14 15 16 17 18 19 20 21 22 23 24

0.5

1.5

2.5

3.5

Flow Rate ltr/min

Pressure Drop (m H

VBX 30 VBX 18

A draining tap must be provided at the lowest point of the system, which will allow the entire system and hot water system to be drained.

Draining taps shall be to the current issue of BS 2879.

3.8

DRAINING TAP

A safety valve need not be fitted to an open vented system. (See

3.16 for sealed systems)

3.8

SAFETY VALVE OPEN VENTED SYSTEM

3.10

PUMP

The pump should be fitted on the flow pipe from the boiler and have isolating valves each side.

A variable duty pump should be set to give a temperature difference of no greater than 20°C between the flow and return, with the thermostat set at “MAX”, which is approximately 80° to give a flow rate as shown in table 1.

See figure 6 for pressure loss of the boiler. High resistance microbore systems may require a higher duty pump.

3.11

FLOW RATE

If it is necessary to alter the flow rate, the system can be fitted with a lockable balancing valve in the main flow or return pipes shown as valve “A” in figure 7. The flow rate through the boiler must not be allowed to fall below that given in table 1.

Table 1. Flow Rate

MINIMUM FLOW RATE

200 l/h

This is equal to 20°C differential at minimum heat input.

3.12

WATER TREATMENT

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.

3.13

OPEN VENTED WATER SYSTEM

The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres (90ft) above the boiler.

The cold feed must be 15mm minimum size. The vent must rise continuously and be unrestricted. It is important that the relative positions of the pump, cold feed

and open vent are as shown in figure 8.

3.14

DOMESTIC HOT WATER CYLINDER

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully

indirect coil type.

3.15

SEALED WATER SYSTEMS

The installation must comply with the appropriate requirements of the current issue of BS4814, BS5449, BS6759, BS6798 and BS7074 Part 1 and 2.

See figure 7 for a suggested layout.

3.16

SAFETY VALVE SEALED SYSTEM

A safety valve must be fitted to a sealed system. It shall be preset, non-adjustable with a lift pressure of 3 bar,

incorporating seating of a resilient material, a test device and a connection for drain.

The drain from the safety valve must be routed outside the building, must not discharge above an entrance or window or any type of public access area, be clear of any electrical fittings and positioned so that any discharge can be seen.

FAULT FINDING

8.1

GENERAL

Before looking for a fault condition, check that:

● The mains electrical supply is turned on.

● The room or cylinder/tank thermostat (where fitted) are calling

for heat.

● The gas service cock is open.

● 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).

For further information contact: Halstead Boilers Ltd. Service Help line: 01926 834834

8.2

DIAGNOSTIC LED INDICATORS

FASCIA PANEL - Refer to Figure 32.

The LED shows code '3' in a lockout condition. For fault finding refer to the diagnostic chart shown below.

8.3

FAULT FINDING CODES

In the event of the appliance failing to light, refer to the Diagnostics Chart.

FACIA PANEL

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. Remove plug cover and check voltage between L3 (orange) and N (blue). If 0 V ac, check external programmer / room thermostat. If 230 V ac, check control for lockout or blocking codes, (refer to section 8.3), check operation of the external pump.

Note: Whenever a CH demand is removed, 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 the Switch Live input is OK and no lockout or blocking code exists and the control is not in anti cycle mode, then replace PCB.

8.4

CENTRAL HEATING FAULT FINDING

3.17

EXPANSION VESSEL

A diaphragm type expansion vessel, conforming to the current issue of BS4814 (see also BS7074 Part 1 and 2) must be connected at a point close to the inlet side of the circulating pump, see the diagrammatic layout, figure 7 unless laid down differently by the manufacturer.

The expansion vessel volume depends on the total water system volume and the initial system design pressure. For any system an accurate calculation of vessel size is given in the current issue of BS5449 and BS7074 Part 1.

Example: For an initial design pressure of 0.7 bar, the minimum total vessel volume required is 0.063 x Total System Volume.

APPLIANCE

NON RETURN

VALVE

3-WAY VALVE

HOT WATER CYLINDER

TANK THERMOSTAT

DRAIN COCK

AIR RELEASE VALVE

AUTOMATIC AIR VENT

MAKE UP BOTTLE Observe minimum static head requirements

PUMP

PRESSURE GAUGE

EXPANSION VESSEL

SAFETY

VALVE

FILL POINT NON-RETURN VALVE

MOTORISED

VALVE

FLOW

RETURN

ROOM THERMOSTAT

TERMINAL

BLOCK

DIRECT HW CONNECT

CH SWITCH

220V RELAY BOX

(Optional)

CH/DHW 2 CHANNEL PROGAMMER

SEALED WATER SYSTEM

NOTE: No automatic by-pass required. However it is

recommended to leave one radiator open and to fit a system bypass in the DHW circuit to ensure pump overrun functionality.

3.18

PRESSURE GAUGE

A pressure gauge with a set pointer and covering at least 0 to 4 bar (0 to 60 lb/in) shall be fitted permanently to the system in a position where it can be seen when filling the system.

Note: A higher initial design pressure requires a larger volume expansion vessel.

The charge pressure must not be less than the static head of the system, that is, the height of the highest point of the system above the expansion vessel.

The water content of the boiler is given in 2.3 General Specifications.

Expansion Vessel Requirements

Vessel 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

L96847350

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.

3.19

WATER MAKEUP

Provision should be made for replacing water loss from the system using a make up bottle mounted in a position higher than the top point of the system, connected through a non-return valve to the return side of either the heating circuit or the hot water cylinder.

Alternatively, provision for make up can be made using a filling loop.

INTERNAL WIRING DIAGRAMS

7.1 : FUNCTIONAL FLOW WIRING DIAGRAM

3.20

FILLING A SEALED WATER SYSTEM

Provision for filling the system at low level must be made, see figure 8. There must be no permanent connection to the mains water supply, even through a non-return valve.

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 Water Guide to the building regulations.

3.21

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.

3.22

EXTERNAL CONTROLS

The VBX appliances may be used with any certified programmer/room thermostat, as described in section 4. For further information contact: Halstead Boilers Ltd, Service Helpline: 01926 834834.

DRAIN

AUTOMATIC AIR VENT

FLOW

RETURN

TANK THERMOSTAT

ROOM THERMOSTAT

TERMINAL

BLOCK

MOTORISED VALVE

LOCKSHIELD VALVE

STOP VALVE

DRAIN

MOTORISED VALVE

COLD FEED

3-WAY VALVE

TO DRAIN

OFF TAP

HOT WATER CYLINDER

COLD WATER STORAGE

APPLIANCE

CH SWITCH

DIRECT HW CONNECT

CH/DHW 2 CHANNEL PROGAMMER

220V RELAY BOX

(Optional)

OPEN WATER SYSTEM

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.

NOTE: No automatic by-pass required. However it is recommended to leave one radiator open and to fit a system bypass in the DHW circuit to ensure pump overrun functionality.

29A SPARK ELECTRODE

29 B DETECTOR ELECTRODE

CONDENSATE DRAIN

6.7

SEALED WATER SYSTEM

a) Check the operation of the pressure relief valve as described in section 5.1 (b).

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 (b) 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.

6.8

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 CH mode. f) Remove the manometer and tighten the inlet pressure test

point sealing screw. g) Test for gas tightness.

6.9

FINAL CHECKS

a) Ensure the sealed chamber door is secure with the six fixing screws.

b) Re-fit all decorative casing panels. c) Return all appliance and external controls (if fitted) to their

original settings.

4.3

MOUNTING THE APPLIANCE

Refer to Figure 10. 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 in a horizontal direction. Then carefully lower the appliance, ensuring that the top locating rail is securely engaged.

b) Connect the central heating system pipes to the central heating flow and return pipes on the boiler.

APPLIANCE INSTALLATION

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:

● Complete appliance

● Paper wall mounting template

● Wa ll mounting plate

● Installation and Servicing Instruction

● User's Instructions

● Benchmark book

● Hardware pack containing:

50 mm x No 10 wood screw - 4 off Wall plug to suit - 4 off 22mm street elbow - 2 off 22mm nuts & olive - 2 off 65mm x 10mm coachbolt - 2 off Rawl Plug to suit - 2 off

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). 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 9. 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 four fixing screws, ensuring that it is level.

Pipe work may be routed from above or below the appliance as required.

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 30, 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.

GAS CONTROL VALVE, FAN & BURNER ASSEMBLY

VBX

Refer to Figure 11. a)

The boiler is supplied with 22mm copper tails for both upwards and downwards (optional) flow and return pipe routing suitable for compression or soldering connections.

USE EXTREME CARE IF SOLDERING THE JOINTS NEAR TO THE APPLIANCE. IF BOILER IS LOCATED IN TIGHT SPACE IT IS RECOMMENDED TO REMOVE THE PIPES FROM THE BOILER.

b) Connect the central heating system pipes to the central heating flow and return pipes on the boiler. If downwards routing is required: The sealed ends must be removed before connecting to the heating system pipes. The upwards pipes must be used for connecting to a vent pipe (open system) or fitting to an automatic air vent (sealed system). The remaining pipe must be solder sealed. The flow and return sensors have to be removed from the upwards pipes and reconnected to the downward pipes (Fig 47; flow is nearest to the front).

c) Commission the central heating system as described in section

5.1, and then proceed to section 4.5.

MOUNTING THE APPLIANCE

SERVICE CONNECTIONS

CONNECTIONS

4.4

CENTRAL HEATING SERVICE

Refer to Figure 11.

Connect the gas supply pipe to the gas service cock. It is

recommended that a minimum of 22 mm diameter OD copper

4.5

GAS CONNECTION

CONDENSATE CONNECTIONS

4.7

AIR / FLUE DUCT INSTALLATION

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 13. 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

Refer to Figure 12.

Connect either a Ø21.5mm or Ø22mm plastic push fit or adhesive overflow pipe to the condensate outlet. It should be piped to drain, preferably within the building, maintaining a continuous 2.5° 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. Ø32mm 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.

ROUTINE SERVICING

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 an adequately sized sample tube fitted. Operate the appliance in Service mode, (see section

5.2). After ten minutes operation check the CO

/CO values and compare with those figures stated in section 2.3. Do not forget to replace the plastic 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 cock.

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:

CONTROL PANEL

COMBUSTION CASE PANELS

from the igniter and detection electrodes. 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) 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.

i) The assembly may then be inspected. j) Re-assemble in reverse order.

VALVE, FAN & BURNER ASSEMBLY

6.2

GAS CONTROL

Refer to Figures 25, 26, 27, and 28 a)

Remove the hinges and take off the hinged front panel.

b) Remove the decorative front cover (4 screws). c) Remove the sealed chamber door (6 screws) d) Disconnect the igniter plug, earth lead and detection plug

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 29. 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.

4.6

CONDENSATE CONNECTION

pipe be used to within 1000 mm of the gas service cock.

•

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

FROM INSIDE THE ROOM

4.7.1

INSTALLING THE AIR/FLUE DUCT

MEASURING THE EXACT FLUE LENGTH

FAN OUTLET EXTERNAL Dia. 60mm

•

TOTAL FLUE LENGTH FROM FLUE OUTLET CENTRE TO OUTSIDE WALL FACE: = LENGTH

WALL

•

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.

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).

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 wall-sealing ring does not become dislodged.

b) Assemble the flue system extension ducts as necessary, referring to Figure 14.

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 14 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 BUILDING

4.7.2

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.

5.8

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.

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 CH. 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 CH Temperature Control knob, 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 for the frost protection circuit to operate.

5.9

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.

5.10

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 955128 - Eden Vbx 18

955126 - Eden Vbx 30 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 955129 - Eden Vbx 18

955127 - Eden Vbx 30 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: 01926 834834.

CASING

FASCIA PANEL AND CONTROLS (CBX model shown)

INLET PRESSURE TEST POINT

5.3

FINAL CHECKS

a) Tu rn off the appliance and remove the manometer. Tighten the appliance inlet pressure test point screw. Re-light the burner and test for gas tightness.

b) Fit the appliance casing as illustrated in Figure 24. Position and secure both side panels and the decorative front cover with screws at the top and bottom.

c) Fit the appliance hinged front panel in position with two screws at the top and bottom.

d) Set the CH Temperature Control to the required setting. Set the room thermostat (if fitted) to the required setting. Refer to hot water cylinder instructions.

If the boiler is connected to a hot water cylinder the CH temperature has to be set to high.

5.4

LOCKOUT / RESET INDICATION

In the event of failure during an ignition sequence, (5 attempts) the LED displays fault code '3'. In order to reset the boiler turn the CH Temperature Control anticlockwise to 'STANDBY' position and then back to 'ON' within

two seconds.

5.5

FROST PROTECTION

The appliance is fitted with a frost protection device. In the event of very cold conditions, the external 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.

e) Ensure programmer and room thermostat (if fitted) are calling for heat.

f) The display changes to 'H'. The fan should start and after a few seconds an ignition will commence.

g) If the burner fails to light the fan will stop. Initially this may be due to air in the gas supply line. The boiler will automatically have five attempts at ignition. It may be necessary to turn the CH Temperature Control knob fully anti-clockwise to reset position and repeat (d). (See section 5.4).

h) When the boiler has lit the display will show 'H.'. 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.

5.6

OVERHEAT PROTECTION

The appliance incorporates flow and return thermostats, which monitor the operating temperature. Abnormal temperatures such as overheating will cause the appliance to go to lockout and the LED display will show code '1'. Allow the appliance to cool and turn the CH Temperature Control knob fully anti-clockwise to the reset position to clear.

5.7

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.

CH SOFT START DEVICE:

After every burner start the burner output stays at low for 3 minutes, to ensure smooth heat up of the system and maximum efficiency.

SERVICE MODE:

The appliance enters the SERVICE mode by turning the control knob fully clockwise. The LED displays a flashing 'H.'. In this mode the appliance runs at the minimum CH output. This mode allows the gas valve offset and CO

emissions to be measured.

4.8

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 15. Live supply to L1, Neutral and Earth as indicated. Check that L1 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 L1 and L3 and connect the device across these terminals. Any external controls fitted must be rated at 230V 50Hz and have volt free contacts.

If using 6-wire 28mm or 1” BSPV4043H on any circuit, white is not needed and must be made electrically safe. The wiring shown is based on the use of 10-way junction box (Honeywell Part No. 42002116-001). Junction Box terminal 10 is switched live and terminal 9 is pump live.

CT200

ROOM THERMOSTAT

L641A

CYLINDER THERMOSTAT

V4043H

HEATING VALV E

V4043H

HOT WATER VALV E

230V mains input

Room thermostat

Cylinder thermostat

Heating valve

Hot water valve

230V mains input

1 2

1 3 2

4 5 2

315

9103 2 1 9 2 3

34567

ELN

891021

HTGN L

2 1 10 3

8 2 1 10 3

1 2 3

Not used

Brown Blue

Grey Orange Green/ yellow

Brown Blue

Grey Orange Green/ yellow

CT200

L641A

V4043H

Programmer

Time controller

Boiler Pump

63 3

Honeywell ST6998 1002 (Link L-5-3)ST 799A

2= Pump live 1=Switched live L=Permanent live

ST6400 ST6300 ST6200

6432

21ENL L NE

Optional

T4360A

Frost thermostat Opens heating circuit only

T6360B Room thermostat

230V 50Hz

Pump

Boiler

L2 L3 E N L1

Motor Motor

V4043H Zone valve heating

V4043H Zone valve DHW

T6360B Room thermostat

L641A Cylinder thermostat

213 1 C

Brown

Grey

Blue

Green Yellow

Green

Yellow

Brown

Orange

Fully pumped 'S' Plan

FULLY PUMPED ‘S’ PLAN

MAINS

PUMP

PROGRAMMER

Room thermostat

Cylinder thermostat

Mid position valve

230V mains input

1 2

6 7

1 3 2

4 5 2

98321 923

34567

ELN

891021

HW Off

HTGHTGOnNL

2 7 8 3

1 2 3

White Blue Grey Orange Green/ yellow

CT200

T4360A

Frost thermostat Opens heating circuit only-use with programmers with spot switching

L641A

V4073A

Programmer

Time controller

Boiler

V4073A Mid position zone valve

Pump

1734

Honeywell ST6998 1002 (Link L-5-3)ST 799A

2= Pump live 1=Switched live L=Permanent live

ST6400 ST6300

ST6200

7643

21ENL LNE

T6360B Room thermostat

230V 50Hz

Pump

Boiler

T6360B Room thermostat

L641A Cylinder thermostat

213

Fully pumped 'Y' Plan

Optional

Blue

Green/yellow

White

Grey

Orange

Pump live

Switched live

Permament live

FULLY PUMPED ‘Y’ PLAN

Internal heater resistor

3mm air gap

Fuse 3A

Fuse 2.5A

Cylinder thermostat

Room thermostat

Frost thermostat

Fused switched isolator

Boiler controls or gas solenoid

Boiler pump over run

C C

N L

N/U

CH on

HW on

S/L

P/L

Boiler

HW Pump

CW Pump

Basic time clock

Programmer

CH/HW programmer

N/U

Earth terminals for Controls,Boiler,Pumps, Electrical mains supply.

N/U

ndDem

ema

Dem

UPP15-50 PUMP PLAN - WIRING CENTRE CONNECTIONS

TYPICAL PROGRAMMER

Pump

Boiler Terminals

Room thermostat

L2 L3 E N L1

Pump live Switched

live

Permament live

Hot water Earth Neutral

230V fused 3 amp

Heating

a) Slacken the screw in the appliance inlet pressure test point and connect a suitable manometer. Refer to Figure 23.

b) Check that the gas supply is turned ON and the gas service cock is OPEN.

c) Switch on the electrical supply. d) Turn the CH temperature Control knob to the midpoint between the

minimum and maximum setting. The display changes from 'o' to 'h'.

COMMISSIONING & TESTING

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 pipe-work is complete. Fill the water systems by following the procedure detailed below in steps a) and b), and referring to Figure 20.

COMMISSIONING THE WATER SYSTEM

To aid venting, a manual air vent is provided on the LHS of the heat exchanger.

Check the system for soundness. Drain the entire system to flush out any debris, and refill making

sure that all the air is properly vented from the system and pump. 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.

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.

b) Sealed Systems

Fill the system until the pressure gauge registers 2.0 bar. Clear any locks and check for soundness.

Check the operation of the pressure relief valve (figure 21) 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. Where this is not possible a manual check should be carried out.

Release the cold water to the initial design pressure.

a) All Systems

A competent person in accordance with the current issue of BS6798 should carry out commissioning.

Fill the system with cold water. Vent the system via the radiator valves and system air vents in accordance with normal practice. Ensure that all system air vents are closed.

New

Drawing

Required

5.2

COMMISSIONING THE APPLIANCE

Refer to Figure 22

Halstead EDEN X Type VBX 18, EDEN X Type VBX 30 Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual