Contents Page Page DECLARATION ELECTRICAL INFORMATION & GENERAL WARNINGS 11.0 General Introduction 11.1 Connecting the power supply Symbols used in the manual 11.2 OpenTherm controls Delivery of the appliance 11.3 OpenTherm wiring Guarantee and responsibility 11.4 Modulating circulating pump (wiring) Liquid fuel information SPARE PARTS Product disclaimer statement...
Declare that; Equipment: Sapphire Domestic Modulating Liquid Fuel Boiler Sapphire 6-32 kW Model: In accordance with the following Directives and Normative documents: 2006/95/EEC Conforms with the safety objectives of the Low Voltage Directive and its amending directives. 2004/108/EC Conforms with the essential protection requirements of the Electromagnetic Compatibility Directive and its amending directives.
Information and General Warnings Introduction The Sapphire User Manual supplied with the appliance: • Is an integral and essential part of the product and must not be separated from the appliance. It must therefore be kept carefully for any necessary consultation and must accompany the appliance even if it is transferred to another owner or user, or to another system.
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Information and General Warnings In the first instance Contact the Sapphire Agent who installed and commissioned the appliance to ensure that the fault does not lie with the system compo- nents or any incorrect setting of the system controls that falls outside of the manufacturer’s guarantee otherwise a service charge could result.
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 to twelve months from the date of installation. • The shell (heat exchanger) of the appliance is covered by a ten year parts and labour guarantee from the date of installation. This is subject to the following: •...
Safety and Prevention Introduction The boiler has been designed and built in compliance with current regulations and directives, applying the known technical rules of safe- ty and envisaging potential danger situations. It is necessary, however, to bear in mind that the improper use of the equipment may lead to situations which could result in risk of the user or third parties, as well as to the health, safety and well-being to the boiler, burner or other items.
Boiler Introduction How a Condensing Appliance Works During the combustion process, hydrogen and oxygen combine to produce heat and water vapour. The water vapour produced is in the form of superheated steam in the heat exchanger. This superheated steam contains sensible heat (available heat) and latent heat (heat locked up in the flue gas).
Technical Data Boiler Dimensions 36.50 Front View Top View Rear View Right Side Left Side Fig.7 Address: 5 Howard Road, Saint Neots, PE19 8ET Tel: 01480 477066 ALL DIMENSIONS IN THE DIAGRAMS ABOVE ARE IN MILLIMETRES Fax: 01480 477022 WWW.eogb.co.uk DRAWING NO &...
Appliance Installation Regulations Compliance The Installation of an EOGB Sapphire boiler must be in accordance with the following recommendations: • Regional Building Regulations such as the Building Regulations for England and Wales, the Building Standards for Scotland etc and any local Bye-laws which you must check with the local authority for the area •...
Appliance Installation Air Intake Adaptor Position and Appliance Panel Access Knock-outs The EOGB Sapphire air intake adaptor is supplied in the accessory box However to utilise the rear option, the exit flue knock-out in the rear panel would have to be removed, For this, please follow steps 1,2,3, & 9. If, however, a side or top flue exit is required (See Fig 9), then the air adaptor would also have to be repositioned.
Appliance Installation 6.5 Balanced Flue Under no circumstances should EOGB Sapphire boilers be connected to existing flue or chimney systems. Only EOGB balanced flue systems and components should be used. Failure to install the correct type of flue system will invalidate the warranty.
Pipe Connections 7.0 Installing the Water Connections The flow and return pipework can be routed to either side of the boiler or the rear, depending on the site requirements and direction of the flue system used. (See Figs below) TOP VIEW LEFT SIDE RIGHT SIDE RIGHT SIDE...
Condensate Disposal 8.0 Condensate Trap When in condensing mode the EOGB Sapphire boiler produces condensate from the water vapour in the flue gases. This water is slightly acidic with a ph. value of around 3. Provision must be made for the safe and effective disposal of this condensate. The EOGB Sapphire boiler is provided with a condensate pump as standard, however if you opt not to use the condensate pump, please see below images (Fig 27) for examples on how to route the condensate discharge but for further information please see the Installers Guide: Conden- sate discharge pipe installation as published by the HHIC.
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Condensate Disposal Examples of Condensate route options with the use of the supplied condensate pump Fig. 25 Fig. 22 Fig. 23 Fig. 26 Fig. 24 SP-MAN-INSTALL-01 Revision 2 21-12-21...
Condensate Disposal Not using the Condensate Pump If for any reason the Condensate Pump is not required, The condensate discharge pipe can be connected 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.
Fuel Supply and Storage Fuel Pump The EOGB Sapphire boiler is fitted with the Danfoss BFPM 61 pump. This pump is pre-set for a two-pipe operation and MUST NOT BE CON- VERTED TO A ONE PIPE OPERATION UNDER ANY CIRCUMSTANCES. 1 or 2 pipe operation can only be achieved by following the advice given in section 9.2 WARNING...
Fuel Supply and Storage Connecting the fuel supply (2 pipe fuel supply system) To connect the two-pipe system a Deaerator is required. The flexible fuel hoses are pre-fitted to the appliance on the burner fuel pump (SEE FIG 34) Please refer to manufacturer’s instructions and OFTEC Technical Book 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.
Fuel Supply and Storage Fuel Storage Liquid Fuel storage tanks should be installed to BS5410 Part 1 for Domestic Appliances or Part 2 for Non-domestic Appliances. Fuel Supply Pipe Sizing Selection of the correct pipe diameter will depend on the position of the oil storage tank relative to the burner and the length of pipe run. The oil supply pipe should be laid as level as possible to avoid air pockets and unnecessary friction losses.
Fuel Supply and Storage Fuel Line Testing Upon completion of the fitting of the fuel supply lines, a pressure test MUST be done to confirm that there are no leaks. Please seek guidance on the pressure test in OFTEC Technical Book 3 IMPORTANT - A De-aerator (if fitted) MUST NOT be connected during pressure testing WARNING Fuel Filters...
Sealed Systems 10.0 Sealed System Installation The EOGB Sapphire boiler is suitable for use with sealed systems complying with the requirements of BS 5449. The maximum temperature of the central heating water is 75°C. The system must also be provided with the following item (Not supplied with the boiler) •...
Sealed Systems 10.4 Filling the Sealed System An air bleed vent(s) is fitted to the top of the boiler. Check that the vent plug on the top is screwed in fully, then unscrew it one complete turn. The procedure for filling the sealed system is as follows: Only ever fill or add water to the system when it is cold and the boiler is off.
Electrical 11.0 General The EOGB Sapphire boiler requires a 230/240 V ~ 50 Hz supply. It must be protected by a 3 Amp fuse. The EOGB Sapphire boiler contains electrical switching equipment and must be earthed. DANGER The supply must be fused at 3 Amp and there must only be one common isolator for the boiler and control system, providing complete electrical isolation.
Appliance Installation 11.4 Modulating Circulating Pump (Wiring) 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 Fig 40 Internal Wiring Diagram (Sapphire PCB Connections) Fig 41...
Exploded Views 12.0 Burner spare parts Fig. 42 Please refer to the next page to find spare part identification SP-MAN-INSTALL-01 Revision 2 21-12-21...
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Exploded Views Labelled Number Part Number Description SS-BURN-013-01 Nozzle Holder Adjuster SS-BURN-014-01 Nozzle Holder Locking Screw SS-BURN-015-01 Nozzle Holder O-Ring (21x6) SS-BURN-012-01 Nozzle Holder KLC20/24 24V DC Flame Detector with fixed 450 mm SS-WIRE-001-01 Cable D01-030H8306 0.45 x 80 EH (23kW Version) D01-030H8310 0.55 x 80 EH (28kW Version) D01-030H8314...
Exploded Views 12.2 Top Tray spare parts Fig. 44 Labelled Number Part Number Description H01-42002116-002 Wiring centre – 10-way junction box SS-WIRE-007-01 USB 5v Power Supply SS-WIRE-009-01 Spacer for USB 5v Socket SS-CASE-028-01 Pump Mounting Bracket - SS D01-071N4106 BFPM61 Oil Pump D01-071N1006 BFPM61 Solenoid coil D01-071N4214...
Exploded Views 12.4 Heat exchanger spare parts Fig. 46 Please refer to the next page to find spare part identification SP-MAN-INSTALL-01 Revision 2 21-12-21...
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Exploded Views Labelled Number Part Number Description SS-ACCESS-005-01 Flue Air Adaptor Intake SS-ACCESS-006-01 M6 x 16 Hex Socket SS button bolts SS-ACCESS-008-01 Flue Air Adaptor Intake gasket SS-ACCESS-004-01 Air Intake Flue Adaptor SS-LOOM-009-01 PT sensor cable SS-ACCESS-006-01 M6 x 16 Hex Socket SS button bolts SS-HEX-009-01 HEX Flue Blanking Plates SS-HEX-003-01...
Exploded Views 12.5 Casings spare parts Fig. 47 Labelled Number Part Number Description SS-CASE-022-01 Boiler Top Casing Panel - BRILLIANT WHITE SS-CASE-007-01 Stud Latch M5 SS-CASE-025-01 Boiler Right Casing Panel - BRILLIANT WHITE SS-CASE-008-01 Clip Latch SS-CASE-006-01 M5 Spring U Clip SS-CASE-024-01 Boiler Left Casing Panel - BRILLIANT WHITE SS-CASE-008-01...
Product Fiche 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) No 813/2013 of 2 August 2013 implementing Directive 2009/125/EC of the European Parliament and of the Council with regard to ecodesign requirements of space heaters and combination heaters.
End of Life Information 14.0 End of Life Information GENERAL EOGB Energy Products Ltd liquid fuel appliances incorporate components manufactured from a variety of different materi- als. The majority of these materials can be recycled. Materials that cannot be recycled must be disposed of according to local regulations using appropriate waste collection and/or disposal services.
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EOGB Energy 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...
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