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Service & Commissioning Manual
Fully Modulating Low NOx Boiler for Domestic Liquid Fuel Heating
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.
SP - MAN - SERVICE - 01
Revision 2
21/12/2021
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Summary of Contents for EOGB Sapphire 6-32 kW
- Page 1 Service & Commissioning Manual Fully Modulating Low NOx Boiler for Domestic Liquid Fuel Heating 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. SP - MAN - SERVICE - 01 Revision 2 21/12/2021...
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Page 2: Table Of Contents
Contents Page Declaration Information & General Warnings Introduction Symbols used in the manual Delivery of the appliance and the User Manual Guarantee and responsibility Liquid fuel information and general instructions Product disclaimer statement Safety and Prevention Introduction Health and Safety information Appliance Introduction Appliance panel descriptions Checking the characteristics of the appliance... -
Page 3: Declaration
Declaration Declaration EC DECLARATION OF CONFORMITY in accordance with BS EN ISO/IEC 17050-1:2004 EOGB Energy Products Ltd 5 Howard Road, Eaton Socon, St Neots, Cambs, PE19 8ET Telephone: +44 (0)1480 477066 Email: sales@sapphireboilers.co.uk Website: www.sapphireboilers.co.uk Declare that; Equipment: Sapphire Domestic Modulating Liquid Fuel Boiler... -
Page 4: Information & General Warnings
This will be extended to a total period of 5/10 years if the appliance is registered with EOGB Energy Products Ltd within thirty days of installation and it is serviced at twelve month intervals. See main Terms and Conditions below. - Page 5 EOGB Energy Products Ltd will not be liable for any charges arising from this process. If a fault covered by the manufacturer’s guarantee is found Ask your Sapphire Agent to contact EOGB Energy Products Ltd Service Department on +44 (0)1480 477066 who will arrange for a competent service engineer to rectify the fault.
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Page 6: Liquid Fuel Information And General Instructions
Information. Information is supplied upon the condition that the persons receiving will make their own determination as to its suitability for their purposes prior to use. In no event will EOGB (and its subsidiaries) be responsible for damages of any nature what- soever resulting from the use of or reliance upon Information. -
Page 7: Safety And Prevention
Please note that the installation, commissioning and servicing MUST only be carried out by a competent, qualified engineer, trained and registered to generic industry standards of competence and who has undertaken additional EOGB manufacturers appliance and burner specific training. In accordance with BS5410 part 1 2019. -
Page 8: Appliance Introduction
Appliance Introduction Appliance panel descriptions Burner Plug 1 Burner Plug 2 On/Off Switch LCD Display Reset Button Fig. 1 Checking the characteristics of the appliance Fig. 2 SP - MAN - SERVICE - 01 Revision 2 21/12/2021... -
Page 9: Electrical
Electrical Wiring diagram Fig. 3 SP - MAN - SERVICE - 01 Revision 2 21/12/2021... -
Page 10: Sapphire Modulating Blue Flame Burner
Sapphire Modulating Blue Flame Burner Technical description of the burner Fully modulating low NOx burner for domestic heating EOGB’s Sapphire blue flame burner delivers excellence in performance and reliability, backed by first-class technical expertise and a personable, responsive service. Low NOx – High performance Sapphire has been designed from the outset to bring about a step-change improvement in domestic heating performance. -
Page 11: Commissioning Pre-Checks
Check and establish if the liquid fuel in the tank is suitable for this boiler specification Check that there are filters fitted with the correct filtration requirements See EOGB Sapphire Boiler Installation Manual Ensure the oil supply is correctly connected. -
Page 12: Boiler Operation And Commissioning
Any attempt to fire or commission this appliance by Step 2 - Upon successful loading, the “Temperature Display unauthorized persons will invalidate the appliance Screen” will be displayed. Fig. 10 Press the “EOGB Logo” warranty. WARNING in the top left hand corner to open the “System Ramp Test Screen”. - Page 13 Fig. 12 Fig. 17 Fig. 13 Fig. 18 Step 5 - Once you reach the “Run Time System Control Screen” press the “Start” button Fig. 19 Fig. 14 Fig. 19 The burner will begin its start sequence and will attempt to establish a flame on “Pump Pressure (bar)”...
- Page 14 Boiler Operation and Commissioning Step 6 - Once the air has been Then press the + or - buttons to increase/decrease the bled from the fuel pump the burner should have established a flame on “Pump pump pressure setting (min 5bar to max 20bar depending Pressure (bar) Setting 7 Bar* on boiler model).
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Page 15: Setting Up The Boiler Set-Point Temperature
Fig. 26 buttons to adjust “Max CH Setpoint” Fig. 30 Please note that EOGB pre-set and highly recommend this The burner will then reset. Once the burner has been setting to be left at 70 °C to ensure correct flow and return successfully commissioned the screen will display the water temperatures for the system design. -
Page 16: Maintenance / Service
Maintenance / Service Maintenance & service Notes on safety for the maintenance Periodic maintenance is essential for the good operation, safety, yield and duration of the burner. It allows you to reduce consumption and polluting emissions and to keep the product in a reliable state over time. The maintenance interventions and the calibration of the burner must only be carried out by a Sapphire Approved Agent, in accordance with the contents of this manual and in compliance with the standards and regulations of current laws. -
Page 17: Replacing The Nozzle
Maintenance / Service Replacing the nozzle As part of a burner service, the oil nozzle must be replaced. With the oil pipe assembly removed, the nozzle can then be changed. Fig. 35 To access the nozzle simply loosen the nozzle holding plate fastening screws. -
Page 18: Servicing Of The Boiler Plate Sealing Gasket, Blast Tube, Electrode, Air Bush And Flame Detector Sight Glass
Maintenance / Service Servicing of the boiler plate sealing gasket, blast tube, electrodes, air bush and flame detector sight glass Once removed, the Boiler Plate Sealing Gasket can be IMPORTANT - Ensure the boilers electrics have been checked for damage and replaced if necessary. Fig. 42 isolated safely before carrying out any service works DANGER Before removing the burner for service, please ensure... - Page 19 Maintenance / Service To change or inspect the ignition electrodes, loosen and To access and clean the site glass, loosen and remove the remove the fixing bolt and slide each electrode out. Fig. 46 fastening bolts to remove the plate. The sight glass and gas- ket can then be inspected/cleaned.
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Page 20: Electrode/Head Settings (Air Bush)
33-35 Sapphire 32 kW 23-25 33-35 EOGB recommends that a cleaning solution such as The nozzle assembly can be adjusted by increasing/de- SCALEBREAKER LS3 from KAMCO or other spray on liquid creasing the brass adjustment nut. boiler cleaner compound be used. (see cleaning product... -
Page 21: Condensate Pump/Trap
Maintenance / Service Condensate pump/trap During the service the condensate trap and pump must be checked before cleaned. To check/clean the trap, disconnect the push on flexible grey waste discharge hose from the trap. Check and clean this hose if required. Caution, the waste discharge hose may contain some condensate. -
Page 22: Boiler Exploded Casings View
Boiler Exploded Casings View Fig. 59 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 Clip Latch... -
Page 23: Boiler Exploded Components View
Boiler Exploded Components View Fig. 60 Please refer to the next page to find spare part identification SP - MAN - SERVICE - 01 Revision 2 21/12/2021... - Page 24 Boiler Exploded Components View 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...
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Page 25: Top Tray Exploded View
Top Tray Exploded View Fig. 61 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 BFPM61 Motor lead... -
Page 26: Burner Exploded View
Burner Exploded View Please refer to the next page to find spare part identification Fig. 62 SP - MAN - SERVICE - 01 Revision 2 21/12/2021... - Page 27 Burner Exploded View 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...
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Page 28: Pcb Exploded View
PCB Exploded View Fig. 63 Labelled Number Part Number Description SS-PCB-008-01 PCB Cable cover SS-LOOM-014-01 Mains supply Cable (Switch to PCB) SS-PCB-004-01 Filtered IEC Power Socket, IEC C14, 3 A, 250 VAC SS-PCB-009-01 Mains Filter Holder SS-PCB-005-02 M4 x 30 Standoff M/F Hex Pillars SS-PCB-007-01 PCB Enclosure Cover (incs Identification label) SS-PCB-012-01... -
Page 29: Oil Line Connections View
Oil Line Connections View Fig. 64 Labelled Number Part Number Description F11-0440-A-14M-S-14F Flexible 440mm Ruby Red Angled 1/4M x 1/4F SS-CASE-031-01 Nozzle Holder Service Support clip SS-HEX-021-01 1/4” Male/Female Elbow SS-HEX-020-01 1/4”BSP Tee M/F/M SS-HEX-016-01 1/4” Male/Female Isolation Valve (Bio) SP - MAN - SERVICE - 01 Revision 2 21/12/2021... -
Page 30: Fault Codes
Fault Codes 10.0 Boiler lockouts and fault codes In the event of a failure, the boiler will go into a lockout phase. The cause of the lockout could be down to a number of things but an error code will be displayed on the boiler panel LCD screen. FIG 65 This error code can be looked up below to provide possible causes of the fault. - Page 32 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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