Epsilon Light Commercial High Efficiency Condensing Boiler EB - 40/50 Installation and Service Manual These instructions should be retained by user. 8G.51.90.04 / 10.17Changes Changes reserved. E. E. & O. E. XX.XX.XXX/XX.XX reserved. E.& O. 0310 349 Innovation has a name.
Explanations of symbols and signs on the Control Tower display.
Content 7 8 9 10 11 12 13 14 Introduction.....................................................................................................................................4 Rules .............................................................................................................................................6 Scope of the supply.........................................................................................................................8 Description of the boiler................
1 Introduction These instructions describe the functioning, installation, use and primary maintenance of A.O. Smith central heating units for the United Kingdom and Ireland. Where necessary the different regulations for each country are separately described. These instructions are intended for the use by Gas Safe Register approved contractors or registered Bord Gais installers in connection with the installation and putting into operation of A.O. Smith boilers.
4 2 1 3 5 8 14 13 7 15 6 T1 T2 A G 16 Epsilon EB 40 1 2 3 4 5 6 7 heat exchanger ignition unit fan unit air inlet damper gas valve safety valve automatic air vent T1 flow sensor T2 return sensor P1 water pressure sensor R C 9 10 11 12 figure 1.
2 Rules The following regulations apply to installation of A.O. Smith central heating boilers: Legislation and Regulations. Gas Safety (Installation and Use). All gas appliances must by law, be installed by a competent person, eg. Members of Gas Safe Register and in accordance with the current Gas Safety Regulation. Failure to install appliance correctly could lead to prosecution. All Gas Safe registered installers carry a Gas Safe ID card and have a registration number.
Take note of the following when maintenance or adjustments are needed: - The unit must be able to function during these activities; for this reason, the unit’s supply voltage, gas pressure and water pressure must be maintained. Ensure that these is not a source of potential danger during these activities. Following maintenance or other activities; always check the installation of all parts through which gas flows (using leak-search spray).
3 Scope of the supply The boiler is supplied ready for use. The supply kit is composed as follows: • • • • • • 4 Boiler with casing; Automatic vent (inside the boiler); Safety valve (inside the boiler); Suspension bracket; Draining valve with T-piece; Fixing material consisting of plugs and screws; • • • • Gas isolation valve; Template on the package wrapper; Installation and Service Manual; User Manual.
Mounting the boiler Install the boiler in a well-ventilated boiler room in accordance to the actual regulations. The room where the boiler will be placed must always be frost free. It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the extremely low surface temperature of the boiler casing during operation.
6 Connecting the boiler The boiler has the following connection pipes; - The central heating pipes. These can be connected to the installation by means of compression fittings; - The gas pipe. It is provided with a female thread into which the tail piece of the supplied gas isolation valve can be screwed; - The condensation drain pipe. It consists of an oval 24 mm plastic pipe. The drain pipe can be connected to this by means of an open connection.
If the installation resistance is higher than the stated value the pump will rotate at maximum pump capacity and the load will be adjusted until an acceptable temperature difference between flow and return water has been obtained. If, after this, the temperature difference remains to much then the boiler will switch itself off and wait until an acceptable temperature has arisen.
6.2 Expansion vessel The central heating system must be provided with an expansion vessel. The expansion vessel which is used should be geared to the water content of the installation. The precharge pressure depends on the installation height above the mounted expansion vessel. See table 6.2.a. installation height above the expansion vessel pre-charge pressure of the expansion vessel 5m 0,5 bar 10 m 1,0 bar 15 m 1,5 bar choice of expansion vessel table 6.2.
- - Should you wish to achieve the required water quality by using chemical additives, then this is your own responsibility. The warranty on the product delivered by A.O. Smith expires, if the water quality does not meet A.O. Smith's specifications or the chemical additives have not been approved by A.O. Smith. On installation and during additions or changes at a later stage, A.O.
6.4 Underfloor heating system (plastic pipes) When connecting or using an underfloor heating system, designed with plastic pipes, or plastic pipes are used elsewhere in the installation,one should ensure that the plastic pipes used comply with the DIN 4726/4729 standard. It is set out in this standard that the pipes may not have oxygen permeability higher than 0.1 g/m³.d at 40°C.
6.6 Condensation drain pipe All A.O. Smith wall hung gas fired condensing boilers contain a syphonic condensate trap to collect and release condensate. The amount of condensate formed is determind by the type of boilers and the water temperature produced by the boiler. Condensate pipework. Press the supplied plastic ribbon tube onto the condensate drain at the bottom of the boiler (fig. 6.6.a).
Final discharge options. The condensate pipe can only terminate into any one of the five areas as shown in the figures on this page. Draining of the condensation water to the external rain guttering is not permitted in view of the danger of freezing. Before putting the boiler into operation fill the syphon with 600 ml of water. Installation and Service Manual Epsilon-Series A B C D E F G H J K L 16 -Condensate from boiler syphon/trap -Sink with internal overflow -25mm dia.
6.7 Flue gas exhaust system and air supply system The flue gas exhaust system and air supply system consists of: - Flue gas pipe; - Air supply pipe; - Roof or wall terminal. The flue gas exhaust system and air supply system must comply with: United Kingdom: The flue gas outlet and air supply installation must comply with the current regulation requirements. IG UP 10 and BS 715. Ireland: - Irish standard is 813 section 9.10.
Furthermore: - Boiler Class indicated on the boiler’s type plate (Flue category) - Locally applicable rules. - The supplier’s installation instructions When in doubt or if you have any questions, always contact A.O. Smith. The appliance connection diameter is 80/125 mm, to which the flue gas outlet and air supply system can be fitted, with or without elbow pieces. The maximum permissible pipe length is set out in Table 6.7.1.a.
We advise to build a simple flue gas system and air supply system. For further information about the available components of the flue gas and air supply system we recommend you to contact A.O. Smith. The A.O. Smith flue gas system is meant and designed solely the use on A.O. Smith central heating boilers adjusted for Nat gas or LPG. The maximum flue gas temperatures are below 70°C (full load 80/60°C) The proper operation can be influenced harmfully by changes of or adjustments to the correct set up.
The terminal must not be located in a place where it is likely to cause a nuisance. For protection of combustibles, refer to IS 813 section 9.10.1. where the terminal is less than 2m (6.6ft) above a pavement or platform to which people have access (including) any balcony or flat roof the terminal must be protected by a guard of durable material. Contact A.O. Smith for a suitable guard.
6.7.1 Dimensioning of the flue gas and air intake duct The flue diameter is determined by the total length of the run, including for the connection pipe, elbows fittings and terminal covers etc. and the type and number of boilers installed into the system. An undersized flue pipe can lead to disorders. Look at table 6.7.1.a for the choice of the system and the correct diameter. The table below shows the maximum flue lengths with the different boiler outputs.
7 Electrical connection The appliance complies with the actual Directives. - A 230V -50Hz mains electrical supply is required fused externally at 5A. - A deviation on the grid of 230V (+10% or -15%) and 50Hz The installation must continue to comply with: United Kingdom: - the national rules for electrical installations. Ireland: - the ECTI national rules for electrical installations The appliance must be connected to an earthed socket. this must be visible and within reach.
Installation and Service Manual Epsilon-Series electrical diagram figure 7.
8 Boiler controls The boiler is provided with a fully automatic microprocessor control, called CMS Control Management System. This control simplifies operation by undertaking all major control functions. Initially when power to the unit is switched on it will remain on standby. There is no indication Led on, untill one of the program keys is pressed. The control panel display will show the relevant state. When the installation is empty the display will show FILL.
8.1 Explanation of the function keys Central Heating program key. Switching the Central Heating on or off (Led on/off); - Hot Water program key. (when applicable) Switching the Domestig Hot Water (DHW) facility on or off (Led on/off); - PC program key. adjusts the pump to continuous water circulation in the central heating system (Led on), or according to the pump overrun times on the relevant programs (Led off); • Mode-key. After briefly pressing, a selection of the data chapters can be retrieved.
9 Filling and venting the boiler and installation The central heating installation needs to be filled with potable water. For filling or topping up the installation you use the filling loop according to the following procedure: 1 Switch on the power supply; 2 The diplay will show FILL; 3 All functions off (heating, DHW and pump); 4 Push briefly the 'STEP'-button: P x.x = water pressure in bar; 5 Open the filling loop (Indication on display increases); 6 Fill up slowly to 1.5 to 1.
10 Commissioning the boiler Before the boiler is fired, ensure that the boiler and the system are well vented and free of air. Purge the gas line between the gas meter and the boiler and carry out a gas soundness test as specified in the current Gas Safety Regulations. The boiler does not require adjustment of the burner pressure and air quantity because it is self adjusting and is factory set at the correct value. 10.
10.2 Adjustments When the boiler is installed it is in principal ready for use. All adjustments of the boiler control are already pre-programd for a heating system with radiators/convectors with a flow temperature of 85°C. The adjustments are described in the Parameter chapter on page 29. In certain cases adjustment have to be altered in case of : - Lower flow temperature Read through the Parameter chapter to adjust the boiler to its installation. Contact A.O. Smith in case of doubt.
1 2 PARA Factory 70°C 01 3 4 max. 00 5 6 7 10 11 14 15 2.3 1.4 -10 0°C 0°C 5 0 23 27 31 36 -3°C 0°C 63°C 0 43 45 48 49 60 max. 0 89 . 00 . 60% 100% 01 Info-Mode INFO . 1 4 5 7 8 16 17 18 20 21 22 23 24 25 26 32 37 46 . °C °C °C °C °C % kW kW F Factory t . GJ GJ GJ Std Std Std Std Std Std . Description maximum flow temperature CH type of CH installation: radiators; air heating; convectors: T max. flow 85°C; K factor heating line 2.
Service-Mode 1 2 3 4 . SERV Value OFF OFF OFF OFF . Error-Mode ERRO Value Err.L - Err.5 1 2 3 °C 4 °C 5 kW 6 % Description boiler in operation with burner function on fan adjustable and burner off pump adjustable with burner on showroom position ON = active and OFF = non active . Range OFF - max. OFF - max. OFF - max. ON - OFF .
11 Isolating the boiler In some situations it may be that the entire boiler must be switched off. By switching off the three keys with the lamps for central heating, hot water and pump program ( , or ), the boiler is switched off. Leave the plug in the wall socket, which means the circulation pump and the three-way valve are activated once every 24 hours in order to prevent jamming. In the event of frost danger it is advisable to drain the boiler and/or the installation.
12.1 Emission checking In order to be able to check on the boiler’s emission during its years of operation, it is recommended to measure the maximum air displacement of the boiler on commissioning. This value may be different for each boiler type. This measuring is only worthwhile if the value is known on commissioning. The following tasks have to be carried out to enable measuring this value: - Press the MODE-key for 5 seconds.
12.2 Check O2 The O2 percentage is set by the factory. It has to be checked during inspection, maintenance and faults. This can be checked by means of the following procedure: - Remove the black cover of the gas valve by unscrewing the sealed screw. Measuring point figure 12.2.a - Put the boiler into operation and take care that it can deliver its heat; - Press the MODE-key for 5 seconds.
12.3 Maintenance activities Required tools: - Cross 2head screwdriver 3 - T-handle key set with 3 bits (hex key 4mm, hex key 5mm and cross head PZ2) - Open end wrench 8mm 1 To carry out the maintenance activities please follow the next procedure: 2 3 Removing casing - Switch off the power supply; - Remove the screw behind the door on the front of the casing (see fig. 12.3.a); - Lift the casing and remove it towards the front. figure 12.3.a The air box - Remove the transparant air box (see fig.
15 16 - Remove the burner cassette (18) from the ventilator unit; - Check the burner cassette for wear and tear, pollution and any breakages. Clean the burner cassette with a soft brush and vacuum cleaner. In the case of breakages, always replace the complete burner cassette (18); - Replace the gasket (17) between the burner (18) and upper casing (15), if required; - Replace the gasket (16) between the upper casing (15) and exchanger, if required. 17 18 figure 12.3.e Position gasket figure 12.3.
13 11 14 12 Condensate tray figure 13.3.k Step 2: Condensate tray - Remove the plug from the flue gas sensor if present; - Turn the two short clamping rods (11 and 12) ¼ turn with the hex key and remove them by pulling them forward; Note the correct turning direction (red indicator, fig. 12.3.
12.4 Draining the installation During servicing one of the following items has to be drained: Central heating system - boiler The central heating system and boiler can be drained using the fill- and drain valve installed in the system. If service valves are installed (advised) the boiler can be drained seperately from the rest of the installation via the drain valves on the service valves. 12.
13 Error indication A detected error is indicated on the display by means of blocking or error messages. A distinction should be made between these two messages due to the fact that blocking can be of a temporary nature, however, error messages are fixed lockings. The control will try its utmost to prevent locking and will temporarily switch off the unit by blocking it. Hereunder is a list of some messages. Blocks with a number in the last 2 positions.
14 Warranty conditions To register your warranty, visit the website www.aosmithinternational.com/content/ product-registration and fill in the Product Registration Form. Registering the boiler gives the owner of the boiler supplied by A.O. Smith Water Heaters the right to the warranty set out below, which defines the commitments of A.O. Smith Water Heaters to the owner. 14.1 General warranty If within 2½ (two and a half) years after the original production date of a central heating boiler supplied by A.O.
14.4 Exclusions The warranty set out in articles 1 and 2 will not apply in the event of: a. damage to the central heating boiler caused by an external factor; b. misuse, neglect (including frost damage), modification, incorrect and/or unauthorized use of the central heating boiler and any attempt to repair leaks; c. non approved contaminants or other substances having been allowed to enter the heating system loop of the central heating boiler (see installation instructions); d.
Annex A Technical specifications Technical specifications Natural Gas Boiler type Type heat exchanger Input Hs CH Qn Input Hi CH Efficiency class according BED Efficiency according EN677 (36/30°C part load, Hi) Efficiency according EN677 (80/60°C full load, Hi) Modulation range CH (capacity 80/60°C) Modulation range CH (capacity 50/30°C) Nox class EN483 O2 CO2 CO Flue gas non-return valve present Flue gas temp. CH (80/60°C on full load) Flue gas temp.
Annex B System water additives When the filling water requirements as referred to in chapter Water Quality have been met, certain additives are allowed for the below mentioned applications and related dosage. Warranty on A.O.Smith delivered installation products expires, if these additives and concentrations are not used in accordance with this annex. Additive type Supplier and specifications Max.
Annex C Dimensions B B F D D wall wall 10 wall 50 C E Minimal 250mm ceiling A R QP H J G K H J S T U K dimensions (in mm) figure C.
g a r c g EB 40 a r c EB 50 boiler connections Boiler type g a r c Concentric flue system Parallel flue system Gas pipe Flow pipe Return pipe Condensate pipe figure C.b mm mm mm mm mm EB 40 80/125 2x 80 1/2"Rp 28 28 24 Epsilon EB 50 80/125 2x 80 3/4"Rp 35 35 24 Installation and Service Manual Epsilon-Series connection diameters table C.
Annex D Installation examples D.1 Radiator installation without thermostatic radiator valves BP figure D.1.a A Boiler: A0 Connection terminal Epsilon boiler A1 Room thermostat A4 Outside sensor tra BP Thermostatic radiator valve Automatic by-pass Use alway a by pass in combination with thermostatic radiator valves.
D.2 Radiator installation with underfloor heating zone Installation and Service Manual Epsilon-Series installation example 46 figure D.2.
Annex E CE Declaration of conformity CE DECLARATION OF CONFORMITY Hereby declares A.O. Smith Water Products Company B.V. that, the condensing boiler types: Epsilon EB 40 EB 50 are in conformity with the provisions of the following EC Directives, including all amendments, and with national legislation implementing these directives: and that the products are in conformity with EC type-examination certificate number E0430, as stated by KIWA Nederland BV, The Netherlands.
your installer A.O. Smith UK, Unit B8 Amstrong Mall, Southwood Business Park, Farnborough, Hampshire GU14 0NR www.aosmith.co.uk “A.O. Smith Water Heaters” is a trading name of Advance Services (Sales) Ltd. Reg.
