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Halstead Eden Cbx 24 - Direct Heating Spares

1. 23 a tst Ne 3 ONLY HALSTEAD APPROVED FLUE KITS OR EXTENSIONS MAY BE USED 5 7 Overheat 23 WITH THESE APPLIANCES 5 8 Other 24 5 9 Users Instructions 24 5 10 Appliance Log 24 5 11 24 6 Routine 25 6 1 Combustion 25 6 2 Gas Control Valve Fan amp Burner 25 6 3 Se 25 6 4 Ignition amp Detection Electrodes 25 6 5 Combustion Chamber amp Heat Exchanger 2 6 6 Condensate 27 6 7 Domestic Cold Water Inlet 27 6 8 Sealed Water System 28 6 9 Re assembly amp Re commissioning 28 6 10 Final GC NOOR EDCEEOEEEFPCEDERFCOHEIAD EVER 28 7 Internal Wiring 29 7 1 Functional Flow Wiring 29 8 FOUN
2. 751030 MANUAL 14 NEW 21 9 10 08 42 Page 30 IW ML f The following paragraphs outline the specifications of the items fitted to the appliances PUMP The available pump head shown in Figure 6 is that in excess of the appliance hydraulic resistance i e that available for the system AVAILABLE PUMP HEADS SBX 30 amp CBX 38 S X E E 5 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Flow Rate ltr min EXPANSION VESSEL The integral expansion vessel is pre charged to a pressure of between 0 5 and 1 0 bar This should be checked before the water system is filled Details below show the water system volume that is acceptable for this vessel If the system water volume is larger then an additional vessel must be fitted to the system BS 5449 and BS 6798 give further details regarding expansion vessel sizing and sealed Systems Expansion Vessel Requirements O75 IU 415 Vessel charge and bar 0 5 initial system pressure Total water content of system using 8 L 1 54 gal capacity L 906 84 73 50 expansion vessel supplied with appliance For systems having a larger capacity multiply the total system capacity in litres gallons by these factors to obtain the total minimum expansion vessel capacity required in litres 0 0833 0 093 0 109 0 156 PRESSURE GAUGE A pressure gauge is situated on the appliance control panel This can be viewed by lowering the bo
3. full clockwise The two LED s above the knob are now flashing In this mode the appliance runs at the minimum CH output This mode allows the gas valve offset and C0 emissions to be measured USER 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 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 both CH and DHW d Advise the user of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frost conditions e Explain the function of the Reset button and how to reset the appliance Emphasise that if cutouts persists the appliance should be turned off and the installer or service engineer consulted f Stress the importance of an annual service by a registered heating engineer g The electrical mains supply to the appliance must remain ON and the ON OFF switch must be left ON for the frost protection circuit to operate APPLIANCE LOG BOOK A logbook is supplied with this appliance to record instal
4. 1 5 Max Mains Water Inlet Pressure si Min Domestic Hot Water Flow l min 2 5 Rate for Operation pml 0 5 Min Central Heating System Pressure Bar Max Central Heating System Pressure Bar Max Domestic Hot Water Temp 60 Min Domestic Hot Water Temp RC 40 Max Central Heating Flow Temp 16 Min Central Heating Flow Temp EC SBX30 0 7 2 9 80 30 CBX38 Propane Propane Propane 15 6 13 1 9 8 3 4 2 8 2 2 18 1 15 3 11 5 CBX32 1 0 14 5 0 1 1 5 10 145 25 0 5 60 40 CBX24 SBX30 Propane GENERAL SPECIFICATIONS Natural Gas and Propane versions Appliance Total weight full Total weight empty Max lift weight Total water capacity Integral expansion vessel capacity Maximum heating system water content using fitted expansion vessel d 0 75 bar Electrical supply Internal fuse Maximum power consumption IP Rating Flue gas temperature Nat Gas 80 60 Propane Flue gas temperature Nat Gas 50 30 C0 value max rate Nat Gas Front door fitted C0 value min rate Nat Gas ref only Front door fitted CO value max rate Nat Gas Front door fitted C0 value max rate Propane Front door fitted C0 value min rate Propane ref only Front door fitted CO value max rate Propane Front door fitted Flue products mass flow rate Nat Gas Flue products mass flow rate Propane Gas Valve Offset d min rate kg kg kg C CBX38 99 4 22 8 42 2 2 4 80 62
5. The CH and DHW isolation cocks are 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 FASCIA PANEL DHW TEMP CONTROL DOMESTIC WATER FAULT FINDING CBX APPLIANCES ONLY When the hot water tap is turned on the control should perform a series of checks followed by an ignition sequence Refer to section 5 2 If the control has powered up correctly but does not respond to a DHW demand check the following a Check that the DHW flow rate at the tap is greater than 2 5 litre minute b Check the operation of the DHW flow turbine Figure 28 c Check the wires to the DHW flow turbine d Check connector X8 is correctly connected to the PCB If the above items are ok replace the PCB If DHW temperature fluctuates heavily during long draw off check the secondary plate heat exchanger filter for debris clean and replace refer to section 9 19 For further information contact Halstead Boilers Ltd Service Help line 0844 371 1111 DIAGN
6. d Remove the flow and return pipes from the heat exchanger refer section 9 8 e Fit the replacement diverter valve motorised head Remove the clip holding the hydroblock adaptor fitting in place and f Re assemble in reverse order ensure that all joints and seals are remove fitting correctly re fitted f Remove the two clips holding the return pipes in place g Undo the nut connecting the CH return pipe to the CH return DIVERTER VALVE MOTORISED HEAD isolating cock and disengage the CH return pipe from the hydroblock h On CBX appliances undo the nut connecting the DHW return pipe to the plate heat exchanger and disengage the DHW return pipe from the hydroblock i On SBX appliances undo the nut connecting the secondary return pipe to the secondary return isolating cock and disengage the secondary return pipe from the hydroblock j Remove the clip holding the flexible hose in place and remove hose k Unscrew the three screws holding the hydroblock onto the mounting studs and remove the hydroblock t Align the replacement hydroblock against the mounting studs and secure using the three screws Re assemble in reverse order ensure that all joints and seals are Pa Ba correctly re fitted G LOCATING SCREW n Open the isolating cocks and vent air from the system using the manual air vent Re pressurise the system as necessary and check for water leaks
7. e To check the combustion gas levels at maximum gas rate place the boiler into Service mode Y as explained above G f Now turn the CH knob to the 12 o clock position and then back fully clockwise into Service mode within 3 seconds The boiler will now run at maximum gas rate for 10 minutes NOTE Check the Carbon Monoxide and Carbon Dioxide levels are within the range quoted in table 2 3 on page 3 Inlet Test Point FASCIA PANEL AND CONTROLS CBX model shown PSOE O ue LED and Reset push Button DHW Economy Economy Comfort Service Error Code CLOCK OVERRIDE 24hr Clock Comfort Switch Error Code LED 1 amp 2 Function LED 3 amp 4 A SWITCH Heating n Mains ON OFF only SUN Switch T Continuous ON Timed OFF ARROW INDICATES CURRENT TIME CH Temp DHW Temperature Control Control Pressure Gauge TABS OUT ON PERIOD TABS IN OFF PERIOD 751030 MANUAL NEW 21 9 10 08 44 Page 47 On the CBX 38 the inlet pressure test point is situated on the gas service cock INLET PRESSURE TEST POINT DHW FLOW APPLIANCES ONLY Aflow regulator is supplied factory fitted to the appliance to ensure that no adjustment is necessary Should the mains flow rate be below the minimum required it is possible to remove the flow regulator from the appliance as instructed in section 9 The nominal pre adjusted flow rate may vary by 5 due to
8. open a DHW tap at the lowest point in the system and allow the pressure to dissipate Close this tap again d Undo the nut connecting the DHW flow turbine to the DHW inlet isolating cock Undo the nut connecting the DHW flow turbine to the water feed pipe and remove the DHW flow turbine containing the DHW Flow Regulator f The DHW filter is located inside the flow cock To remove it first remove the top hat washer and then prise the filter out with a pointed tool The assembly can now be flushed clean using water and parts replaced as necessary h Re assemble in reverse order using a new fibre washer ensure that all joints and seals are correctly re fitted i Open the DHW inlet isolating cock and vent air from the system by opening each hot water tap in the house in turn PCB HOUSING NG Propane chip card Electrical Connectors Securing Screws 9 2 DRAINING THE APPLIANCE There may be some slight water spillage so electrical components should be protected Refer to Figures 43 amp 53 al Before draining give the appliance a brief CH demand to ensure the diverter valve is in the CH position b Ensure supply voltage is isolated c If not draining the entire CH system close the CH flow CH return water isolating cocks d Close the DHW return water isolating cock where fitted e Drain down the system from the external drain point and drain the appliance using the drain ta
9. 9 2 9 6 8 2 8 6 17 4 17 4 CBX32 CBX24 54 9 51 7 52 8 49 9 42 0 39 0 2 1 1 8 8 84 230V 50Hz Fuse at 3A T4H 4A 250V 148 IP33 79 77 74 72 41 43 9 0 9 4 8 5 8 9 8 2 8 6 8 2 8 6 5 150 10 3 11 0 9 4 10 0 100 240 14 7 11 0 14 7 11 0 3 0 SBX30 55 2 52 8 41 0 24 73 76 41 9 0 9 4 8 7 9 1 9 7 10 3 13 7 13 7 751030 MANUAL NEW 21 9 10 08 39 Page 10 Connections CBX32 CBX24 SBX30 CBX38 Gas 15 mm compression 22 mm compression CH flow 22 mm compression CH return 22 mm compression DHW inlet CBX appliance only 15 mm compression DHW outlet CBX appliance only 15 mm compression DHW return SBX appliance only 22 mm compression Pressure relief valve outlet 15 mm tail Condensate Drain 21 5 22 mm plastic overflow pipe OVERALL DIMENSIONS AND MINIMUM CLEARANCES M pat mm T 100mm 0 200 5mm SEE NOTE NOTE P 760mm 10mm for L normal 914mm operation 9mm 450mm for installation and Servicing 200mm ON CONCENTRIC AIR FLUE DUCT SPECIFICATIONS The EDEN x type range can be installed to a number of different concentric flue systems The different flue applications as shown in Figure 2 are available as kits usually comprising the connecting parts to the appliance and end terminal Flue extension ducts and extension elbows are available as accessories 751030 MANUAL NEW 21 9 10 08 39 Page 11 A ML 10
10. 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 Itis important that the position of the terminal allows free passage of air across it at all times c It is ESSENTIAL TO ENSURE that products of combustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors other sources of natural air infiltration or forced ventilation air conditioning d The minimum acceptable dimensions from the terminal to obstructions and ventilation openings are specified in Figure 6 e Iftheterminal 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 plu
11. ELECTRICAL CONNECTOR Note It is likely that there will still be some water spillage when the Hydroblock is removed 4 HYDROBLOCK ASSEMBLY PRIMARY HEAT EXCHANGER RETURN PIPE AUTO AIR VENT SMALL OUTLET PLUG FIBRE WASHER PIPEWORK ADAPTOR LARGE OUTLET PLUG EXPANSION VESSEL HOSE PUMP ELECTRICS COVER LARGE PIPE CLIP SMALL PIPE CLIP HYDROBLOCK MOUNTING POINT o PIPE 0 RING PUMP ELECTRICAL CONNECTOR CH RETURN PIPE PRIMARY RETURN PIPE PUMP AIR BLEED SCREW PUMP HEAD LOCATING SCREW DIVERTER ELECTRICAL CONNECTOR DIVERTER MOTOR 37 751030 MANUAL 36 jl k 4 Ld o ql NEW 21 9 10 08 41 Page 20 a X ML Disconnect the condensate drainpipe from the condensate drainpipe sump adaptor refer to section 9 18 Unscrew the three nuts holding the heat exchanger to the back panel refer to Figure 43 Remove the heat exchanger Disconnect the condensate drainpipe sump adaptor from the heat exchanger Remove the flue hood from the heat exchanger two screws and fit the flue hood onto the new heat exchanger Check integrity of the flue hood seals and replace as necessary Remove the manual air vent and vent tube from the heat exchanger and fit onto to new heat exchanger refer to Figure 43 Fit the condensate drainpipe sump adaptor to the heat exchanger and flue hood Re assemble in reverse order check integrity of the flow and return pipe 0 rings and
12. No flame Lockout flame signal Lockout after 5 ignition Flue gas sensor No flame Defective sensor No flame Defective gas valve Flame continues after demand ends Defective fan No flame CRC error No flame Error in power supply No flame Water flow failure Flame for a short period only PCB error No flame BCC error No flame Differential check faulty Flame for 15 seconds Activate BCC No flame Safety system failure No flame DHW cold No light indication No flame 08 42 Page 31 d REASON Water temperature greater than 105 C Low gas pressure No flame signal on ignition or loss of signal during operation attempts Flue gas temperature greater than 95 C Defective flow return or flue sensor 5 sec flame signal after burner is switched off Missing or Erroneous RPM signal Internal Eprom data error Low mains voltage Sensor temperature differential incorrect Internal error Incorrect missing BCC Zero check faulty DHW or CH New BCC Failure of internal self checking system Defective DHW turbine or Diverter valve Defective power supply Faulty connector ACTION Check no airis in heat exchanger CH system Check pump operation Check diverter valve operation Check PCB X1C connector Check mains lead to pump Check flow thermistor Check gas supply Check gas service cock Check gas valve and lead Check detection electrode lead Check gas sup
13. P nor iw a june PRESSURE RELIEF VALVE uf GAUGE 10 751030 MANUAL NEW 21 9 10 08 41 Page 23 BURNER Refer to Figures 38 39 amp 40 a Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp burner assembly refer to section 6 2 c Unscrew the three torx screws T 25 holding the manifold to the combustion chamber front cover and remove the manifold refer to Figure 38 d Remove the gasket and withdraw the burner refer to Figure 39 e Fit replacement burner taking care not to damage the insulation and ensure burner is correctly located by lining up the locating tab f Fit new gasket refer to Figure 40 g Re assemble in reverse order ensure that all joints and seals are correctly re fitted O9 COMBUSTION CHAMBER FRONT INSULATION The design of the appliance is such that the combustion chamber insulation should not require replacement unless mechanically damaged It is recommended that to prevent dust the insulation be dampened prior to removal and that a protective mask is worn when changing or handling the insulation material Refer to Figure 41 a Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp 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
14. Re assemble in reverse order ensure that all joints and seals are 3 correctly re fitted d Undo the nut connecting the flow pipe from the main heat exchanger to the plate heat exchanger and rotate in an anticlockwise direction to give access to the filter 9 1 PRESSURE GAUGE e Lift out the filter and clean under a tap Refer to Figure 24 g Refit the filter or replace as necessary and re assemble in reverse a Ensure supply voltage is isolated order ensure that all joints and seals are correctly re fitted b Drain down the appliance refer to section 9 24 h If it is suspected that the plate heat exchanger is blocked or is Disconnect the pressure gauge capillary from the pressure relief leaking then proceed as follows vius i Undo the nut connecting the pipe from the hydroblock to the plate d Disengage the pressure gauge from the fascia panel and remove the heat exchanger and rotate out of the way gauge j Undo the nut connecting the plate heat exchanger to the CH flow e Fit the new pressure gauge and re assemble in reverse order water isolating cock pipe Ij isolat pen the isolating cocks and vent air from the system using the k Undo the nut connecting the plate heat exchanger to the DHW outlet manual air vent Re pressurise the system as necessary and check pp for water leaks Undo the nut connecting the plate heat exchanger to the DHW water isolating cock pipe 9 2 AUTO AIR VENT m Lif
15. Refer to Figure 54 Key GCPart No Description No off Makers Pt No 1 Ignition Electrode 1 988526 2 Detection Electrode 1 988527 3 Spark generator Unit incl spark leads 1 500665 4a Gas Control Valve NG LPG CBX24 32 SBX30 1 988315 4b Gas Control Valve NG LPG CBX38 1 988640 5 Fan Assembly 1 601015 6a Burner CBX32 1 700601 6b Burner CBX24 1 700600 6c Burner CBX38 SBX30 1 700602 7a Heat Exchanger CBX32 1 451031 7b Heat Exchanger CBX24 1 451032 7c Heat Exchanger CBX38 5BX30 1 451030 8 Pump Head 6 metre 1 500672 9 Diverter Valve Motorised Head 1 500673 10 Hydroblock Assembly 1 500650 11 Expansion Vessel 1 451020 12 Pressure Relief Valve 1 300734 13 Water Temperature Sensor 2 500661 14 Flue Sensor 1 500660 15a Plate Heat Exchanger CBX24 32 1 451015 15b Plate Heat Exchanger CBX38 1 451018 16 Plate Heat Exchanger Filter 1 500498 17 Pressure Gauge 1 450961 18 Auto Air Vent 1 500674 19 Control PCB incl cover 1 988488 20 Time Clock 1 600520 21 DHW Flow Turbine 1 300733 22a DHW Flow Regulator CBX32 1 300715 22b DHW Flow Regulator CBX24 1 300717 22c DHW Flow Regulator CBX 38 1 300719 23 DHW Filter 1 500497 24 Manual Bleed valve 1 300730 Heat Exchanger o ring kit 988489 Hydroblock o ring kit 988490 751030 MANUAL 40 NEW 21 9 10 08 39 Page 12 A 9 2 CONTROL PCB Refer to Figures 19 24 amp 52 al Ensure supply voltage is isolated b Lower the controls front panel and
16. again Undo the nut holding DHW turbine to the water inlet isolating cock The filter inside the isolating cock can now be carefully removed and cleaned as necessary by flushing with water Re assemble in reverse order ensuring all seals are replaced correctly Refer to Figure 28 6mm 0 5 4 GAS CONTROL VALVE FAN amp BURNER ASSEMBLY FAN COMBUSTION CHAMBER FRONT COVER GAS VALVE F FEED PIPE INSULATION INLET PRESSURE TEST POINT GAS VALVE 27 751030 MANUAL NEW 21 9 10 08 43 Page 40 CBX FLUE GAS SENSOR MANUAL BLEED VALVE PRIMARY HEAT EXCHANGER MBUSTION CHAMBER BURNER ASSEMBLY ER NER CH FLOW THERMISTOR IGNITION ELECTRODE PMO EXPANSION VESSEL GNITION MODULE DETECTION ELECTRODE DEANE OFFSET PRESSURE TEST POINT CH RETURN THERMISTOR FAN MAX C0 THROTTLE OFFSET ADJUSTMENT SCREW ADJUSTMENT GAS CONTROL VALVE AUTOMATIC AIR VENT GAS VALVE LEAD AND PLUG HYDROBLOCK AND PUMP CONDENSATE TRAP FILTER FLOW TURBINE PLATE HEAT EXCHANGER GAS ISOLATING COCK PRESSURE RELIEF VALVE PRESSURE GAUGE TIME CLOCK CONTROL PANEL SBX FLUE GAS SENSOR MANUAL BLEED VALVE PRIMARY HEAT EXCHANGER COMBUSTION CHAMBER BURNER ASSEMBLY FRONT COVER CH FLOW THERMISTOR IGNITION ELECTRODE EXPANSION VESSEL IGNITION MODULE DETECTION ELECTRODE CONDENSATE DRAIN PIPE OFFSET PRESSURE TEST POINT CH RETURN THERMISTOR FAN MAX C0 THROTTLE OFFSET ADJUSTMENT SCREW ADJUSTMENT
17. 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 FRONT INSULATION INNER SEAL OUTER A 9 79 COMBUSTION CHAMBER REAR INSULATION Refer to Figure 42 a Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp 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 SCREW WASHER REAR INSULATION HEAT EXCHANGER Refer to Figures 15 amp 43 al Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp burner assembly refer to section 6 2 c Disconnect the electrical leads to the flue sensor flow sensor and return sensor Drain down the appliance refer to section 9 24 Disconnect the flue system from the appliance 4 screws and lift up to disengage the flue from the flue hood refer to Figure 15 f Remove the retaining clip from
18. external controls if fitted to their original settings 751030 MANUAL NEW 21 9 10 08 43 Page 37 CE INSTALLATION 4 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 C 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 Wall mounting plate Plumbing jig Installation and Servicing Instruction User s Instructions Benchmark book Hardware pack containing 90 mm x No 10 wood screws 4 off Wall plugs 4 off 22 mm copper street elbows 2 off 3 off SBX appliance 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 PREPARING THE WALL al 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 hol
19. factory tolerances and mains water pressure fluctuation FINAL CHECKS al Turn both the DHW and CH temperature control knobs to standby b Turn the appliance on off switch to the off 0 position remove the manometer and tighten the appliance inlet pressure test point screw Re light the burner and test for gas tightness Fittheappliance casing as described and illustrated in Figure 21 Fit each side panel with two screws at the top and bottom of each panel Position and fit controls cover in place using screws provided Ensure it hinges correctly Fit the front panel in position using locating studs and ensure it s correctly seated by pressing d Setthe heating and hot water controls to the required settings For CBX appliances ensure that the clock override switch is in the timed position and check that the time clock is set at the desired time periods Set the room thermostat if fitted to the required setting e For SBX appliances if the cylinder tank sensor if fitted set the hot water sensor to the required setting Refer to separate cylinder tank sensor instructions CASING LOWER DOOR HINGE FIXINGS RUBBER M4 SCREWS GROMMETS 3 PER SIDE LOCKOUT INDICATION In the event of failure during an ignition sequence 5 attempts the Reset LED will show steady RED By pressing and holding the Reset button for 3 seconds the Reset LED will flash RED and LEDs 1 to 4 will display the error code 0011 To R
20. fibre washers and replace as necessary Ensure that all joints and seals are correctly re fitted Open the isolating cocks and vent air from the system using the manual air vent Re pressurise the system as necessary and check for water leaks Note It is likely that the heat exchanger will still contain water HEAT EXCHANGER MANUAL AIR VENT FLUE SENSOR RETAINING CLIP FIXING 4 POINTS C FLUE HOOD Refer to Figures 44 b c d fl g h Ensure supply voltage is isolated and that the gas supply is isolated Remove the gas control valve fan amp burner assembly refer to section 6 2 Remove the heat exchanger refer to section 9 8 Disconnect the condensate drainpipe sump adaptor from the heat exchanger refer to section 9 18 Remove the existing flue hood from the heat exchanger two screws and fit the replacement flue hood onto the heat exchanger use new flue hood seals refer to Figure 44 Fit the condensate drainpipe sump adaptor to the heat exchanger and flue hood Unscrew the flue sensor from the existing flue hood and fit onto the new flue hood refer to section 9 16 Re assemble in reverse order check integrity of the flow and return pipe 0 rings and fibre washers and replace as necessary Ensure that all joints and seals are correctly re fitted i Open the isolating cocks and vent air from the system using the manual air vent Re pressurise the system as necessar
21. length 30m ACCESSORIES Description Part No Resistive Length Flue extension duct 500mm 956092 450mm Flue extension duct 1000mm Incl 1 x support bracket 956093 950mm 93 extension elbow 956091 1550mm 45 extension elbow pair 956090 775mm Air inlet duct included in kit N A N A Straight adapter 60 80 included in kit N A N A 91 5 adapter elbow 80 80 included in kit N A N A Support bracket 100mm 840517 N A 93 flanged elbow included in kit 956082 N A Vertical turret socket 956087 N A Flexi tube 10m 956110 10m Flexi tube 20m 956111 20m Flexi tube 30m 956112 30m Straight duct 80 included in kit N A N A Chimney terminal included in kit N A N A NOTE RESISTIVE LENGTH INFORMATION ONLY REQUIRED FOR COAXIAL FLUE PARTS THE CORRUGATED FLEXI TUBE FLUE PARTS ARE FIXED AND ALL PARTS ARE REQUIRED FOR EVERY APPLICATION 751030 MANUAL NEW 21 9 10 08 41 Page 19 N ML 9 1 DIVERTER VALVE MOTORISED HEAD HYDROBLOCK ASSEMBLY Refer to Figure 46 Refer to Figure 47 al Ensure supply voltage is isolated al Ensure supply voltage is isolated b Disconnectthe electrical lead to the diverter valve motorised head b Disconnectthe electrical leads to the pump head and diverter valve Unscrew the locating screw refer to Figure 46 motorised head d Unclip the diverter valve motorised head and slide it down to E Gown tha ppLan te refer to section 2 24 disengage it from the hydroblock body
22. lower the control fascia panel Unplug the electrical leads from the PCB Refer to section 7 d Unplug the BCC if fitted Remove the PCB plastic cover f Unclip the PCB and withdraw g Carefully remove the three control knobs noting their position and fit onto new PCB hl Fit the new PCB and plug in the BCC if previously used i Re assemble in reverse order ensuring control knobs are free to move and reset button operates j Turn ON the electrical supply and set the ON OFF switch to ON if the Reset LED Refer to section 8 3 shows steady red proceed as follows a Press the Reset button The Reset LED and LED 1 should flash once b Wait approximately 5 seconds while the control is re programmed and then press the Reset button to initialise the control TIME CLOCK CBX APPLIANCES ONLY Ensure supply voltage is isolated Lower the controls front panel and lower the control fascia panel Unplug the electrical leads from the Refer to section 7 d Unplug the four electrical leads from the back of the clock Remove the four retaining screws and withdraw the clock from the control panel f Fitthe new clock and re assemble in reverse order 9 DHW FLOW TURBINE DHW FLOW REGULATOR AND DHW FILTER CBX APPLIANCES ONLY Refer to Figure 28 al Ensure supply voltage is isolated b Remove the electrical lead to the DHW flow turbine c Close the DHW inlet isolating cock
23. 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 A ML C PRESSURE RELIEF VALVE CONNECTION The safety valve is located at the bottom RHS of the appliance Connect the copper tail provided to the safety valve outlet and then connect a discharge pipe of not less than 15 mm diameter copper to the tail The pipe should be positioned so that the discharge of water or steam can be noticed but cannot create a hazard to the occupants of the premises or damage electrical components or wiring 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 al Measure the required flue length as shown in Figure 14 Refer to section 2 5 to determine whether any extension kits are required Installations using only the standard ducts or standard ducts with straight extensions are described in this section Installation instructions for all other flue systems are included in the various flue kits b Ensure th
24. or internal space with other opened flued appliances then the size of the air vent necessary should be calculated in accordance with BS 5440 2 Table 2 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 CONDENSATE DISPOSAL The condensate drain connection is suitable for either 21 5 mm or 22 mm plastic push fit or adhesive overflow pipes and fittings It should be piped to drain preferably within the building maintaining a continuous 2 5 fall away from the appliance If the drain is routed to outside it should be to a drain or soak away and any external pipe work should be in 32 mm Insulation to protect from freezing in cold weather conditions is also advisable Note if the appliance is installed in a garage all pipe work should be in 32 mm Ensure that the condensate discharge system complies with any local regulations in force GAS SUPPLY 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 t
25. order ensure that all joints and seals are correctly re fitted Open the isolating cocks and vent air from the system using the manual air vent Re pressurise the system as necessary and check for water leaks EXPANSION VESSEL TOP MOUNTING RAIL EXPANSION VESSEL REMOVE SPIRE CLIP FROM THIS POSITION CONNECTION POINT FOR FLEXIBLE HOSE BOTTOM MOUNTING RAIL 9 1 PRESSURE RELIEF VALVE Refer to Figures 18 amp 24 al Ensure supply voltage is isolated b Drain down the appliance refer to section 9 24 c Undo the nut securing the discharge tail pipe to the pressure relief valve and remove Undo the nut securing the pressure gauge capillary and remove d Undo the nut securing the pressure relief valve to the CH flow pipe and remove the pressure relief valve Fit the replacement pressure relief valve using new fibre washers f Re assemble in reverse order ensure that all joints and seals are correctly re fitted g Open the isolating cocks and vent air from the system using the manual air vent Re pressurise the system as necessary and check for water leaks 38 Note the pressure relief valve should not be used to drain the system QU WATER TEMPERATURE SENSORS Refer to Figure 49 a Ensure supply voltage is isolated b Disconnectthe electrical lead from the sensor to be changed Unclip the sensor from the pipe and remove d Clip the replacement sensor onto the pipe and position as shown i
26. sampling point a LA 60 100mm concentric chimney adaptor pipe HHHHHHHHHHHHHHI 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 KIT F TWIN FLUE SYSTEM C53 PART NO 956080 This flue system kit is designed for installations where the air intake position is different than the flue duct exit point The kit comprises of a twin adaptor from which the air intake is taken from the adjacent outside wall see example Figure 3g and the flue duct is routed vertically through the roof A ML It has to be noted that the flue duct is under pressure when the appliance is in operation and the duct can leak poisonous carbon monoxide if the duct components are not correctly assembled It is not recommended to route the flue duct through living space areas i e bed rooms living rooms etc For installation details refer to the instructions provided with the twin flued kit For C53 flue systems the terminal for the supply of combustion air and for the evacuation of combustion products shall not be installed on opposite walls of the building Maximum flue resistance permitted for a twin flued system z 52 Pa Minimum flue resistance permitted for a twin flued system z 23 5 Pa Flue Component Flue Resistance Pa Part Number Twin Flue Adaptor required 95 Air Inlet Terminal required 3 Chimney Terminal required 0 5
27. the heat exchanger flow outlet and undo the nut connecting the flow pipe to the plate to plate heat exchanger On SBX appliances undo the nut connecting the flow pipe to the CH flow isolating cock refer to Figure 43 g Rotate the flow pipe anticlockwise and gently pull down to disengage the flow pipe from the heat exchanger h Remove the retaining clip from the heat exchanger return inlet and undo the nut connecting the flow pipe to the hydroblock adaptor fitting i Rotate the return pipe clockwise and gently pull down to disengage the return pipe from the heat exchanger 35 751030 MANUAL NEW 21 9 10 08 41 Page 24 If the gas control valve is changed then when the appliance is running the flue gas C0 should be measured refer to section 6 1 and compared to the values stated section 2 3 If the measured value does not correspond to the Performance Data then contact Halstead Boilers Ltd Service Help line 0844 371 1111 Always seal the gas valve adjustment screw with paint after adjustment Refer to Figures 35 36 amp 37 al Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp 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 a
28. these instructions 4 3 Mounting The 18 44 Central Heating amp Domestic Hot Water Service Connections 18 A vertical concentric outlet kit is also available for installations where an AE s AM outside wall is not accessible or where it is desired to fit the duct through 4 6 Condensate 19 i 4 47 Pressure Relief Valve 19 the roof Installation using the horizontal duct is described in the main MU A text of these instructions and additional information is provided in the 4 10 Optional Cylinder Tank Temperature Sensor vertical outlet kit for the vertical installation option Note If the vertical SBX Appliances 20 outlet kit is to be used access to the roof is necessary 5 EE 21 5 Filling the Water 21 Other flue kits are available for open flued B23 split flued C53 and 5 2 Commissioning the 22 inati y DHW Flow Rate Chx Appliances Only special C13 applications contact Halstead Boilers Ltd Service Help 5 4 EE 23 Line 0844 371 1111 for further details 5 5
29. 111 751030 MANUAL NEW 21 9 10 08 44 Page 45 9 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 AN Before commencing the commissioning procedure ensure that the gas service cock is turned on the electricity supply is isolated and that the CH and DHW pipe work where fitted is complete A special feature of 3 the CBX appliances is that the water systems can be completely filled 4 prior to fitting the appliance It is recommended that this procedure be followed even when the appliance is to be fitted immediately after filling the system Fill the water systems by following the procedure detailed below steps 1 to 5 and referring to Figure 17 FILLING THE WATER SYSTEM 1 2 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 2 COMMISSIONING THE WATER SYSTEM i an A 1 ist e 1 1 4 nu i p 1 1 Pos DN CONDENSATE FILLING CONDEN OUTLET n EON VALVE NOTE TRAP FLLN6 PEW FILLING PARTS FITTED CHRETURN LOOP CH ION VALV
30. 2 90 4 92 3 92 2 92 2 92 4 Seasonal Efficiency SEDBUK Band 2 Nox Classification Class 2 751030 MANUAL NEW 21 9 10 08 39 Page 7 aa BENCHMARK No Senchmar GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No NOTIFICATION No CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER CYLINDER T STAT amp PROGRAMMER TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE m3 hr ft3 hr BURNER OPERATING PRESSURE IF APPLICABLE N A mBar CENTRAL HEATING FLOW TEMPERATURE C CENTRAL HEATING RETURN TEMPERATURE C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE am
31. 60 mm dia straight duct 1 metre 1 956101 80 mm dia straight duct 2 metre 2 956102 90 Elbow 80 80 8 956100 45 Elbow 80 80 4 956099 Split pipe vertical flue outlet kit Part no 956080 Roof terminal with pitched roof flashing kit The flue resistance for the following accessories has to be considered 80mm flue extension 90 elbow 45 elbow Max length 30m CBX24 CBX32 SBX30 21m CBX38 If the flue pipe passes through habitable rooms within the same dwelling the flue pipe must be routed through vented air ducts If the flue pipe passes through compartment from wall floors the requirements set out in Building Regulations Part B must be followed 80mm twin adaptor with sampling point 80mm air intake Kit F Split flue system 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 751030 MANUAL NEW 21 9 10 08 41 Page 18 AN wy FLUE LENGTHS Length supplied in standard kit horizontal 815mm Max horizontal length from boiler to chimney 607100mm 2000mm Min horizontal length from boiler to chimney 60 100mm 100mm Max vertical length from boiler to chimney 60 100mm 2000mm Min vertical length from boiler to chimney 60 100 200mm Length supplied in standard kit vertical available in 10m 20m and 30m length N A Flexi tube min length om Flexi tube max
32. 9500 87700 65900 109500 109500 87700 05900 109500 Net kW 30 6 24 5 18 4 30 4 30 6 24 5 18 4 30 4 Central Heating Input Btu h 104440 83600 62800 103700 104440 83600 52800 103700 Max Rate Poss kW 34 0 27 2 20 4 33 8 33 2 26 6 20 0 33 0 Btu h 116000 92800 69600 115300 113400 91000 68300 112700 Net kW 9 2 1 3 9 5 1 6 9 2 IR 5 2 7 6 Central Heating Input Btu h 31400 24900 18800 26000 31400 24900 18800 26000 Min Rate ross kW 10 2 8 2 6 1 8 4 10 0 9 6 0 8 3 Btu h 34800 28000 20800 28600 34000 27000 20500 28300 Max kW 38 0 32 0 24 0 38 0 32 0 24 0 Domestic Hot Water Output Btu h 129600 109200 81900 129600 109200 81900 Min kW 9 0 7 9 9 0 9 0 is 23 Btu h 30700 27000 20100 30700 27000 20100 Net kW 30 8 32 7 24 5 38 8 32 7 24 5 Domestic Hot Water Input Btu h 132300 111600 83500 132300 111600 83600 Max rate B kW 43 1 36 2 21 2 42 35 5 26 6 Btu h 146900 123500 92800 143600 121000 90800 Net kW 9 2 1 3 5 5 9 2 7 3 95 Domestic Hot Water Input Btu h 31400 24900 18800 31400 24900 18800 rate Bic kW 10 2 8 2 6 1 10 0 7 9 6 0 Btu h 34800 28000 20800 34000 27000 20500 m3 h 3 24 2 59 1 95 3 22 Central Heating Gas Rate m3 h 41 0 3 46 2 59 Domestic Hot Water Gas Rate Max ft3 h 144 8 122 2 91 5 after 10 min operation hot kg h 2g 255 19 Seasonal Efficiency 90 2 90 8 90
33. ANUAL NEW 21 9 10 08 44 Page 43 6 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 COMBUSTION The appliance incorporates a flue sampling point on the appliance flue elbow or appliance vertical flue adaptor If the service engineer has suitable equipment to analyse the flue gas the plastic cap may be removed and a 6 mm inside diameter sample tube fitted For CBX appliances operate in DHW mode at full rate for SBX appliances operate the appliance in Service mode see section 5 2 After ten minutes operation check the C02 CO values and compare with those figures stated in section 2 3 Do not forget to replace the cap after use When the appliance is operating at maximum output check that the gas supply pressure is 20 0 mbar using the inlet pressure test point located on the gas supply pipe Before commencing any service operation ISOLATE the mains electrical supply and TURN OFF the gas supply at the main service cock GAS CONTROL VALVE FAN amp BURNER ASSEMBLY Refer
34. E 3 s STOP CHECK A 4 HEATING Note VALVE VALVE A SYSTEM The appliance ASSEMBLY RETURN has a built in filling loop MAINS WATER MAINS CISTERN amp SUPPLY WATER SUPPLY OVERFLOW HEATING PRESSURE PUMP STOP SYSTEM amp REDUCING VALVE VALVE RETURN METHOD B IF REQUIRED RECOMMENDED AND APPROVED METHOD DNE FOR FILLING A CLOSED CIRCUIT IN A HOUSE R24 2a WATER REGULATIONS GUIDE 16 751030 MANUAL 26 21 9 10 08 43 NEW 7 7 1 FUNCTIONAL FLOW WIRING DIAGRAM BOILER Page 35 BOILER PUMP MAINS RPAN 000 000 GAS VALVES ad O MZ LU LL z OS lt LL a ra lt T O en HYDROBLOCK DIVERTER Roomstat L2 or link L N mains NE F power d external pump 230 a U gas valves spark generator 230Vac J 1 1 burner fan ugweeg 230 diverter valve 230Vac 0000 0080 1 DHW tank thermostat thermistor b 0000 e q Return temp thermistor gt O N Flow temp e Back q thermistor B Flue temp thermistor GREEN AU e E Y e E DHW e EoWN turbine a Ww 5 29 751030 MANUAL PIPE RETAINING CLIP FLOW TUBE TRAP TUBE LOCK NUTS CONDENSATE DRAIN DRAIN SUMPCAP SEALED WATER SYSTEM al Check the operation of the pressur
35. E GAS DRAIN PLUMBING JIG COLD SUPPLY WATER IN 5 6 7 GAS al CH FLOW DRAIN WASTE OUTLET 9 NOTE TRAP PARTS SECONDARY FITTED INSIDE TANK OPTIONAL Check that the CH flow return and DHW return on SBX appliance if used isolating valves are in the open position Fill the system with water using one of the approved methods described in section 3 7 to about 2 0 bar filling loop provided on CBX appliances Vent the system via the radiator valves and system air vents in accordance with normal practice Ensure that all system air vents are closed To aid venting a manual air vent is provided on the LHS of the heat exchanger and an automatic air vent on the pump assembly Check the system for soundness Check the operation of the pressure relief valve Figure 18 by lifting the lever on the valve gently to ease the valve off its seat Checking that water is discharged release the lever and ensure that the valve seats correctly and does not leak 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 PRESSURE GAUGE CAPILLARY PRESSURE RELIEF VALVE Drain the entire system to flush out any debris and refill to 0 2 bar above the system design pressure between 0 5 and 1 5 bar by repeating the above procedure Follow th
36. ENS NN SEAL INSTALLING THE AIR FLUE DUCT FROM INSIDE THE ROOM Wall thickness up to 800 mm 31 only al Pushthe 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 Ld Assemble the flue system extension ducts as necessary referring to Figure 15 c Pull the flue system towards the appliance to seat the external sealing ring against the outside wall ensuring that the duct joints are not disturbed d Use the internal sealing ring to make good the internal hole and check that the terminal is correctly located on the outside wall Where possible this should be visually checked from outside the building Figure 16 shows a view of the flue system correctly installed e Finally locate and secure the elbow to the appliance using the four screws provided INSTALLING THE AIR FLUE DUCT FROM OUTSIDE THE ROOM Flue hole diameter 100 mm wall liner not necessary al 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 Assemble the flue system extension ducts as necessary referring to the flue kit instruc
37. ERIAL No COMMENTS SIGNATURE SERVICE 7 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 9 Dare ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE DATE SERVICE 2 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 4 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 6 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 8 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 10 rc ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE 751030 MANUAL NEW 21 9 10 08 39 Page 5 IMPORTANT INFORMATION 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 Electromagnet
38. FLUE C33 PART NO 956085 External vertical flue kit Part no 956085 Roof terminal 7 with rain cover AW S Max lengths from top of boiler to Air Cowl Fig 3 c Offset vertical flue 242 amp SBX 30 a measured from boiler flue outlet centre line to the centre line of the extension elbow b measured from the top of the boiler to the underside of the air cowl Maximum allowable length of a b 8900mm 2 949 KIT C HORIZONTAL ANTI PLUME For outside installations _ the pipe joints have to be covered with special Lip seal to prevent rain ingress 60 100mm concentric air flue pipe 93 flanged elbow concentric Fart 956093 with sampling point 1m extension n FLUE KIT C13 PART NO 956084 z 48 00 If the standard horizontal terminal is likely to cause nuisance to a re neighbour or buildings because of excess pluming then this particular flue kit raises the flue gas outlet point to a higher elevation with the ri minimum amount of changes The flue gas duct is teed off from the concentric part and covered by an 80mm outer tube to protect the flue a DEL 2 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 Suitable for installations i
39. GAS CONTROL VALVE AUTOMATIC AIR VENT GAS VALVE LEAD AND PLUG HYDROBLOCK AND PUMP CONDENSATE TRAP GAS ISOLATING COCK PRESSURE RELIEF VALVE PRESSURE GAUGE TIME CLOCK CONTROL BOX CONTROL PANEL 26 751030 MANUAL NEW 21 9 10 08 43 Page 41 C GAS CONNECTION Refer to Figure 12 Connect the gas supply pipe to the gas service cock It is recommended that a minimum of 22 mm diameter OD copper pipe be used to within 1000 mm of the gas service cock For full rate operate CBX appliances in DHW mode 1 CONDENSATE CONNECTIONS CONDENSATE DRAIN MUST BE 2 022 CONDENSATE DRAIN MUST BE 2 022 SINK WASTE ees 1 4 rA a4 EXTERNAL PIPE MUST BE gt 032mm C CONDENSATE CONNECTION Refer to Figure 13 Connect preferably a 22 mm plastic push fit or adhesive overflow pipe to the condensate outlet It should be piped to drain preferably within the building maintaining a continuous 2 fall away from the appliance Note if an additional U trap is fitted between the appliance and the discharge point then a visible air break is necessary between the appliance and trap because a trap is already provided within the appliance 32 mm pipe should be used for external pipe work or if the appliance is installed in a garage If the drain is routed externally to drain or soak away then the external length should be kept as short as possible and not exceed 3000
40. GULATIONS 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 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation It should also be in accordance with the relevant recommendations in the current editions of the following British Standards and Codes of Practice BS 5449 BS 5546 BS 5440 1 BS 5440 2 BS 6798 BS 6891 Institute of Gas Engineer document IGE UP 7 BS 7074 expansion vessel BS 5482 propane installations and 15813 for IE IMPORTANT NOTE Manufacturer s instruction must NOT be taken in any way as overriding statutory obligations APPLIANCE LOCATION THE FO
41. LLOWING LIMITATIONS MUST BE OBSERVED WHEN SITING THE APPLIANCE a The appliance is not suitable for external installations The position selected for installation should be within the building unless otherwise protected by a suitable enclosure and MUST allow adequate space for installation servicing and operation of the appliance and for air circulation around it Section 2 4 and Ld 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 Ifthe appliance is to be fitted in a timber framed building it should be fitted in accordance with the British Gas publication Guide for Gas Installations In Timber Frame Housing Institute of Gas Engineers document IGE UP 7 If in doubt advice must be sought from the Local Gas Supplier d The appliance is approved to a protection rating of IP33 Therefore if the appliance is to be installed in a room containing a bath or a shower any electrical switch or control utilising mains electricity must be so situated that it cannot be touched by a person using the bath or shower Attention is drawn to the requirements of the current BS 7671 I E E Wiring Regulations and in Scotland the electrical provisions of the Building Regulations applicable in Scotland FLUE TERMINAL POSITION DETAILED RECOMMENDATIONS FOR FLUE INSTALLATION
42. NG HOLES MARK POSITION SBX OF TOP AND SIDES WALL FIXING HOLES BOILER LOCATING TABS WALL MOUNTING PLATE WALL PLATE LOCATING TABS PLUMBING JIG WALL FIXING HOLES 17 751030 MANUAL NEW 21 9 10 10 11 REAR FLUE 97mm CBX 24 52 amp SBX30 105mm 38 POSITION OF d 225 2 DUCT HOLE 7225 2 C MOUNTING THE APPLIANCE Refer to Figure 11 al Liftthe appliance into position approximately 10 mm above the top of the wall mounting plate and use the side wings on the plate to locate the appliance horizontally Then carefully lower the appliance ensuring that the top locating tabs are securely engaged b Connect the central heating system pipes to the central heating flow and return pipes on the boiler Pipe work may be routed from above or below the appliance as required CENTRAL HEATING amp DOMESTIC HOT WATER SERVICE CONNECTIONS Refer to Figure 12 Commission the central heating system and domestic hot water system for CBX appliances as described in section 5 1 and then proceed to Section 4 9 MOUNTING THE APPLIANCE SIDE WINGS LOCATING TABS LIFTING POINT 08 43 Page 38 97mm 24 32 amp SBX 30 E CBX 38 POSITION OF WALL MOUNTING PLATE SERVICE CONNECTION PIPES NOT SUPPLIED MAINS CENTRAL WATER IN p DOMES HEATING amp FLOW GAS HOTWATER RETURN TURBINE S
43. OSTIC LED INDICATORS FASCIA PANEL Figure 30 The Reset LED shows steady RED in a lockout condition and the error code will be displayed by the 4 yellow lights above the two control knobs For fault finding refer to the diagnostic chart shown below together With the notes given in sections 8 3 8 4 and 8 5 Depending on the fault condition the boiler can be reset by pressing the RED Reset light C FAULT FINDING CODES In the event of the appliance failing to light refer to the Diagnostics Chart 7 RESET amp burner lock outLED m D LED 4 ON OFF CONTROL SWITCH CENTRAL HEATING FAULT FINDING Upon demand for Central Heating closure of the time switch and room thermostat where fitted the controls should carry out a set of start up checks followed by an ignition sequence Refer to Section 5 2 If the control has powered up correctly but does not respond to a CH demand Check voltage between pin 2 connector X1A orange wire and pin 2 connector X1B blue wire If 0 V ac check room thermostat and clock If 230 V ac check control for lockout or blocking codes refer to section 8 3 check operation of the pump Note Whenever a CH demand is removed either by the timer the room thermostat or by the appliance s internal temperature control an anti Cycle mode is initiated which prevents the appliance from firing in CH mode for 5 minutes Ensure that the control is not in this mode b
44. UPPLY FILLING 00 DRAIN PS PRESSURE POINT RELIEF CONDENSATE OUTLET SBX SERVICE CONNECTIONS SERVICE CONNECTION PIPES NOT SUPPLIED SECONDARY RETURN FROM MEX GAS TANK SUPPLY OPTIONAL 4 CENTRAL HEATING FLOW PRESSURE DRAIN POINT CONDENSATE OUTLET 751030 MANUAL NEW 21 9 10 08 43 Page 39 P t COMBUSTION CHAMBER 5 HEAT EXCHANGER yx 26A SPARK ELECTRODE NS IIIS Inspect the inside of the combustion chamber for debris If necessary SS 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 TO BIN mE CONDENSATE DRAIN A NS NN The condensate Drain has a removable cap Figure 27 which allows the NN m removal of debris that may be caught within it Place a bowl under the SS cap to catch the condensate and remove the cap Any debris inside will S be expelled at this point Replace the cap ensuring a good seal is made EE Discard the condensate and debris 6 29 DOMESTIC COLD WATER INLET FILTER CBX APPLIANCES ONLY Close the water inlet isolating cock open a domestic hot water tap at the lowest point in the system and allow the pressure to dissipate Close this tap
45. an additional bend in the flue and has an equivalent length of 775 mm Vertical Turret Socket For use with elevated horizontal flues and vertical terminals Vertical Roof Terminal For use where an external wall is not available or where it is desirable to route the ducts vertically For installation details refer to the instructions provided with the individual flue kits These optional kits may be used with the standard flue kits to produce an extensive range of flue options providing that the following rules are Strictly obeyed al The maximum minimum permissible length of the room sealed flue system are Horizontal flue terminal all orientations maximum 10000 mm 394 in Horizontal flue terminal rear exit minimum 250 mm 10 in Vertical flue terminal maximum 12000 mm 472 in Vertical flue terminal minimum 600 mm 231 2 in The equivalent flue length must not exceed the maximum values stated 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 ins
46. and Filter CBX Appliances 39 9 18 Condensate Drain 39 9 19 Pressure 39 9 20 AUG Air Vell so cvs cer Gia m RO 39 9 21 Control POB RH 40 9 22 Time Clock CBX Appliances 40 9 23 DHW Flow Turbine Flow Regulator and Filter CBX Appliances Only 40 9 24 Draining The Appliance 40 10 Short Parts List ccccceucucueueevaueeeusueaeaveusueusauepaus 41 751030 MANUAL NEW 21 9 10 08 39 Page 4 A ES SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record below SERVICE PROVIDER Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the appliance manufacturer s specified spare part when replacing gas controls SERVICE 1 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 3 ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 5 Dar ENGINEER NAME COMPANY NAME TEL No CORGI ID S
47. and control 23 Appliance Hydraulic CIfeUills iun cta aeta tintas rr nete 10 a hot water cylinder directly 3 Installation 12 7 SE MM MOM COMM D The appliances feature an attractive white stove enamelled casing with ene ea su ESO ERREUR ke here edid otii inset control panels The flue systems are in white stove enamel to give ue TEPMINALFOSIUON 31 Ventilation Requirements 12 a clean attractive appearance to the installation 3 5 Condensate 5 5 13 34 Gas Supply ii 13 A standard horizontal concentric air flue duct terminal is available 37 Central Heating systems esee 13 maximum duct length of 755 mm 29in suitable for room sealed 3 8 Domestic Hot Water System 14 pn f 39 Electricity Supply 16 applications The duct assembly is connected to the appliance via a turret 310 External Controls iiis 16 which can be orientated to provide different horizontal duct directions fee AD E D gt Extension ducts may be fitted in accordance with and up to the maximum 42 Preparing The Wall sees 17 dimensions stated in
48. ar sdlsfea0 Eden X Type CBX 24 52 amp 58 m AND SERVICING INSTRUCTIONS TO BE GIVEN TO THE USER CE 0086 EC 87 BP 35 G C Appliance No 47 260 05 Eden CBX 24 G C Appliance No 47 260 04 Eden CBX 32 G C Appliance No 47 260 14 Eden CBX 38 G C Appliance No 41 260 13 Eden SBX 30 G C Appliance No 47 260 07 Eden CBX 24 Propane G C Appliance No 47 260 06 Eden CBX 32 Propane G C Appliance No 47 260 15 Eden CBX 38 Propane G C Appliance No 41 260 16 Eden SBX 30 Propane 751030 MANUAL NEW 21 9 10 08 39 Page 2 IE 1 UL 0 1 1 Important 1 12 General Description 1 The Halstead Eden CBX and Eden SBX range are high efficiency E EE 2 condensing fully automatic wall mounted gas appliances suitable for ceci AER cm att 2 ee 2 either room sealed or opened flued applications for use with natural gas 23 General Specifications seen 620 and LPG 931 The Eden CBX combination appliances provide the Vveralt Dimensions INIMUM UedaTdhC6S 25 Concentric Air Flue Duct Specifications 4 user with both central heating CH and domestic hot water DHW on MEE demand with DHW pre heat feature The Eden SBX models are suitable 28 Additional Concentric Flue Kis cene for a sealed central heating system with the facility to heat
49. at all inner and outer tube sealing rings are provided and assemble the air flue ducts as shown in the flue instructions c Construct the correct flue length by building the flue out from the appliance Ensure that the flue and air seals are correctly fitted before assembly and that each section is fully engaged 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 1 MEASURING THE EXACT FLUE LENGTH ETC TOTAL FLUE LENGTH E FROM OUTLET CENTRE 7 TO OUTSIDE WALL FACE a2 LENGTH L FAN OUTLET EXTERNAL Dia 60mm 19 751030 MANUAL NEW 21 9 10 08 44 Page 42 NZ 130mm Dia 1 HOLE WITH n INTERNAL WALL WALL LINER N SEALING RING v SEAL FITTED EXTERNAL WALL SEALING RING 1 INSERT ASSEMBLED n FLUE SYSTEM 3 SLIDE FROM INSIDE T INTERNAL KE ROON 2 ALIGNASSEMBLED FLUE WALL SYSTEM ELBOW TO SEALING RING APPLIANCE AND SECURE SEALING RING Sy FORMAGOOD OP
50. check that the gas supply is metered and ascertain whether it is possible to measure the gas rate If the gas input rate can be measured then the requirements of GSIUR 26 9 can be met including any specific requirements in manufacturers instructions gt AIRINLET COWL If gas input rate cannot be measured then to satisfy the intent of GSIUR 26 9 the engineer shall measure the combustion quality of the appliance in accordance with BS 7967 or the manufacturers instructions If the engineer does not have the required equipment and no alternative test is specified by the manufacturer then the appliance shall be turned off and disconnected as an un commissioned appliance until such time that equipment is available to undertake such tests If a new gas valve is fitted it must be adjusted as per the instructions that are supplied with the new gas valve A suitable calibrated flue gas analyser is required to measure the C02 IMPORTANT After any adjustment of the gas valve it is essential to check the combustion levels at minimum gas rate table 2 3 If the Carbon Monoxide or Carbon Dioxide levels are outside the range quoted call Halstead Boilers Ltd Technical Helpline on 0844 371 1111 If in doubt ASK SWIRL PLATE AIR INLET COWL TOP AIR INLET COWL BOTTOM 751030 MANUAL NEW 21 9 10 08 42 Page 28 9 ACEMENT OF PARTS Before commencing any service operation ISOLATE the mains electrical supply and TURN OFF t
51. d from the Domestic Heating and Hot Water Guide to the building regulations DOMESTIC HOT WATER SYSTEM CBX APPLIANCES ONLY Check that the mains water pressure is sufficient as stated 2 2 Performance Data to produce the required DHW flow rate but does not exceed the maximum DHW pressure 10 bar If necessary a pressure reducing valve must be fitted to the mains supply before the DHW inlet connection b The final 600 mm 24 in of the mains supply pipe to the boiler must be copper c Avoid long DHW pipe runs and several hot water draw off points d Insulate the hot water pipes if accessible to minimise the heat losses within the pipes to keep the water hot longer e A domestic hot water regulator is fitted within the appliance to control the maximum water flow rate This may be removed to obtain higher flow rates Higher flow rates will not damage the appliance but may reduce the water temperature below an acceptable level DOMESTIC HOT COLD WATER SUPPLY TAPS AND MIXING TAPS All equipment designed for use at mains water pressure is suitable SHOWERS amp BIDETS Any mains pressure shower or bidet complying with the Local Water Undertaking byelaws is suitable 751030 MANUAL LED CODE 1234 OOO 0000 0000 0000 0000 0000 0000 000 0000 0000 0000 0000 0000 0000 OOOO OOOO NEW 21 9 10 FAULT EFFECT Overheated appliance No gas
52. djust to the user s habitual requirements Thus during long periods of no DHW draw off e g overnight no pre heat is provided With DHW Economy selected no pre heat is provided KEEP HOT FACILITY EDEN CBX appliances only This feature is designed to provide hot water very quickly without wasting too much water Therefore you may notice that after EVERY hot water draw off the burner may stay on for a short period of a few seconds This is to pre heat the hot water circuit and prepare the appliance for the next hot water draw off This feature applies in both the Comfort and Economy modes OPTIONAL HOT WATER DELAY PERIOD EDEN CBX appliances only After every hot water draw off the appliance may stay in this mode for a few minutes if selected even though a central heating demand is present LED 3 amp 4 as shown in the user manual will be off during this period This feature reduces the hot water outlet temperature fluctuations between draw offs This feature is particularly handy when having a shower In households with many hot water taps or larger families this feature could cause some unwanted delays in providing central heating To override the few minute delay briefly turn the CH control knob or room thermostat if fitted and the appliance will change over to CH almost immediately at least 1 minute after last burner cycle SERVICE MODE The appliance enters the SERVICE mode by turning the control knob to SERVICE
53. e commissioning procedure described below and then repeat this instruction with the system hot It is recommended that the system be cleaned with a recognised system cleaner such as Fernox or Sentinel On CBX appliances open the DHW inlet valve and operate each hot water tap in turn to clear all the air from the pipes and the appliance Remove the pump cap use a screwdriver to rotate the pump shaft Replace the cap Disconnect the filling loop from the system 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 21 751030 MANUAL NEW 21 9 10 08 44 Page 46 A COMMISSIONING THE APPLIANCE Adjustment of the Gas Valve NOTE DO NOT ATTEMPT TO ADJUST THE GAS VALVE NOTE The combustion values at minimum gas rate UNLESS YOU HAVE A SUITABLE PORTABLE and maximum gas rate must be checked using a COMBUSTION GAS ANALYSER THAT IS CHECKED AND WITHIN CALIBRATION COMPLIANCE WITH BS7967 2 BS7967 3 AND BS7967 4 15 ESSENTIAL Suitable calibrated flue gas analyser Compliance with BS7967 2 BS7967 3 and BS7967 4 is essential Combustion checks at minimum gas rate g With the front door fitted put the boiler into Service Mode at maximum gas rate see points e amp f oppos
54. e relief valve as described in section 5 1 b Check the correct operation of the pressure gauge by noting the reading when cold and check that the pressure increases with temperature Replace the gauge if readings are suspect Check that the system is at its original cold design pressure If necessary re pressurise the system as described in section 5 1 and search for and rectify any leaks causing loss of water d Incase 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 NEW 21 9 10 08 43 Page 36 E 2 CONDENSATE DRAIN SUMP ADAPTOR MAINS COLD INLET CONICAL FILTER SEALING WASHER FLOW REGULATOR FLOW TURBINE RE ASSEMBLY amp RE COMMISSIONING al Re assemble all components in reverse order b Checkthat 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 Checkthe operation of the appliance in both CH and DHW modes as applicable f Remove the manometer and tighten the inlet pressure test point sealing screw g Test for gas tightness 6 1 FINAL CHECKS al Ensure the fascia panel into the upright position and secure with the two screws b Re fit the front casing panel Return all appliance and
55. es 4 Select one from each group Refer to Figure 10 c Mark the position of the flue outlet For side flue installation extend the flue centre line on to the sidewall where the flue length exceeds 775 mm a flue slope angle of 2 5 needs to be taken into account Refer to Figure 10 Remove the paper template d Cut the hole in the wall for the air flue duct preferably with a core boring tool The hole must be horizontal and not be less than 100 mm in diameter If the hole is not accessible from outside its minimum diameter must be sufficient to allow insertion of the wall liner 130 mm 5in The wall liner is available as an optional extra and must be sealed in position with mortar or equivalent e Drill the four fixing holes using a 6mm drill and insert the wall plugs provided f Hang the wall mounting plate using two fixing screws in the top ensuring that it is level Hook the plumbing jig onto the two bottom locating tabs of the wall mounting plate Refer to Figure 9 g Enter the bottom two fixing screws into the wall plugs and tighten up all four screws If required service connections may be made now before mounting the appliance Refer to section 5 Pipe work may be routed from above or below the appliance as required MARK POSITION OF TOP AND SIDES WALL FIXING HOLES 7 BOILER LOCATING TABS WALL MOUNTING PLATE WALL PLATE LOCATING TABS PLUMBING JIG WALL FIXI
56. eset the appliance and initiate a further ignition attempt press the Reset button NOTE In the event of failure during normal running the Reset LED will show steady RED To access the relevant error codes press the Reset button for three seconds The Reset LED will flash RED To reset the appliance press the Reset button Refer to fault finding Section 8 G FROST PROTECTION The appliance is fitted with a frost protection device In the event of very cold conditions the pump may operate and the appliance light for a few minutes to protect the appliance and system from potential frost damage This can only function if the gas and electricity supplies are maintained and the ON OFF switch on the appliance is left ON T On CBX appliances the time clock can be switched to the OFF setting OVERHEAT PROTECTION The appliance incorporates flow and return thermostats which monitor the appliance s operating temperature Abnormal temperatures such as overheating will cause the appliance to go to lockout and the Reset button will show steady RED if the error codes are accessed the LED 4 code 0001 will illuminate Allow the appliance to cool and then press the Reset button to clear SIDE PANEL 4 SECURING SCREWS 4 PER SIDE LI BALLSTUDS 3 PER SIDE 23 751030 MANUAL NEW 21 9 10 08 44 Page 48 ML A sjhalsfead Glen Dimplex Boilers Stoney Lane Prescot Merseyside L35 2XW F
57. eurer ERE E a bx testeb bei 30 8 1 erreren ei bees cbt DM DLE DERI ERN COT Face es 30 82 Diagnostic LED Indicators SE 30 8 3 Faulting Finding Codes 30 8 4 Domestic Hot Water Fault 30 8 5 Central Heating Fault 30 9 Replacement Of Parts uu 32 9 1 Ignition and Detection 32 9 2 Igniter Unit and Ignition 32 9 3 Gas Control Valve including Air Inlet 1 33 9 4 S D PO ee ER E 34 95 DUNC MR REED RES 35 9 6 Combustion Chamber Front Insulation 35 9 7 Combustion Chamber 1 5 35 9 8 Heat Exchanger PE 35 9 9 T A A 36 9 10 Pump Head 36 9 11 Diverter Valve Motorised 37 9 12 Hydroblock 5 37 9 13 Expansion Vessel Rrr eR nade URP ODER 38 9 14 Pressure Relief 38 9 15 Water Temperature 38 9 16 PUG Sensors Lucis toesea dic oi Qr EY CIE 38 9 17 Plate Heat Exchanger
58. f the appliance can t be repositioned For installation details refer to the flue kit instructions 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 routed vertically Dimensions from vertical terminals to opening alongside the outside wall to above the roofline Special seals are required windows should be in line with Figure 5 to prevent rainwater penetrating the pipe joints For installation details refer to the flue kit instructions 751030 MANUAL NEW 21 9 10 08 41 Page 15 N ML FLUE SENSOR PLATE HEAT EXCHANGER PRIMARY FLOW PIPE PLATE HEAT EXCHANGER b Open the drain sump cap while holding a receptacle beneath to capture any condensate FILTER CBX APPLIANCES ONLY c Disconnect the condensate drainpipe from the appliance Refer to Figure 51 d ii the two locknuts holding the system in place a Ensure supply voltage is isolated el Unclip the hose from the bracket b Drain down the appliance refer to section 9 24 f nis the condensate drainpipe sump adaptor by gently pulling Close the DHW inlet isolating cock open a DHW tap at the lowest g Remove the condensate drain system clean or replace as necessar point in the system and allow the pressure to dissipate Close this ine P tap again h
59. he 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 IGNITION AND DETECTION ELECTRODES Refer to Figure 31 al Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp burner assembly refer to section 6 2 c Unscrew the two screws holding the electrode remove electrode and used gasket d Fit the new electrode and new gasket ELECTRODE PLUG ELECTRODE IGNITION GASKET 32 IGNITOR UNIT AND IGNITION LEADS IGNITION MODULE SCREW 32 e Check that electrode is aligned as detailed in Figures 26 a or 26 b f Re assemble in reverse order Ensure that all joints and seals are correctly re fitted C IGNITER UNIT AND IGNITION LEADS Refer to Figure 32 al Ensure supply voltage is isolated b Remove the plug and earth lead from the ignition electrode c Remove the electrical supply leads d Unscrew the two screws holding the igniter unit remove igniter unit e Fit the new igniter unit f Re assemble in reverse order ensure that the igniter unit is orientated as shown in Figure 32 and that the brown electric supply lead is fitted to position 1 on the ignite
60. he maximum appliance input plus the demand of any other installed appliance BS 6891 1988 minimum of 22 mm diameter pipe work is recommended within 1000 mm of the appliance gas cock e Natural gas appliances The governor at the meter must give a constant outlet pressure of 20 mbar 8 in wg when all appliances on the system are running Propane appliances The regulator must give a constant outlet pressure of 37 mbar 14 9 in wg when all appliances on the system are running f The gas supply line should be purged WARNING Before purging open all doors and windows also extinguish any cigarettes pipes and any other naked lights 9 The complete installation must be tested for gas tightness a The appliances incorporate all the components necessary to allow them to be connected to a sealed central heating system Refer to Figure 7a for a typical system design which incorporates radiators and a drain facility that must be provided at the lowest point in the system to allow complete drain down b The installation should be designed to operate with a flow temperature of up to 95 C CENTRAL HEATING SYSTEM c A sealed system must only be filled by a competent person d The available pump head for the appliances are given in Figure 6 el Ifthermostatic radiator valves are fitted a radiator must be fitted with two lock shield valves to enable correct operation of the pump overrun facility 13
61. ic 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
62. ical Helpline 0844 371 1111 with the boiler 15 751030 MANUAL NEW 21 9 10 08 43 Page 34 A ML ELECTRICITY SUPPLY EXTERNAL CONTROLS al Wiring external to the appliance must be in accordance with the The CBX appliances may be used with any certified mains voltage room current E E Wiring regulations BS 7671 for electrical installation thermostat and the SBX appliances with any certified and any local regulations which apply programmer room thermostat as described in section 4 A low voltage b The mains cable must be at least 0 75 mm2 24 0 2 mm PVC DHW cylinder tank sensor is available as a kit for use with SBX insulated to BS 6500 table 16 appliances c THIS APPLIANCE MUST BE EARTHED Failure to provide a For further information contact Halstead Boilers Ltd Service Helpline satisfactory earth connection will result in appliance malfunction 0844 371 1111 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 ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM AN FLEXIBLE HOSE UNION TEMPORARY CONNECTION To be removed imediately after filling METHOD DOUBL
63. ite If the Carbon Dioxide 02 level is outside the required values adjust the throttle adjustment screw Fig 19 Clockwise to decrease 02 or Anti Clockwise to increase C02 h When the CO level has stabilised check the Carbon Monoxide C0 level is within the range shown in Table 2 3 on page 3 IMPORTANT After any adjustment of the gas valve it is essential to check the combustion levels at minimum gas rate table 2 3 If the Carbon Monoxide or Carbon Dioxide levels are outside the range quoted call Halstead Boilers Ltd Technical Helpline on 0844 371 1111 If in doubt ASK To check the flue gas levels at minimum gas rate it is necessary to set the boiler into Service Mode Y Fig 196 NOTE Service mode automatically stops after 10 minutes and the boiler returns to normal operation Turn the CH knob fully clockwise Note the knob will turn past the maximum temperature mark to Service mode Y Fig 19b The two CH lights 3 amp 4 will flash continuously the boiler is now running at minimum rate d Check the Carbon Monoxide CO and Carbon Dioxide C02 readings are within the range quoted in table 2 3 on page 3 Gas Valve NOTE f the combustion levels are outside the NOTE FACTORY SET a Throttle DO NOT ADJUST warranty void if adjusted range quoted in table 2 3 see Adjustment of the Gas Valve opposite Adjuster Combustion checks at maximum gas rate
64. lation 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 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 955123 Eden CBX 32 955124 Eden CBX 24 955125 Eden SBX 30 988642 Eden CBX 38 Conversion Instructions Gas Control Valve Data Badge Natural Gas Boiler Chip Card Nat Gas Cork Gasket Polydome Badge Natural Gas Kit Numbers Natural Gas to Propane 955120 Eden CBX 32 955121 Eden CBX 24 955122 Eden SBX 30 988641 Eden CBX 38 Conversion Instructions Gas Control Valve Data Badge Propane Boiler Chip Card Propane Cork Gasket Polydome Badge Propane Kit Numbers 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 0844 371 1
65. me in terms of adjacent surfaces and neighbouring properties A special flue terminal Kit C is available to raise the flue discharge point use of this terminal will limit the maximum flue length available For further information contact Halstead Boiler Ltd Service Help Line 0844 371 1111 VENTILATION REQUIREMENTS Detailed recommendations for air supply are given in BS 5440 2 The following notes are for general guidance al Itis 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 Where an open flued B23 system is used then an air vent must be provided in the same room or internal space as the flue duct air inlet with a minimum free area of at least CBX 38 159 cm CBX 32 128 5 cm CBX 24 87 5 cm SBX 30 117 cm 751030 MANUAL NEW 21 9 10 08 42 Page 27 N ML GAS CONTROL VALVE GAS FEED PIPE CONNECTION TO GAS CONTROL VALVE INCLUDING AIR INLET COWL Refer to Figures 33 34 amp 35 al Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan amp burner assembly refer to section 6 2 c Unscrew four screws holding the gas feed pipe and remove gas feed pipe refer to Figure 33 Note Newer versions may have a
66. n Figure 49 e Reconnect the electrical lead 49aFLOW SENSOR 49b RETURN SENSOR d a 11 cm 9 1 FLUE SENSOR Refer to Figure 50 al 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 751030 MANUAL NEW 21 9 10 08 41 Page 17 KIT CHIMNEY FLUE LINER KIT B23 PART NO 956082 This kit is suitable for open flue application in accordance with BS5440 where a room sealed flue installation is impractical The kit comprises of a flue adaptor from the appliance to the chimney a flexible plastic flue liner with connection parts and chimney terminal see Figure 3f Where an open flue system is used then an air vent must be provided in the same room or internal space as the flue duct air inlet see section 3 4 For installation details refer to the flue kit instructions Maximum flue resistive length 30m Chimney flue liner kit Part no 956082 M Chimney terminal In replacement installations the chimney has to be cleared of debris and all flue parts 7 Flexible corrugated plastic flue liner 80mm according to EN 14471 r Maximum length 30m CBX24 CBX32 SBX30 21m CBX38 inimum length 5m NNN 93 flanged elbow concentric with
67. nd cowl refer to Figures 35 and 36 WITHDRAWING BURNER Unscrew the four screws holding the fan to the burner manifold and remove fan refer to Figure 37 f Attach and secure the replacement fan replace the gasket g Re assemble in reverse order ensure that all joints and seals are correctly re fitted GAS VALVE MOUNTING PLATE GAS VALVE e MOUNTING PLATE LOCATING TAB 751030 MANUAL NEW 21 9 10 08 41 Page 25 CD Domestic Hot Water Mode CBX PRIMARY HEAT EXCHANGER BURNER amp BURNER FLANGE EXPANSION VESSEL PRIMARY FLOW CH RETURN N THERMISTOR CA AUTOMATIC AIR VENT CONDENSATE TRAP DHW COLD INLET PLATE HEAT RETURN 1 FLOW EXCHANGER TURBINE in AONA CONDENSATE FILLING ET DHW OUTLET duo QU omm PRESSURE RELIEF VALVE Ti GAUGE 4t Central Heating Mode SBX FLUE PRODUCTS PRIMARY HEAT EXCHANGER BURNER amp BURNER FLANGE EXPANSION VESSEL PRIMARY FLOW CH RETURN THERMISTOR m me AUTOMATIC AIR VENT CH RETURN UMP amp HYDROBLOCK CONDENSATE RAP e 3 BAR PRESURE PRESSURE RELIEF VALVE CONDENSATE 10 SECONDARY RETURN OUTLET FROM STORAGE TANK IF REQUIRED 1 1 751030 MANUAL 12 NEW 21 9 10 08 41 Page 26 d STATUTORY REQUIREMENTS GAS SAFETY INSTALLATION AND USE RE
68. or telephone enquiries call 0844 371 1111 WRAS sc Website www glendimplexboilers com e AP RO Pert of the Glen Dimplex Group SN benchmark irem Glen Dimplex Boilers is continuously improving its products and may therefore change specifications without prior notice commissioning amp servicing of central heating systems The statutory rights of the consumer are not affected 03 10 751030 Issue 4 SALES AND SERVICE HELPLINE O844 371 1111
69. p RECORD GAS RATE m3 hr ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE N A mBar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE Its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO RATIO READING N A YES CO CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING PRINT CORGI ID No ENG S NAME SIGN 751030 MANUAL NEW 21 9 10 08 39 Page 8 42 751030 MANUAL NEW 21 9 10 08 39 Page 9 aS EE Appliance CBX38 CBX32 CBX24 Design Domestic Hot Water Umin 15 6 13 1 9 8 Performance raised 35 C gpm 3 4 2 8 2 2 DHW Specific Rate D EN 625 Umin 18 1 15 3 11 5 Min Mains Water Inlet Pressure Bar 1 0 for Max Heat Output psi 14 5 Min Mains Water Inlet Pressure Bar 0 1 for Operation psi
70. p on the CH flow water isolating cock in conjunction with the manual air vent located on the LHS of the heat exchanger refer to Figures 43 and 53 f Where the DHW circuit is to be worked on close the DHW inlet isolating cock open a DHW tap at the lowest point in the system and allow the pressure to dissipate Close this tap again Note the pressure relief valve should not be used to drain the system DRAIN POINT 751030 MANUAL NEW 21 9 10 08 39 Page 13 A FLUE OPTIONS ML Chimney flue liner kit Part no 956082 Raised external flue outlet kit Part no 956084 Vertical flue kit Part no 956081 with flat roof flashing plate Split pipe vertical flue outlet kit gt Part no 956080 J with flat roof flashing plate Vertical flue kit Part no 956081 External vertical flue kit Part no 956085 Telescopic horizontal flue kit Part no 956120 The following systems are available for the EDEN x type range For full fitting instructions refer to the leaflet supplied with the flue kit 2 60 100 flue accessories cause nuisance to neighbours or other buildings 0 5m flue extension duct 956092 1m flue extension duct 956003 93 flue extension elbow 956091 45 flue extension elbow 2x 956090 Vertical flue turret 956087 The pluming from the flue may Harizontal terminal has built in fall in the flue to allow condensate to d
71. pansion vessel is not required if the total CH system content is less than 84 litres but one is required for systems with volumes greater than 84 litres refer to section 3 7 A separate DHW expansion vessel is not required for the CBX appliances 751030 MANUAL NEW 21 9 10 08 39 Page 6 GAS CATEGORIES These appliances are certified to comply with the requirements of EN Eden CBX 38 Propane Eden CBX 32 Propane 483 EN 677 and EN 625 for use in GB and IE Great Britain and Ireland Eden CBX 24 Propane Eden SBX 30 Propane using the following gas categories A ML Insp 631 Propane with a regulated gas supply at 37 mbar 14 9 in wg Eden CBX 38 Eden CBX 32 Eden CBX 24 Eden SBX 30 inlet pressure Insp 620 with a governed gas supply at 20 mbar 8 in wg inlet The appliance classification as defined in EN 483 may be any of the pressure following depending on the chosen flue option C44 C33 or Bos Xm Appliance CBX38 CBX32 CBX24 SBX30 CBX38 CBX32 CBX24 SBX30 Propane Propane Propane Propane Mode Rate kW 30 0 24 0 18 0 30 0 30 0 24 0 18 0 30 0 Central Heating Output Max non condensing Btu h 102400 81900 61400 102400 102400 81900 61400 102400 80 60 C Min kW 9 0 7 9 5 9 8 2 9 0 1 9 5 9 8 2 Btu h 30700 27000 20100 28000 30700 27000 20100 28000 Central Heating Output Max kW 32 1 25 7 19 3 32 1 32 1 25 7 19 3 32 1 condensing 50 30 C Btu h 10
72. ply Check gas valve and lead Check PCB X2A amp X2B connectors Check spark generator spark electrode Check mains earth lead continuity Check flue sensor Check flue system Check no air is in heat exchanger CH system Check pump Check PCB PCB connectors Check flow return and flue sensors Check wiring to sensors Check PCB X6 amp X8 connectors Check gas valve and lead Check PCB Check fan Check mains fan lead amp connector Check low voltage fan lead amp connector Check PCB X3 connector Check pump operation Check diverter valve operation Check PCB Check mains voltage Check PCB connectors Check water pressure Check pump Check no air is in heat exchanger CH system Check flow and return sensors Check wires to sensors not crossed Check PCB Reseat or replace BCC Check flow and return sensors Check wires to sensors not crossed Check PCB Press reset to activate Check PCB Check DHW turbine amp lead Check Diverter valve amp lead Check PCB X4 connector Check filter in plate heat exchanger Check power supply Check PCB X1B connector Check PCB fuse Check PCB X1A connector 31 751030 MANUAL 30 NEW 21 9 10 08 42 Page 32 A GENERAL Before looking for a fault condition check that The mains electrical supply is turned on The clock room or cylinder tank thermostat where fitted are calling for heat The gas service cock is open
73. r unit g Ensure that all joints and seals are correctly re fitted ELECTRODE DETECTION IGNITION LEAD EARTH LEAD IGNITION ELECTRODE 751030 MANUAL NEW 21 9 10 08 42 Page 29 7 FLUE TERMINAL POSITION SPECIAL REQUIREMENTS FORA VERTICALLY BALANCED FLUE Minimum spacin 300mm Position A Directly below an openable window 12in air vent or any other ventilation opening B Below gutter drain soil pipe 75mm Jin C Below eaves 200mm Bin D Below a balcony 200mm Gin 2500mm 98in E From vertical drain pipes and 150mm bin soil pipes F From internal or external corners 300mm 12in internal corners 1000mm 4Uin 6 Above adjacent ground or balcony level 300mm 12in H From a surface facing the terminal 600mm 24in 2500mm 98in Facing terminals 1200mm 48in 2500mm 98in J From opening door window in 1200mm 48in carport into dwelling not recommended K Vertically from a terminal on the 1500mm 60in same wall L Horizontally from a terminal on the 300mm 12in same wall M Adjacent to opening 300mm 12in N Below carport 600mm 24in not recommended 0 From adjacent wall 300mm 12in P From adjacent opening window 1000mm 40in Q From another terminal 600mm 24in R Minimum height 300mm 12in Recommended by the boiler manufacturing industry to prevent pluming nuisance and damage to buildings A ML If the appliance is installed in a room
74. rain away B60 100mm concenine Standard horizontal wall terminal Max length 10 mirs 83 flanged elbow concentric Min length 250mm viis with sampling point Il horizontal flue requires extension pipe the flue should be installed such that there is no section less than yE 2 5 F fo the horizontal ee Traditional concentric flue system Figure 3a with a maximum length of 10m The flanged flue elbow is designed with 3 slope towards the appliance so that the condensate can easily drain off It has to be considered that for every metre horizontal flue length the terminal exit centreline is approx 45 mm higher than the elhows centreline The standard telescopic terminal is 615mm max length and 430mm min length but can be cut to a minimum flue length of 250mm which is suitable for single 100mm 4 brick walls Suitable for 25 45 Pitch Angle Roof terminal with rain cover and pitched root flashing kit flue accessories 0 5m extension duct 855082 1m flue extension duct 956093 93 flue extension elbow 956091 45 flue extension elbow 2x 956090 Pitched roof flashing kit 956089 Flat roof flashing plate 840512 _ 93 flanged flue elbow 956086 Max lengtht2m Top of Boller Min length 0 6m J to underside of Cowl Vertical flue sockel with sampling point Standard concentric 100 60 vertical flue application Figures 3b 3c
75. res when using the plume diverter BOILER IA Clearance H 600mm MIN BOILER 22 287222222 Clearance F 751030 MANUAL NEW 21 9 10 08 41 Page 22 The diverter allows the terminal clearance to be reduced as follows see diagrams below Clearance H From a surface facing the terminal 600mm Clearance F From internal or external clearances 300mm b Choose the direction required to deflect the flue products left or right only Push the diverter elbow onto the angled outlet of the flue terminal in the desired rotational position and ensure the diverter is pushed up to the shoulder to fully engage the rubber seal d Fix the diverter to the flue terminal with the self drilling screw provided Do not use a power tool to fit screw Note The Plume Diverter terminal must not under any circumstances deflect flue products downwards APPLIANCE HYDRAULIC CIRCUITS FLUE 4 Central Heating Mode CBX PRIMARY HEAT EXCHANGER BURNER amp BURNER FLANGE EXPANSION VESSEL CH FLOW THERMISTOR PRIMARY FLOW CH RETURN THERMISTOR AUTOMATIC AIR VENT PUMP amp 1 HYDROBLOCK DHWCOLD INLET O 3 f PLATE HEAT n EXCHANGER ONDENSATE AP FLOW TURBINE FILLING e LOOP E H CONDENSATE HoT OUTLET CH
76. single flange nut securing the gas feed pipe d Unscrew three torx screws 7 20 and remove gas control valve refer to Figure 34 e Unclip the top section of the black plastic air inlet cowl from the fan assembly and remove white plastic insert clean or replace as necessary refer to Figure 35 f Refit or replace the top section of the black plastic air inlet cowl ensuring that it is clipped into place and that the holes in the white plastic insert are aligned with the fixing holes 4 SCREWS g Attach and secure the gas feed pipe to the replacement gas valve using a new gasket 2 CONTROL VALVE 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 C02 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 0844 371 1111 COMBUSTION CHECK SET UP When installing commissioning or servicing a gas appliance that incorporates a pre mix burner and zero 3 TORX set governor because it is not possible to measure an SCREWS operating pressure the engineer should first
77. t up the plate heat exchanger and remove n Fit the replacement plate heat exchanger using new case seals as necessary ensuring the filter is fitted a Ensure supply voltage is isolated o Re assemble in reverse order ensure that all joints and seals are b Drain down the appliance refer to section 9 24 correctly re fitted Disconnect the vent tube from the auto air vent and check that it is p Open the isolating cocks and vent air from the system using the free from blockage manual air vent Re pressurise the system as necessary and check d Unscrew the auto air vent and fit replacement for water leaks e Re assemble in reverse order ensure that all joints and seals are correctly re fitted f Open the isolating cocks and vent air from the system using the Refer to Figure 27 Ensure supply voltage is isolated manual air vent Re pressurise the system as necessary and check for water leaks 39 751030 MANUAL NEW 21 9 10 08 41 Page 16 9 1 EXPANSION VESSEL Refer to Figure 48 al b d fj g h Ensure supply voltage is isolated Drain down the appliance refer to section 9 24 Remove the spire clip on the case in front of the expansion vessel Undo the nut connecting the flexible hose to the expansion vessel and remove hose Slide the expansion vessel forward and remove Slide the replacement expansion vessel in place Re assemble in reverse
78. 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 A J Nb GENERAL DESCRIPTION The appliances incorporate a microprocessor based fully modulating air gas ratio control system with direct burner ignition which provides a modulated heat output to either central heating CH or domestic hot water DHW demands and with internal frost protection provided as standard across the range The heat exchanger is constructed from stainless steel A combined circulating pump diverter valve and automatic air vent assembly pressure gauge safety valve and system expansion vessel are included Isolation valves are fitted to the service connections The CBX appliances have a DHW flow detection device which gives priority to DHW demand and proportions the required heating load to the DHW flow rate an electro mechanical 24 hour time clock is also fitted as standard to the CBX appliances The appliances may be used with any certified mains voltage room thermostat or programmer room thermostat SBX appliances and can operate without the need for an automatic bypass valve however if thermostatic radiator valves are installed it is recommended that one radiator is fitted with lockshield valves normally in the bathroom to allow the pump overrun facility to operate correctly A separate CH ex
79. the electrodels and their gasket IGNITION amp DETECTION ELECTRODES Check that the alignments of the ignition and detection electrodes are correct Refer to Figure 26 Adjust by carefully bending the tip of the electrode rod whilst supporting the base of the rod Do not put any pressure on the ceramic insulation COMBUSTION CASE PANELS 751030 MANUAL 24 NEW 21 9 10 08 44 Page 44 A E aF OTHER FEATURES The following additional features are included in the appliance specification ANTI CYCLE DEVICE When the appliance cycles on its central heating control thermostat a slow cycle device operates The timer set to 5 minutes is activated after the end of each burn cycle to prevent rapid cycling of the burner ANTI PUMP SEIZURE DEVICE Providing that a power supply is maintained and the appliance ON OFF switch is ON the pump will operate for at least 20 seconds in every 23 hours regardless of heat demand to prevent pump seizure during periods where the appliance is not used CH SOFT START DEVICE After every burner start in CH mode the burner output stays at low for 3 minutes to ensure smooth heat up of the system and maximum efficiency DHW PRE HEAT CBX appliances only DHW Comfort selected With no demand for DHW the appliance will fire periodically for a few seconds to maintain the DHW plate heat exchanger in a heated condition This feature will automatically a
80. through roof attics with a maximum length of 12m The kit comprises of the roof terminal vertical adaptor with sampling point and bracket The maximum length is measured from the top of the appliance casing to the underside of the air cowl Note Flues which exceed 7mtrs in length will be subject to a small percentage decrease in heat input below the standard tolerance as shown graph A on the following page 751030 MANUAL NEW 21 9 10 08 41 Page 14 A GRAPHA Reduction in heat input as flue length increases 102 0 eee 101 0 1004 Raised external flue outlet kit zm Part no 956084 o m 5 2 TE sg Li 94 0 93 0 d Raised 60mm flue 920 outlet duct with 0 2 4 5 7 9 0 I aaomm anti freeze Flue Length m E MAX height of raised from top of boiler Horizontal flues C43 up to 10m in length or equivalent may be used 63 flanged elbow concentric 17 to centre of outlet however a reduction in the heat input will occur The graph shows mE PORE ass details L HL CBX32 amp SBX30 _ Min height 1m Standard horizontal flue x adaptor has an already built in fall in the flue to allow the condensate to drain away LI terminal with rain cover and pitched roof flashing b Sy Kit Sy ENS D EXTERNAL VERTICAL
81. tions 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 20 cLECTRICAL CONNECTIONS Connect the electricity supply and external controls using suitable mains cable as follows Wire the cable s into the appropriate connections in the electrical plug provided referring to Figure 16 Live supply to L1 Neutral and Earth as indicated Check that L2 and L3 are linked To provide correct cable retention fit the piece of tubing supplied over the cable as it passes through the clamping arrangement The cable will be held in position as the plug cover is fitted If a programmer room thermostat is to be fitted remove the red link between L2 and L3 and connect the device across these terminals Any external controls fitted must be rated at 230V 50Hz and have volt free contacts NOTE If room thermostat is to be fitted remove the link and connect room thermostat across L2 and L3 OPTIONAL CYLINDER TANK TEMPERATURE SENSOR SBX APPLIANCES ONLY If this sensor kit is used refer to the separate kit for instructions for installation and wiring details 751030 M
82. to Figures 22 23 24 and 25 Remove the casing front panel pulls off b Lower the controls panel 2 screws c Remove the sealed chamber front panels 11 screws d Disconnect the igniter plug earth lead and detection plug from the igniter and detection electrodes CONTROL PANEL FIXING SCREWS A ML Unscrew the screw holding the gas valve lead plug and disconnect the plug f Disconnect the electrical leads from the fan 2 plugs g Undo the nut holding the gas valve feed pipe to the gas isolating cock and disconnect h Disengage the gas valve feed pipe grommet from the casing by pushing it up i Remove the 6 nuts holding the combustion chamber front cover in place j Remove the gas control valve fan amp burner assembly by carefully pulling forward the combustion chamber front and rotating the assembly anticlockwise so that the burner points forward then disengage the gas valve feed pipe from the casing by lifting up the assembly Take care not to damage the insulation k The assembly may then be inspected t Re assemble in reverse order G 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 al Inspectthe ignition and detection electrodes situ If necessary clean using a soft brush If either the electrode or the ceramic insulation shows signs of damage or wear replace
83. tructions 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 8 A ML Sum PLUME DIVERTER TERMINAL INSTALLATION Plume Diverter Kit Part No 956103 For use with Standard horizontal telescopic flue kit Part no 956120 only This kit is provided to assist in fitting a condensing boiler with reduced clearances when fitted in good practice according to the Guide to Condensing Boiler Installation published by DEFRA HMSO This kit allows the boiler flue outlet to be directed to the left or to the right only INSTALLATION INSTRUCTIONS Under certain operating conditions condensing appliances have a tendency to form a plume of water vapour at the terminal Therefore consideration should be given when fitting the Plume Diverter in terms of plume dispersal onto adjacent surfaces and neighbouring properties a Refer to section 2 5 for instructions on fitting the flue system Also see Figure 9 for all other clearances The resistance of the diverter is equivalent to 0 5 metre of flue length Ensure this is used when calculating the maximum allowable flue length maximum horizontal flue length restricted to 4 5 met
84. ttom front panel PRESSURE RELIEF VALVE A pressure relief valve set to 3 bar 43 5 psi is supplied with the appliance however it will start to open at approximately 2 7 bar It should not be used to flush the system FILLING LOOP A filling loop is supplied loose with the appliance for connecting the mains water supply to the CH system so that the system can be filled on installation or whenever water pressure has been removed for system modifications etc The filling loop complies with the current water supply water fittings regulations Methods of filling a sealed system are shown in Figure 8 WATER TREATMENT CLEANSING AND FLUSHING THE HEATING SYSTEM NOTE British Standard BS7593 1992 stresses the importance of cleansing and flushing of the system to ensure it continues to run efficiently with the minimum of maintenance necessary Halstead Boilers fully support this professional approach and recommend that the system is cleansed with an effective chemical cleanser and protected long term with a suitable inhibitor Such products are available from Fernox and Sentinal CONTROLS As a minimum it is recommended that a room thermostat be installed to control the appliance Thermostatic radiator valves may be fitted to the system however they must not be fitted in the room where the room thermostat is fitted There must be at least one radiator installed with lock shield valves that should not be closed Further guidance can be obtaine
85. y removing power from the control and restoring it after a delay of 10 seconds If room thermostat and clock are OK and no lockout or blocking code exists and the control is not in anti cycle mode then replace PCB 751030 7 lt MANUAL NEW 21 9 10 08 43 Page 33 Z TS IF TYPICAL SYSTEM DESIGN FOR EDEN CBX APPLIANCE TIME nee Sas f cs m j MAINS WATER IN RADIATOR WITH 2 LOCKSHIELD CH FLOW VALVES IN OPEN PRESSURE POSITION CH RETURN RELIEF OUTLET TO DRAIN DOMESTIC HOT WATER 7 OUT V DOMESTIC DOMESTIC COLD WATER HOT WATER DRAIN COCK AT LOWEST POINT iro IN SYSTEM OPTIONAL SYSTEM DESIGN WITH UNVENTED STORAGE GAS SUPPLY CYLINDER FOR EDEN SBX PRESSURE REDUCING amp b VALVE if required ROOM STAT N BS STOP VALVE 2 CHANNEL DHW CH Fixed Spindle STANDARD TIMESWITCH N MAINS WATER JUNCTION BOX R RETURN Ps F FLOW l CYLINDER CONTROL STAT 2x TWO PORT SPRING RETURN VALVES y DRAIN COCK AT LOWEST POINT IN THE SYSTEM NOTE CBX circuit No automatic by pass required However it is recommended to leave one radiator open to ensure pump over run function It is also recommended to fit TRV s on all radiators except in rooms with a room thermostat For information please contact Halstead Boilers NOTE SBX circuit For detailed system designs see the seperate booklet supplied Techn
86. y and check for water leaks FLUE HOOD FLUE SEAL FLUE HOOD GASKET FIXING POINTS CONDENSATE DRAIN 9 1 PUMP HEAD ONLY Refer to Figure 45 al Ensure supply voltage is isolated b Disconnect the electrical lead to the pump head Drain down the appliance refer to section 9 24 d Using long Allen key unscrew the four screws holding the pump head refer to Figure 45 e Remove the pump head and fit replacement pump head using a new 0 ring seal f Re assemble in reverse order ensure that all joints and seals are correctly re fitted g Open the isolating cocks and vent air from the system using the manual air vent Re pressurise the system as necessary and check for water leaks Note It is likely that there will still be some water spillage when the head is removed PUMP HEAD ELECTRICAL LEAD f 4 SCREWS 751030 MANUAL NEW 21 9 10 08 41 Page 21 ADDITIONAL CONCENTRIC FLUE KITS 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

Halstead Eden Cbx 24 - Direct Heating Spares

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