Sapphire Audio 6-32 kW, Installation Manual

Page 1: ...ic Liquid Fuel Heating Installation Manual Sapphire 6 32kW Sapphire fully modulating liquid fuel boiler operates via OpenTherm protocol for smart connectivity Intelligent flame detection functionality ErP and BED tested and approved Exceeds the 2018 ErP directive for NOx emissions ...

Page 2: ...ter connections 14 8 CONDENSATE TRAP DISPOSAL 8 0 Condensate trap 15 8 1 Condensate route options with condensate pump 16 8 2 Not using the condensate pump 17 8 3 Condensate route options without condensate pump 17 9 FUEL SUPPLY AND STORAGE 9 0 Fuel pump 18 9 1 Connecting the fuel supply 1 pipe 18 9 2 Connecting the fuel supply 2 pipe 19 9 3 Pump warranty 19 9 4 Fuel storage 20 9 5 Fuel supply pip...

Page 3: ...e Directive and its amending directives 2004 108 EC Conforms with the essential protection requirements of the Electromagnetic Compatibility Directive and its amending directives 92 42 EC Conforms with the requirements of the Boiler Efficiency Directive 2010 30 EU Conforms with the Labelling of Energy related products to EU no 811 2013 2009 125 EC Conforms with the Ecodesign of Energy related prod...

Page 4: ...o have the appliance and system checked at least once a year by a representative of the manufacturer or suitably qualified technician To ensure a periodic check the manufacturer recommends entering into a Maintenance Contract 2 DANGER WARNING CAUTION DANGER 2 3 Guarantee and responsibility CAUTION Information and General Warnings Thank you for purchasing the EOGB Energy Products Ltd fully modulati...

Page 5: ...ntrary to the manufacturer s installation and servicing instructions Damage due to external causes such as bad weather conditions flood storms lightning frost snow or ice fire explosion accident or theft Fault s due to incorrectly sized expansion vessel s incorrect vessel charge pressure or inadequate expansion on the system Fault s caused by external electrics and external components not supplied...

Page 6: ... or not it is advised of the possibility of such damages With the exception of injuries to persons EOGB s liability is limited to the customer s right to return defective non conforming products as provided by the relevant product warranty 4 Information and General Warnings This guarantee will be invalid if the appliance does not have an annual every twelve month service and will then be limited t...

Page 7: ...intended The following other materials are present in the product INSULATION MATERIALS Material Types Ceramic fibre board mineral wool Description Rigid board slabs sleeves gaskets ropes Known Hazards May cause temporary irritation or rash to skin High dust levels may irritate eyes and upper respiratory system Precautions Avoid unnecessary or rough handling or harsh abrasion of boards Normal handl...

Page 8: ... for use with a fully pumped central heating system with indirect domestic hot water cylinder They are not suitable for use with either a direct cylinder or a primatic cylinder or gravity hot water The boilers are suitable for use on open vented or sealed central heating systems The EOGB Sapphire boilers are supplied with the control panel and burner factory fitted 4 2 Flue Options EOGB advises tha...

Page 9: ...Primary Overheat Thermostat 19 Secondary Overheat Thermostat 20 EOGB Sapphire Wiring Case 21 EBI Transformer 22 Air Pressure Switch 23 Nozzle Assembly 24 KLC Flame Scanner 24v 25 Inverter Driven Fan Motor 26 Electrodes 27 Burner to Boiler Flange Plate 28 Blast Tube 29 Burner to Boiler Gasket 30 Atomising Nozzle 31 Sight Glass 32 Danfoss BFPM61 Pump 33 Solenoid Coil 34 Pressure Transducer 35 Pump M...

Page 10: ...SP MAN INSTALL 01 Revision 2 21 12 21 8 4 5 Checking the characteristics of the boiler Fig 6 Boiler Introduction ...

Page 11: ...dary Limit Thermostat safety shut off temp C 110 3 C Maximum hearth temperature C 100 Electrical supply Volts 1ph 230 50Hz Total Consumption kWh 0 66 Oil connection Dependant on installation Max operating pressure sealed system bar 3 Weight includes burner but excludes flue 5 0 Technical Boiler information Heating system pressure cold Calculated depending on system size Refer to the Domestic Heati...

Page 12: ...86 860 137 111 34 R 2 5 R 6 5 4 756 25 6 36 50 R 8 2 0 R 6 5 4 2 20 748 68 R20 44 310 812 Front View Top View Rear View Right Side Tel 01480 477066 Fax 01480 477022 WWW eogb co uk Address 5 Howard Road Saint Neots PE19 8ET DRAWING NO DESCRIPTION 0001 001R1 Sapphire Boiler Assembly MATERIAL FINISH REVISION Date Name DRAWN Unless Stated Otherwise IF IN DOUBT ASK Don t Scale Drawing 17 08 2021 A A B ...

Page 13: ...he boiler to be manoeuvred into position and to provide additional ventilation EOGB Advise a minimum of a 10mm gap around the sides and rear of the boiler Note depending on which flue exit options is used some additional clearances may be required Please see separate EOGB Sapphire Boiler Flue instructions for minimum gap clearances As the boiler is serviced from the front a minimum clearance of 75...

Page 14: ...ove the intake and gasket see Fig 9 5 Remove the chosen exit flue manifold sealing plate by removing the 4 x bolts plate and gasket see Fig 11 6 Re fit the flue manifold sealing plate and gasket to the rear manifold exit 7 Reroute the air intake ducting as shown in FIG 9 for each exit option 8 Then fit the air intake adaptor using the same 4 x securing bolts and gasket Ensure that the flue securin...

Page 15: ... boiler balanced flue provides options for side rear or top flue entry see Fig 12 Once the air intake adaptor has been fitted see section 6 4 Push the balanced flue section into the flue connection adapter please ensure that the rubber flue seals are fitted and lubricated Refer to EOGB Sapphire Boiler Flues Instructions for more info Ensure that once fitted that the flue securing clamps located on...

Page 16: ...at Fig 19 Fig 20 Please ensure that the unused Flow Port is sealed using the 3 4 BSP end cap and PTFE tape and jointing compound suitable for Heating Systems CAUTION 328 37 25 6 19 R 8 44 R 2 0 310 44 68 812 750 112 425 86 44 432 R6 5 R2 5 34 112 137 1 861 757 74 RIGHT SIDE REAR VIEW A B C D E F G H J 16 15 14 13 12 11 10 9 8 7 6 mm TEL 01480 477066 Fax 01480 477022 e mail technical eog EOGB Energ...

Page 17: ...ls or where the soil is poorly drained Any damage due to condensate backing up into the boiler due to a high water table in the case of a soak away or flooded drains when the condensate disposal is via a gulley or soil stack is not covered by the EOGB product warranty IMPORTANT Copper or steel pipe is NOT suitable and MUST NOT be used EOGB Sapphire Appliances are supplied with a condensate trap to ...

Page 18: ...SP MAN INSTALL 01 Revision 2 21 12 21 16 8 1 Examples of Condensate route options with the use of the supplied condensate pump Fig 22 Fig 23 Fig 24 Fig 25 Fig 26 Condensate Disposal ...

Page 19: ...ed directly to the condensate trap Please see below image Fig 27 for examples on how to route discharge the condensate but for further information please see the Installers Guide Condensate discharge pipe installation as published by the HHIC 8 3 Examples of Condensate route options when NOT using the supplied condensate pump Fig 27 Fig 28 Fig 29 Fig 30 Condensate Disposal ...

Page 20: ... LINE PORT Fig 31 9 1 Connecting the fuel supply 1 Pipe fuel supply system with standard Sapphire loop system When connecting a single pipe fuel line supply please use the flexible fuel lines pre fitted and should be made in accordance with BS5410 Part 1 Domestic The fuel supply line can be routed through the boiler casing via one of the side or rear knock out sections SEE FIG 32 and connect on to...

Page 21: ... 3 for more guidance on the installation of a two pipe system The fuel supply lines can be routed through the boiler casing via one of the side or rear knock out sections SEE FIG 32 9 3 Pump warranty For pumps used outside the stated technical data and used with oil containing abrasive particles Danfoss EOGB cannot give any warranty Note The solenoid valve must be replaced after 250 000 operations...

Page 22: ...o determine the maximum allowable pipe run on a Gravity Feed System using the Sapphire Loop System Table 4 is a general guide to determine the maximum allowable pipe run on a Sub Gravity Feed System using the Sapphire Loop System or De Aerator Maximum Allowable Pipe Run From Tank To Burner metres Fuel Flow rate 2 5 kg h 30kW HEAD metres 4mm inside dia 5mm inside dia 6mm inside dia 4 0 100 100 100 ...

Page 23: ...ters on the fuel supply line It is recommended that a good quality strainer type fuel filter be fitted at the tank end no greater than 50 microns and a secondary paper type filter less than 15 Micron to be used to protect the burner pump and nozzle from contamination 9 8 Fire Valve A remote sensing fire valve must be installed in the fuel supply line and comply with BS5410 Part 1 It must be locate...

Page 24: ...low temperature 50 C Return temperature 40 C Differential 10 C For additional guidance please refer to the Domestic Heating Design Guide published by CIBSE 10 2 Before you fill the system To avoid the danger of dirt and foreign matter entering the boiler the complete heating system MUST be thoroughly flushed cleaned and treated out before the boiler is connected and then again after the system has ...

Page 25: ...ck valves either side of the filling loop and disconnect the loop 10 5 Venting the Circulating Water Pump It is important that the circulating water pump is properly vented to avoid it running dry and damaging its bearings Please refer to pump manufacturer s instructions on how to vent the pump 10 6 Pressure Relief Safety Valve Not Supplied Now the pressure relief safety valve operation must be che...

Page 26: ...casing 4 Wire as per Fig 40 5 Ensure that all external wiring is adequately supported Do not switch on the electricity supply at this stage 11 2 OpenTherm Controls OpenTherm is the name given to a form of communication of information between modulating condensing central heating applianc es and room thermostats It sets the rules as to how the appliance and room thermostat communicate with each oth...

Page 27: ...iring On the EOGB Sapphire boiler an external modulating circulation pump will need to be wired into the EOGB Sapphire wiring centre on terminals 8 9 and 10 See Fig 40 External Wiring Diagram Internal Wiring Diagram Sapphire PCB Connections Fig 41 Appliance Installation Fig 40 ...

Page 28: ...SP MAN INSTALL 01 Revision 2 21 12 21 26 Fig 42 Exploded Views 12 0 Burner spare parts Please refer to the next page to find spare part identification ...

Page 29: ...ly 10 SS BURN 007 01 Air box to housing plate sealing gasket 11 SS BURN 005 01 Ignition electrode set SS BURN 052 01 Electrode Rubber Washer 12 SS BURN 006 01 Air Box 73mm 13 SS CASE 027 01 Transformer Pr Sw Bracket 14 SS BURN 048 01 EBI Ignition Transformer 230v 15 H01 84444329 Air Pressure Switch DL2 H01 75457584 Air Pressure Switch D2 Plastic Cover Screw 16 SS BURN 002 01 Air box to flange seal...

Page 30: ...s supply Cable Switch to PCB 3 SS PCB 004 01 Filtered IEC Power Socket IEC C14 3 A 250 VAC 4 SS PCB 009 01 Mains Filter Holder 5 SS PCB 005 02 M4 x 30 Standoff M F Hex Pillars 6 SS PCB 007 01 PCB Enclosure Cover incs Identification label 7 SS PCB 012 01 Cable capture clip 8 SS PCB 001 01 PCB Control Board 9 SS PCB 006 01 PCB Enclosure 12 1 PCB spare parts ...

Page 31: ...61 Motor lead D01 071N4215 BFPM61 Transducer lead SS LOOM 010 01 BFPM61 Pump solenoid lead 6 SS BURN 038 01 Flexible pipe 7 SS LOOM 007 01 PCB to Fan Socket SS LOOM 004 01 Fan Loom 8 SS CASE 013 01 Bulking plug spacer 9 SS LOOM 006 01 PCB to Burner Socket SS LOOM 005 01 Burner Loom 10 SS PCB 002 01 LCD Display SS WIRE 006 01 Coiled USB Angled to Angled lead 11 SS CASE 014 01 LCD Screen Spacer 12 S...

Page 32: ...er Description 1 F11 0440 A 14M S 14F Flexible 440mm Ruby Red Angled 1 4M x 1 4F 2 SS CASE 031 01 Nozzle Holder Service Support clip 3 SS HEX 021 01 1 4 Male Female Elbow 4 SS HEX 020 01 1 4 BSP Tee M F M 5 SS HEX 016 01 1 4 Male Female Isolation Valve Bio 12 3 Fuel connection spare parts ...

Page 33: ...SP MAN INSTALL 01 Revision 2 21 12 21 31 Please refer to the next page to find spare part identification Fig 46 Exploded Views 12 4 Heat exchanger spare parts ...

Page 34: ...Adaptor Male 17 SS TRAP 006 02 Trap Union Nipple Stainless Steel 316 18 SS TRAP 014 01 12mm OD 8mm ID Condensate hose 200cm SS TRAP 004 01 10 12mm Pipe Clips Pump clip 19 SS TRAP 003 01 12mm OD 8mm ID Condensate hose 40cm SS TRAP 004 01 10 12mm Pipe Clips Pump clip SS TRAP 005 01 12 14mm Pipe Clips Trap clip 20 SS TRAP 002 01 Condense Pump 21 SS TRAPKIT 001 01 Condensate Trap SS TRAP 001 01 3 4 to...

Page 35: ... Panel BRILLIANT WHITE SS CASE 008 01 Clip Latch SS CASE 006 01 M5 Spring U Clip 4 SS CASE 021 01 Boiler Casing Door BRILLIANT WHITE SS CASE 007 01 Stud Latch M5 5 SS CASE 023 01 Boiler Rear Casing Panel BLACK SS CASE 006 01 M5 Spring U Clip 6 SS CASE 001 01 Casing Acoustic Top Casing 7 SS CASE 003 01 Casing Acoustic Right Casing 8 SS CASE 004 01 Casing Acoustic Rear Casing 9 SS CASE 002 01 Casing...

Page 36: ... of nitrogen oxides NOx mg kWh 65 Annual energy consumption QHE GJ 72 71 13 0 Product Fiche It has been concluded that The full and part load efficiency test results obtained are deemed to satisfy the requirements of the Boiler Efficiency Directive 92 42 EEC The appliance is deemed to satisfy the minimum efficiency requirements of the Commission Delegated Regulation EU No Commission Regulation EU ...

Page 37: ...w the Health and Safety Infor mation given in the User Manual provided with the appliance RECYCLING Many of the materials used in EOGB Sapphire liquid fuel boilers can be recycled these are listed below COMPONENT MATERIAL Outer casing panels Mild steel polyester powder coated Heat exchanger Stainless steel Pipework Copper Burner body flange Aluminium alloy Burner oil pump Aluminium alloy steel Ele...

Page 38: ... Products Ltd 5 Howard Road Eaton Socon St Neots Cambridgeshire PE19 8ET Tel 01480 477066 Fax 01480 477022 Email sales sapphireboilers co uk www sapphireboilers co uk www youtube com EOGBenergyproducts EOGBburners ...