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Sabre HE No Retarder.P65

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Sabre HE No Retarder.P65 Installation & Servicing Instructions THESE INSTRUCTIONS TO BE RETAINED BY USER Contents Design principles and operating sequence Page Servicing instructions Page 1.1 Principle components 2 6.1 General 14 1.2 Mode of operation (at rest) 2 6.2 Routine annual servicing 14 1.3 Mode of operation (heating) 2 6.3 Replacement of components 14 1.4 Mode of operation (DHW) 2 6.4 Component removal procedure 14 1.5 Safety devices 2 6.5 Pump assembly 14 6.6 Safety valve 15 Technical data Page 6.7 Automatic air release valve 15 2.1 Central heating 3 6.8 Water pressure switch 15 2.2 Domestic hot water 3 6.9 Pressure gauge 15 2.3 Gas pressure 3 6.10 Primary thermistor 15 2.4 Expansion vessel 3 6.11 High limit thermostat 15 2.5 Dimensions 3 6.12 PCB 15 2.6 Clearances 3 6.13 Gas valve 15 2.7 Connections 3 6.14 Integral time switch 16 2.8 Electrical 3 6.15 Electrode, burner thermostat, burner & injectors 16 2.9 Flue details 3 6.16 Flue fan 17 2.10 Efficiency 3 6.17 Main heat exchanger 17 2.11 Pump duty 4 6.18 Air pressure switch 17 2.12 Appliance 4 6.19 Flow restrictor 17 General requirements (UK) Page 6.20 DHW flow switch 18 3.1 Related documents 5 6.21 DHW heat exchanger 18 3.2 Location of appliance 5 6.22 Valve actuator 18 3.3 Gas supply 5 6.23 Divertor valve cartridge 18 3.4 Flue system 5 6.24 DHW thermistor 18 3.5 Air supply 5 6.25 Automatic by-pass 18 3.6 Water circulation 5 6.26 DHW non-return valve 18 3.6.1 Pipework 6 6.27 Expansion vessel 18 3.6.2 Automatic by-pass 6 6.27.1 Expansion vessel removal (with sufficient clearance above) 18 3.6.3 Drain cocks 6 6.27.2 Expansion vessel removal (with insufficient clearance above) 19 3.6.4 Air release points 6 6.28.1 Latent heat collector 19 3.6.5 Expansion vessel 6 6.28.2 Dismantling the latent heat collector 19 3.6.6 Filling point 6 6.29 Condense trap removal 19 3.6.7 Low pressure sealed system 6 Checks, adjustments and fault finding page 3.6.8 Frequent filling 6 7.1 Checking appliance operation 20 3.7 Electrical supply 6 7.2 Appliance mode of operation 20 3.8 Showers 6 7.2.1 Selector switch in the OFF position 20 3.9 Mounting on a combustible surface 7 7.2.2 Selector switch in the hot water only position 20 3.10 Timber framed building 7 7.2.3 Selector switch in the heating & hot water position 20 3.11 Inhibitors 7 7.2.4 Appliance functions 20 Installation Page 7.2.5 DHW mode 20 4.1 Delivery 8 7.2.6 Heating mode 21 4.2 Contents 8 7.3 Checking & adjusting burner pressure 22 4.3 Unpacking 8 7.3.1 Setting the maximum burner pressure 22 4.4 Preparation for mounting the appliance 8 7.3.2 Setting the minimum burner pressure 22 4.5 Fitting the flue 8 7.3.3 Setting the minimum CH output 22 4.5.1 Concentric horizontal flue 8 7.4 Combustion analysis test 22 4.5.2 Concentric vertical flue 9 7.5 Checking the expansion vessel 23 4.6 Connecting the gas and water 10 7.6 External faults 23 4.6.1 Gas 10 7.6.1 Installation faults 23 4.6.2 Flow and return 10 7.7 Electrical checks 23 4.6.3 Cold water inlet 10 7.7.1 Earth continuity test 23 4.6.4 Hot water outlet 10 7.7.2 Short circuit check 23 4.6.5 Safety valve 10 7.7.3 Polarity check 23 4.6.6 Condense pipe 10 7.7.4 Reversed polarity or supply fault 24 4.7 Electrical connections 11 7.7.5 Resistance to earth check 24 4.7.1 Casing removal 11 7.8 Fault finding 24 4.7.2 Appliance terminal block 11 7.8.1 Replacing the main PCB 24 4.7.3 Connecting the mains (230V) input 11 7.9 Fault codes 24 7.10 Fault finding 25-30 Commissioning Page Wiring diagrams Page 5.1 Gas supply installation 12 8.1 External wiring 31 5.2 The heating system 12 8.2 Typical control applications 31 5.3 Initial filling of the system 12 8.3 Room thermostat 31 5.4 Initial flushing 12 8.4 Other controls 31 5.5 Filling the hot water system 12 Functional diagram 32 5.6 Pre-operation checks 12 5.7 Initial lighting 12 Exploded diagrams Page 5.7.1 Checking burner pressures 12 Table 1-5 33-37 5.8 Final flushing of the heating system 12 L.P.G. instructions Page 5.8.1 Inhibitors 12 10.1 Related documents 40 5.9 Setting the boiler operating temperature 12 10.2 Technical data 40 5.9.1 Setting the DHW temperature 13 10.3 Converting the appliance gas supply 40 5.10 Setting the system design pressure 13 10.4 Gas supply 40 5.11 Regulating the hot water 13 10.5 Gas supply installation 40 5.11.1 Changing the flow restrictor 13 10.6 Checking & adjusting burner pressure 40 5.11.2 Regulating the central heating system 13 10.6.1 Setting the maximum burner pressure 40 5.12 Final checks 13 10.6.2 Setting the minimum burner pressure 40 5.13 Instructing the user 13 41 INTRODUCTION The Sabre HE range of appliances is comprised of 2 powered flue outlet with an annular coaxial combustion models of high-efficiency combination boiler with inputs air intake that can be rotated - horizontally - through 360 to heating & DHW of 25, 29 & 35kW respectively. Each degrees for various horizontal or vertical applications. appliance - by design - incorporates electronic ignition, The Sabre HE range is approved for use with C12 & C32 circulating pump, expansion vessel, safety valve, pres- type flue applications. sure gauge and automatic by-pass. These appliances are designed for use with a sealed system only; consequently they are not intended for use The Sabre HE range is produced as room sealed, cat- on open vented systems egory II2H3P appliances, suitable for internal wall mount- ing applications only. They are provided with a fan Fig.1 General Layout 1 Diverter valve motor 2 Discharge valve 3 Domestic hot water heat exchanger 4 Safety valve 5 Pump 6 Pressure switch 7 Auto air vent (AAV) 8 Electrode 9 Main burner 10 Main heat exchanger 11 Latent heat collector 12 Flue gas analysis test point 13 Flue outlet 14 Air intake 15 Differential pressure switch 16 Silicone pressure tube (-) 17 Silicone pressure tube (+) 18 Fan assembly 19 CH NTC sensor 20 Combustion chamber 21 High limit thermostat 22 Expansion vessel 23 Condensate pressure switch 24 Ignition transformer 25 Condense trap 26 Modulator coil 27 Gas valve 28 DHW flow switch 29 Pressure gauge 30 DHW position 31 Mode selector switch 32 Fault indicator led 33 CH position 34 Timeclock Fig. 1 29 30 3132 33 34 1 SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE 1.1 PRINCIPLE COMPONENTS 1.3 MODE OF OPERATION (Heating) ● A fully integrated electronic control board fea- When there is a request for heat via the time clock turing electronic temperature control, anti-cy- and/or any external control, the pump and fan are cle control, pump over-run, LED fault indicator, started, the fan will then prove the air pressure full gas modulation. switch. At this point an ignition sequence is ● Low-water-content, copper heat exchanger. enabled. ● Electronic ignition with flame supervision. Ignition is sensed by the electronic circuitry to ● Integral high-head pump. ensure flame stability at the burner. Once suc- ● Fan. cessful ignition has been achieved, the electronic ● Air pressure switch. circuitry increases the gas rate to 75% for a ● Expansion vessel. period of 15 minutes. Thereafter, the boiler’s ● Water pressure switch. output will either be increase to maximum or ● Two-stage gas valve. modulate to suit the set requirement. ● Pressure gauge. ● Safety valve. When the appliance reaches the desired tem- ● Condense switch. perature the burner will shut down and the boiler will perform a three-minute anti-cycle (timer de- 1.2 MODE OF OPERATION (at rest) lay). When the appliance is at rest and there are no requests for heating or DHW, the following func- When the request for heat has been satisfied the tions are active: appliance pump and fan may continue to operate ● Frost-protection system: the frost-protection to dissipate any residual heat within the appli- system protects the appliance against the risk ance. of frost damage. Should the temperature of the 1.4 MODE OF OPERATION (DHW) appliance fall to 5 °C, the boiler will function in When there is a request for DHW via a hot water the heating mode at minimum power until it outlet or tap, the pump and fan are started, the fan reaches 35 °C. will then prove the air pressure switch. At this ● Anti-block function: the anti-block function ena- point an ignition sequence is enabled. bles the pump and divertor valve actuator, to be energised for short periods, when the appli- Ignition is sensed by the electronic circuitry to ance has been inactive for more than 19-hours. ensure flame stability at the burner. Once suc- cessful ignition has been achieved, the electronic circuitry increases the gas rate to maximum or flue air will modulate output to stabilise the temperature.
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