Instruction Manual Installation, Maintenance and User Guide NHC 25B/30B/41B (Boiler House w/ Combi Option) NHC 25E/30E/41E (External w/ Combi Option) NHC 25H/30H/41H (Boiler House w/ Heat Only) NHC 25EH/30EH/41EH (External w/ Heat Only) Instruction Manual Read the instructions fully before installing or using the appliance. INSTALLER, this manual is to be affixed adjacent to the boiler. CONSUMER, retain this manual for future reference purposes. Constant development efforts may result in minor deviations in illustrations, functional steps and technical data without prior notice. Pictures and drawings in the instructions can be different from the appliance. All product images are provided by the manufacturer and are for reference purposes only.
Homeowner Safety instructions Product Fiche Operation & Display Panel (OBC100) Room Thermostat (LCR-2WE) - Combi Only Vacation/Standby Mode - Combi only Heating Mode - Combi only Hot water Mode - Combi only Fault Codes 4 5 6 7 8 9 10 11 Contents Installer Design Standards Safety Flue Regulations Before Using The Boiler How To Use Safety Devices Everyday Checks Servicing The Boiler Plumbing Schematic Commissioning The Boiler Component Overview Electric Wiring Diagram Wiring - Installation Variations OTC Mode Troubleshooting Fault Codes Product Information Spare Parts Specifications Warranty 12 13 14 18 20 22 23 24 26 30 31 36 37 42 43 44 45 46 49 50
Safety Instructions Safety-related messages and instructions have been provided in this manual and on the boiler to warn you and others of a potential injury hazard. Read and follow all safety messages and instructions throughout this manual. It is very important to understand this safety section for operating, installing and servicing of the boiler. In addition to this, under the Consumer Protection Act 1987 and Section 6 of the Health & Safety Act 1974, we are required to provide information on substances hazardous to health. The small quantities of adhesives and sealants used in the product are cured. They present no known hazards when used in the manner for which they are intended. This is a safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. Indicates an imminently hazardous situation which if not avoided, could result in severe injury or death. Indicates a potentially hazardous situation which, if not avoided, could result in severe injury or death. Indicates an imminently hazardous situation which, if not avoided, could result in minor moderate injury. Earth Use of fire forbidden Dangerous electric current 4
Product Fiche KD Navien Unit NHC 25B NHC 30B NHC 41B Space heating : temperature application Medium Medium Medium XL XL XXL A A A B B B Rated heat output kw 24.0 27.9 36.8 Space heating : annual energy consumption kwh 76 89 116 Water heating : annual electricity consumption(combi only) kwh 94 93 105 Water heating : annual fuel consumption(combi only) GJ 22 23 30 % 91 90 91 % 64 62 67 Sound power level db 68 66 69 Read the user's information and installation manual before the application is assembled, installed or maintained. 5
Operation and display panel (OBC100) LCD indicate the temp of heating water, the value of K-Factor, and occurrence of trouble displayed the failure code. * See page 11 for Error Code Table LCR-2WE Programmer- Combi only The LCR-2WE remote control panel will activate by pushing the power on/off button. 6
Room Thermostat (LCR-2WE) - Combi only LCD Display Indicating each function and status LED Lamp Operation/Service Up/Down Heating Heating Mode Adjusting Temp. Power Room Thermostat Power ON/OFF Standby Mode Standby Setting Mode Hot Water Hot Water Mode LCD Temperature Operation Indicator Heating Mode Standby Mode Hot water Mode Hot water Temperature (Lo/Mid/Hi) 7
Vacation/Standby Mode - Combi only If you are not at home, you can set the Standby Mode to save heating energy by pressing. Press button. will be displayed and Standby Mode will be set. To cancel vacation/standby mode press the button to return to the heating mode. 8
Heating mode - Combi only Press the button. Set the heating temp. with / button. blinks when selecting Boiler Temp. Mode when blinks, set the desired boiler temp. between 40~80 C by adjusting / button, after a while, it is automatically saved. Boiler temp. can be set by 1 C. After the required temperature has been selected, is on and current boiler water temp. is displayed. The LCR-2WE room thermostat is designed to control a heating system according to time and temperature, in connection with a valve controller (red colored cable). 9
Hot Water Mode - Combi only Use this function only when hot water is needed. Press button. Set the heating temp. with / button. will be displayed and Hot Water Mode will be set. Adjusting hot water temp. by 3step; Low load, Medium load, High load capacity of combustion. You can determine whether the changeover from DHW mode to Heating mode by pushing " button. CAUTION 1. Please be careful that infants and young children do not use hot water without a guardian present. 2. While others are using hot water, do not change the hot water temp. setting for safety. 10
Fault Codes Fault codes take priority over all other display functions in the event of a system fault occurring and the LCD shows one of the following numeric error codes. If multiple faults occur, the corresponding fault codes are displayed alternately for about two seconds each. Fault at the boiler Fault at the room controller Error Code Cause Error Code Cause 02 Low water level 51 Electrical backup system failure 03 52 Functional button defective 04 05 06 12 16 Temp. sensor wire disconnected Short circuit of Temp. sensor High limit thermostat Electrical backup The LCR-2WE retains the setting parameters when the power or shut down by power outages and back to the preset operation. To reset the boiler switch the power button on -> off -> on. If problem persists, contact your local installer. 11
INSTALLER SECTION Design Standards EMC Directive (Electromagnetic compatibility) 89/336/EC Standards: EN 61000-6-1: Electromagnetic Compatibility Generic Standard Immunity for residential, commercial and light industrial environments. (Feb 2001) EN 61000-6-3: Electromagnetic Compatibility Generic Standard Emission standard for residential, commercial and light industrial environments. (Feb 2001) LV Directive (Low voltage) 73/23/EEC Standard: EN 60335-1: Household and similar electrical appliances - Safety (May 2001) Boiler Efficiency Directive 92/42/EEC Standard: BSEN 304: Oil boilers with forced draft burners. Fuel Spillage 1. Switch off all electrical and other ignition sources. 2. Remove all contaminated clothing to safeguard against fire risk and skin damage. Wash affected skin thoroughly with soap and water and remove clothing to a safe well ventilated area and allow to air before cleaning. 3. Contain and smother the spill using sand or other suitable oil absorbent media or non-combustible material. 4. Do not allow fuel to escape into drains or water courses. If this happens, contact the relevant authorities in your area. (Ireland only). Contact the Environment Agency on 0800 807060 (UK Only) 5. Consult local authority about disposal of contaminated soil, see http://www.housing.gov.ie/local-government/administration/localauthorities/local-authorities 12
Safety Safe use of kerosene. These fuels give off a flammable vapour when heated moderately. Vapour ignites easily, burns intensely and may cause explosion. The vapour can follow along at ground level for considerable distances from open containers and spillages collecting as an explosive mixture in drains, cellars, etc. Fuels remove natural oils and fats from the skin and this may cause irritation and cracking of skin. Barrier cream containing lanolin is highly recommended together with good personal hygiene and where necessary appropriate personal protection equipment. (P.P.E.) Gas oil may also cause irreversible damage to health on prolonged or repeated skin contact. Always store fuels in a properly constructed and labelled tank. Always handle fuel in open air or well ventilated space away from sources of ignition and refrain from smoking. Always drain fuel using a proper fuel retriever, funnel or mechanical siphon. Never apply heat to a fuel tank, container or pipework. Never siphon fuel through tube by mouth. If accidentally swallowed contact doctor immediately and do NOT induce vomiting. Avoid inhaling fuel vapour as this can cause light headedness and seriously impair judgement. First Aid If fuel is accidently swallowed: Seek medical attention immediately and DO NOT induce vomiting. If fuel is splashed into your eyes: Wash out with running water for at least ten minutes and seek medical attention as soon as possible. 13
Flues Regulations Balanced Flue Siting a) Horizontal from opening, airbrick, opening window etc. b) From an internal or external corner. c) Below an opening, airbrick, opening window etc. Information supplied by Book Four, 2010. Please see note at foot of page. Note: 1. Terminal should be positioned to avoid combustion products entering the building or accumulating in stagnant pockets around buildings. 2. The terminal must be protected by a guard if it is less than 2 metres above ground level or in a position where any person has access. 3. A heat protection shield should be fitted if the terminal is less than 850mm from a plastic or painted gutter or less than 450mm from painted eaves. Saturn Heating recommends as per OFTEC recommendations that the flue should be a minimum distance of 1 metre from openings so that it does not cause a nuisance and permits the dispersal of combustion products. 14 Building Regulations A B C Northern Ireland 600 600 600 Republic of Ireland 600 600 600 Where the terminal is within 1 metre of any plastic material, such material should be protected from the effects of combustion products of fuel. There are additional general requirements in most regulations and standards that the flue must be positioned so that it does not cause a nuisance and permits the dispersal of combustion products. Note: The Building Regulations clearances shown above are the minimum allowed. Contact Saturn Heating Technical Department for futher advice in this regard. ALWAYS CHECK FOR ANY BUILDING REGULATIONS AMENDMENTS WHICH MAY HAVE BEEN ISSUED AFTER THE PUBLICATION OF THIS MANUAL
Flues Regulations Clearances advised by the British Standards, provided by OFTEC, for open flues, low level balanced flues and balanced flues fitted to oil fired boilers. Minimum distances to terminals in millimetres as measured from top of the chimney or the rim of a low level discharge opening. Aplliance Burner Type Pressure Vapourising Jet A Directly below an opening, air brick, opening window etc 600 Not allowed B Horizontally to an opening, air brick, opening window etc 600 Not allowed C Below a gutter, eaves or balcony without protection 75 Not allowed D Below a gutter or a balcony without protection 600 Not allowed E From vertical sanitary pipework 300 Not allowed F From an internal or external corner or surface or boundary 300 Not allowed alongside the terminal G Above ground or balcony level 300 Not allowed H From a surface or boundary facing the terminal 600 Not allowed J From a terminal facing a terminal 1200 Not allowed K Vertically from a terminal on the same wall 1500 Not allowed L Horizontally from a terminal on the same wall 750 Not allowed M Above the highest point of an intersection with the roof 600 1000 N From a vertical structure on the side of the terminal 750 2300 O Above a vertical structure less than 750mm from the side of the 600 1000 terminal P Directly below an opening, air brick, opening window etc. 1500 Not allowed Notes: - Terminals should be positioned so as to avoid products of combustion accumulating in stagnant pockets around the building or entering into buildings. - Appliances burning Class D oil have additional restrictions (See OFTEC Book 4 2010) - Vertical structure in N, O and P include tank or lift rooms, parapets, dormers etc. 15
Flues Regulations - Terminating positions A to L are only permitted for appliances that have been approved for low level flue discharge when tested to OFS A100 or A101 - Terminating positions must be at least 1.8 metres distant from an oil storage tank unless a wall with at least 30 mins fire resistance and extending 300mm higher and wider than the tank is provided between the tank and the terminating position. - Where a flue is terminated less than 600mm away from a projection above it and the projection consists of plastic or has a combustible or painted surface, then a heat shield of at least 750mm wide should be fitted to protect these surfaces. - For terminals used with vapourising burners, a horizontal distance of at least 2300mm is required between the terminal and the roof line. - If the lowest part of the terminal is less than 2 metres above the ground, balcony, flat roof or other place to which any person has access, the terminal must be protected by a guard. - Notwithstanding the dimensions given in the drawing and table, a terminal should not be sited closer than 300mm to combustible material. Ventilation & Combustion Air Conventional Flue Boilers An adequate supply of combustion and ventilation air is essential for efficient and safe boiler operation and the openings for this should be positioned to cause least possible draught, with no possibility of being accidentally blocked. Please note, the British Standard Code of Practice for Oil Firing BS5410:Part 1, requires a permanent air inlet opening of 550mm² per kw (above 5kW) of boiler rated output. (Note: 1kW = 3412 Btu/h). Also when the boiler is installed in a compartment or confined space, ventilation openings are required to ventilate and to avoid overheating in the boiler area. FULL TEXT of both BS 5410 Part 1: 1997 and appropriate Building Regulations for each country should be obtained and fully applied. 16
Flues Regulations N.B. Please Carefully Note: In OFTEC Book Four, 2010 page 33, 6.6.5 states that for the Republic of Ireland, It is not permitted to install open flue appliances in domestic garages, therefore only room sealed balance flue appliances should be installed in a garage location Definitions: Combustion Air: Air required directly by boiler oil burner for combustion process. Ventilation Air: Air required in the room for ventilation, cooling, etc. and to promote a healthy living environment. Other Notable Regulations Oil Storage Tank Siting For single family dwellings where oil storage is external and does not exceed 3500 litres, the following separation distances apply: Fire Valve Installation For reasons of safety, a fire valve is an essential part of an appliance installation, although the fire valve body is located within the oil supply system. Fire valves should be of the remote acting type which are capable of cutting off the flow of oil outside the building in the event of a fire or overheat situation occurring at the appliance. * See OFTEC Book 3, 2010 Edition for full details on both Oil Storage Tank Siting and also Fire Valve Installation. 17
Before using the boiler Fuel It is essential to use only kerosene or light oil. It is better to use kerosene when the temperature can drop below -5 C. Choose a fuel storage location in accordance with local regulations (See page 14 - Flue Regulations). Take care to avoid the ingress of water and/or dirt during re-filling as this can lead to flame failure or affect the lifespan of the boiler. Ensure that the power is turned off and the oil tank is isolated before refilling. A fuel filter with a filter rating of 70microns or better must be fitted to the fuel supply, to the appliance. Pre-Start Checks Check all pipe connections thoroughly for leaks before start-up. 18
and that the low water level alarm is not activated. Notes when using Take care when positioning the boiler. Do not locate in the immediate vicinity of flammable materials. suitable measurement equipment to ensure correct combustion is taking place. Do not plug out the power supply as this will de-activate the frost protection. Avo o e e o e The domestic hot water supply is not recommended for potable use.(combi only) 19
How to use Purging the oil supply Avoid complete emptying of the oil tank. This can lead to air being introduced to the fuel system and may result in ignition failure. Loosen the screw in the oil filter. This will allow the fuel supply line to vent. When oil starts to flow re-tighten the screw (this is only possible in positive head oil supply applications). In negative head oil supply applications the fuel supply line must be purged using the oil pump vent screw. For this the oil filter screw must be in the tightened position. Open the oil pump vent screw and switch on the power to the boiler. After 6-7 seconds the pump has purged the air and the CHECK light will show on the control panel. The boiler will stop. 20
Reset the boiler by turning the power off and on. Close the oil pump vent, press the power button again and the boiler will ignite. If the boiler fails to fire after 3 successive attempts contact the Saturn technical helpline on 1890 929 112. Preparation and checking before start-up Ensure the system is full and at suitable operation pressures. Fill and thoroughly purge all connected pipework. The boiler must always be correctly grounded according to relevant local regulations. Connect the boiler to the main 220v supply and press the power button. The RUN light should show after a short period. Volt free boiler call (Orange cable) Warning: Connecting power to this cable will damage the boiler control panel. Full wiring instructions on pages 36-41 21
Safety devices Ignition safety device When the boiler does not ignite, or if the flame falls the flame detector (photocell) will deactivate the boiler. Low water level safety device If the water level is insufficient in the boiler the low water level sensor will deactivate the boiler. Once the system is adequately refilled this will automatically reset. Overheat prevention If the temperature of the boiler rises to dangerously high levels the overheat sensor will deactivate the boiler. In this instance the CHECK light will show. To reset press the RESET button on the overheat preventer. Frost freezing prevention At a boiler temperature of 9 C the circulating pump will be activated. At a boiler temperature of 2 C the burner will ignite. For this reason, power must be maintained to the boiler, even if the system is not in use. Power-failure protection In the event of power failure the oil supply will automatically be isolated from the combustion chamber. 22
Everyday checks Points to be checked once or more a year Ensure that combustible materials are not stored near the boiler. Keep the area around the boiler clean and free from obstruction to allow for free air flow. Check for fuel leaks within the fuel storage/supply system and check for water leaks within and around the boiler. Inspect the inside of the oil tank for water or debris. 23
Servicing The Boiler Cleaning of the boiler Soot build-up within the boiler will reduce its The boiler should be serviced annually by an approved service engineer. Cleaning the oil filter To clean the oil filter, first isolate the oil supply. Remove the oil cup by unscrewing and pulling the cup downwards. Wash the filter and the inside of the coil cup using clean kerosene. Flexible oil line Flexible oil lines must be changed every 2 years, if no date is specified on the old line it must be changed for good practice and OFTEC regulations Cleaning the oil tank The oil tank should be checked during the annual service and cleaned of all water and debris as required. 24
Cleaning the flame detector If the flame detector (photocell) becomes sooty or dirty the reduced sensitivity will cause erratic and incorrect boiler operation. Remove the flame detector (photocell) which is located at the top of the burner. Wipe the glass surface of the flame detector (photocell) using a clean rag and replace. Checking the flue pipe During the annual service the flue system should be checked for correct installation, blockages, corrosion or leakage. Any abnormalities found should be rectified immediately. 25
Plumbing Schematic Choosing of the installation place Choose an installation site that allows easy access for installation, maintenance and operation. When choosing an installation site, take care to conform to all local regulations and standards. Allow as much free space around the boiler as possible for maintenance and reduced fire hazard. Ensure that the boiler is accessible in order to allow for easy adjustment of the boiler temperature. The boiler should not be sited close to storage areas of combustible materials. Consider condensate and boiler drainage requirements when choosing the boiler location. Installation diagram : Cistern tank install type Open cistern tank Expansion Tank Combi only Water Cold Water Inlet Boiler Back Never install any valve between boiler and cistern tank Supply Water Pipe Minimum 1.5 m Circulating Pump Distributor Heating Flow Heating Return Distributor Cold Water Heating Coil Fan Coil Radiator Hot Water Drain Condensate Outlet Drain F.L 26
Sealed System Combi only Water Cold Water Inlet Boiler Back Filter Hot Water Outlet Safety Valve Air Exhaust Valve Reducing Valve Check Valve Circulation Pump Distributor Cold Water Hot Water Heating Water Outlet Sealed Expansion Tank Heating Coil Fan Coil Radiator Drain Condensate Outlet Drain Install the condensate outlet hose as above F.L Precautions 1. The system should be installed with a pressure safety valve rated to 3.5 Bar or less. 2. The maximum operating pressure is 3.5 Bar. Neither the boiler nor any connected pipe work should be exposed to pressures in excess of this. 3. Always install the boiler and the connected system according to local regulations. 27
Example of a standard installation Flue Installation It is recommended that the flue system not exceed 7 metres in length and that no more than 2 bends be used. Subtract one metre for every 90 bend and 500ml for every 45 bend. Condensing boiler model : NHC25B/30B/41B VENTILATING OPENING FIRE WALL, SEMI FIRE WALL 150mm OVER FIREPROOF INSULATION MATERIAL 10 OVER 300mm OVER AIR INLET FIREPROOF INSULATION MATERIAL The flue should be installed at an angle of no more than 10. The flue should be made from heat-resistant non-corrosive material. CAUTION Allowing combustion gas to re-enter the boiler room can result in a build up of carbon monoxide, which could result in poisoning. Saturn recommends the installation of a suitable carbon monoxide detector on all installations. 28
1. Condensate is produced when the condensing boiler is running and should be piped to the drainage system. 2. Link the drain hose with the outlet of the neutralization system which is located at the bottom of boiler and then connect the end of the hose to a soak pit. 3. Please make sure that the neutralizer in the boiler is filled with water. 4. The condensate drain system should be installed to minimise the risk of freezing. Ensure the condensate is sent to a suitable waste outlet in accordance with regulations. 29
Commissioning The Boiler 1. Prime the boiler with kerosene and press the power button on, ensuring there is a heat request from your time clock. The boiler then takes 3 attempts to go into ignition phase. 2. The fan will start up and purge the air through the heat exchanger - Troubleshooting if sequence missed: No heat request, or incorrect wiring, please refer to "Wiring The Boiler" 3. The transformer will begin to generate a spark at the electrodes - Troubleshooting if sequence missed: Photocell disconnected/dirty: reconnect/clean 4. The oil pump will engage to pump oil to the burner - Troubleshooting if sequence missed: Not fully primed with oil bowl filled and oil line clear of air This will be apparent by the pump making a loud noise 5. Successful ignition can be seen through the sight glass All boilers come pretested from the factory, so minimal adjustments are needed on commissioning. Using a flue gas analyser, you are looking for the following read outs: - 11.5% Co2-50-60 PPM Simply adjust the damper opening on the burner to achieve these numbers 30
Component Overview The structure of the boiler ModelNo: NHC 25B/30B/41B FE flue, Φ75 Controller Burner Assembly Overheat preventer Temperature sensor Low water level sensor Heat Exchanger Neutralizer assembly Electronic pump & Oil filter Return water pipe for space heating 31
Component Overview The structure of burner ModelNo: NHC 25B/30B/41B Damper Fan 3 Fan 2 Fan 1 Fan Causing Flame detector Fan Motor Inner tube Nozzle Air holder Ignition Electrode Blow tube & flame holder 32
Component Overview The principle of the burner ModelNo: NHC 25B/30B/41B Air Flow Oil Fluid Air Flow Burner Running Mechanism 1) Fan (motor) working 2) Ignition transformer is working 3) Electronic pump is working ; oil pressure increase 4) Sensing combustion and flame 5) Continuous combustion Air holder : assist the ignition Oil inlet Flame holder : Oil & air mixing zone Construction of Burner 33
Component Overview The structure of the heat exchanger ModelNo: NHC 25B/30B/41B Baffle plates Straight pipes H.E. for DHW Combustion chamber NHC-25H/30H/41H does not come with an in-built DHW heat exchanger. NHC-25EH/30EH/41EH does not come with an in-built DHW heat exchanger. 34
Component Overview The principle of the heat exchanger ModelNo: NHC 25B/30B/41B 200 C under Heat Fluid Heat transfer Fluid Counter Flow : 2 times Parallel Flow : 1 time Counter Flow Parallel Flow Counter Flow 75 C under Fluid Flow Figure of Heat transfer method Chamber Temp. about 800 C Condensate outlet Construction of Condensing Boiler NHC-25H/30H/41H does not come with an in-built DHW heat exchanger. NHC-25EH/30EH/41EH does not come with an in-built DHW heat exchanger. 35
3 5 A 1 B 6 4 B C 4 6 1 3 5 B C 1 3 5 4 6 Electric wiring diagram ModelNo: NHC 25B/30B/41B 1 2 3 4 5 6 Color : White 10 21 09 20 08 19 07 18 06 17 Red 16 05 04 15 White 14 03 13 D 02 12 01 11 Black Black Skyblue Brown Blue C A Brown Skyblue Yellow BLACK TUBE Brown Black Green + Yellow Red Blue Orange A LOW WATER SENSOR Black Blue OIL PREHEATER CABLE Brown Blue CIRCULATION PUMP Green + Yellow Brown Blue Brown [BOILER] EARTH HIGH LIMIT STAT HEATING WATER TEMP. SENSOR VOLT-FREE HEAT REQUEST WEATHER COMP MODE (White) D [BURNER] WEATHER COMP MODE Blue Yellow BOOSTER PUMP C Power cord Blue Brown D C OIL PUMP (White) Green + Yellow Brown Black AUXILIARY SENSOR OUTDOOR TEMP. SENSOR 36
Electric Wiring Installation Variations 3 Core Wiring Diagram (Warning, without permanent supply, the frost stat is disabled) Note: Boiler temperature display will only be shown when there is a heat request through the switch live as permanent supply has not been provided. 37
Electric Wiring Installation Variations 4 Core Wiring Diagram Note: Due to the above setup using a 230v switch live, for a heat request from the boiler, an NO stepdown relay or a motorised valve is needed to connect into the low voltage heat request orange cables. 38
Electric Wiring Installation Variations 5 Core Wiring Diagram Note: Simply join single auxiliaries from multiple MV s and bring to the boiler in 2 core fashion. If any MV opens, the volt free auxiliary will call for a heat request. 39
Electric Wiring Installation Variations 5 Core Wiring Diagram - Combi Only Note: Simply connect the volt free orange heat call to the back of the combi controller, and now the red cables coming from the controller, by extension, become your low voltage heat call. 40
Room thermostat (LCR-2WE) - Combi only All wiring must be in accordance with its instructions for connections with the valve controller properly and unused wire should be insulated and short-circuited. 1. Connect the cables of room thermostat properly to the terminal of valve contoller in accordance with following each colored cable; - Red : Heating - Blue : Fault signal (NA) - Yellow : Combustion signal (NA) Unused wire should be insulated and short-circuited. 2. The pin rail on the back of the thermostat must connect to 2 orange cables from the boiler. 3. Fix the wall socket with the screws provided. 4. Carefully push and fit the thermostat on to the wall socket until it clicks in position. Boiler Room thermostat Input/output terminal Valve Controller Main Controller AC 220V Red wires N L Auxillary wires MV 41
OTC Mode If an outdoor temperature probe is connected, the weather compensation function can be used in conjunction with the weather comp' relay available at your local Saturn stockist. 1) With this function, the target primary temperature is automatically set according to the outdoor temperature (K-Factor). 2) When the outdoor temperature sensor is connected, OTC lamp is turned on. 3) The outdoor temperature sensor should be placed in an area to avoid temperature fluctuations caused from direct sunlight. Preferable the sensor should be located in a north facing location. K-Factor 42
Troubleshooting Happening Cause Solution methods 1. On pressing the 1. The temperature in the 1. This is not a problem. power button, the boiler is above the set When the temperature of the motor doesn t work temperature. boiler goes down, it will restart. 2. No power. 2. Check 5 AMP fuse spur/power. 3. No heat request. 3. Check time clock and stats for heat request. 2. The motor rotates, but the boiler doesn t ignite 1. The oil valve is locked. 2. There is no oil in the tank. 3. There is air in pipes. 4. 1. Open the valve. 2. Supply oil. 3. 4. Clean the boiler. 3. The boiler ignites, but immediately stops 1. The oil in the oil tank is insufficient. 2. The flame detector cannot sense. 3. The oil filter is blocked. 4. Impurities in the oil. 1. Supply more oil. 2. Clean the flame detector. 3. Clean the oil filter. 4. Replace the oil with good oil. 4. The electronic pump makes noise 1. The oil filter is blocked. 2. There is air in the oil line. 3. The oil tank is empty. 1. Clean the oil filter. 2. Vent the oil line. 3. Ref ill the oil tank. 5. On igniting, it backfires 1. Electrode fault. 1. Check and clean electrode. 2. Dirty nozzle. 2. Check nozzle and change if necessary. 6. Smoke and soot build up 8. The appliance does not go into OTC mode 1. The oil is bad or has impure materials. 2. The air for combustion is short. 1. The Outdoor Temperature sensor is not connected correctly. 2. OTC Mode turns off during Hot Water activation 1. Replace the oil. 2. Check external filter bowl. 1. Check that the Outdoor Temp sensor has been connected properly. 2. Check the OTC mode is working by returning to Central Heating mode (Press the Mode button repeatedly, until or is displayed.) Please contact Saturn Technical department for any unclear matters. 43
Fault Codes When an error occurs, the LCD shows one of the following numeric error codes with letter E. Error Code 02 Cause Low water level 03 Misfire 04 05 06 12 Flame failure Temp. sensor wire disconnected Short circuit of Temp. sensor Misfire in combustion 16 High limit thermostat 44
Product Information KD Navien symbol Unit NHC 25B NHC 30B NHC 41B Condensing boiler YES YES YES Low-temperature(**) boiler NO NO NO B1 boiler NO NO NO Combination heater YES YES YES Rated heat output Prated kw 24.0 27.9 36.8 Seasonal space heating energy efficiency ηs % 91 90 91 Useful heat output "At rated heat output and high-temperature regime(*)" "At 30% of rated heat output and low-temperature regime(**)" P4 kw 24.0 27.9 36.8 P1 kw 7.7 9.3 11.9 "At rated heat output and high-temperature regime(*)" "At 30% of rated heat output and low-temperature regime(**)" Auxiliary electricity consumption η4 % 92.1 91.3 91.7 η1 % 97.4 96.0 96.6 At full load elmax kw 0.136 0.145 0.163 At part load elmin kw 0.057 0.060 0.066 In standby mode Psb kw 0.013 0.014 0.012 Other items Standby heat loss Pstby kw 0.111 0.111 0.140 Ignition burner power consumption Pign kw 0 0 0 Annual energy consumption QHE kwh 76 89 116 Sound power level, indoors LWA db 68 66 69 For combination heaters Declared load profile XL XL XXL Daily electricity consumption Qelec kwh 0.443 0.440 0.468 Annual electricity consumption AEC kwh 94 93 105 Water heating energy efficiency ηwh % 64 62 67 Daily fuel consumption Qfuel kwh 28.617 29.532 35.339 Annual fuel consumption AFC GJ 22 23 30 Contact details Saturn Heating Ltd, Shercock Road, Carrickmacross Co. Monaghan, Ireland (*) High-temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet. (**) Low-temperature means for condensing boilers 30 C, for low-temperature boilers 37 C and for other heaters 50 C return temperature (at heater inlet). 45
Spare Parts List (Burner) 46
Spare Parts List (Burner) No. Part No. Part Name NOTE 1 30007780D Harness ALL MODEL 2 3 20014282A 20014294A Upper Plate Fixing plate NHC-25B NHC-25B 20005292A 20005531A Upper Plate Fixing plate NHC-30,41B NHC-30,41B 4 30007195A Window Ass'y ALL MODEL 20014284A Side Cover(left) NHC-25B 5 20012251A Side Cover(left) NHC-30B 20012483A Side Cover(left) NHC-41B 20014286A Side Cover(right) NHC-25B 6 20012274A Side Cover(right) NHC-30B 20012494A Side Cover(right) NHC-41B 20014288A Rear Cover NHC-25B 7 20012298A Rear Cover NHC-30B 20005373A Rear Cover NHC-41B 20017026A Front Cover NHC-25B 8 20017126A Front Cover NHC-30B 20017127A Front Cover NHC-41B 9 30012754A PCB Ass'y ALL MODEL 10 30002845A Preheater Assembly ALL MODEL 11 30003527B Internal Flue ALL MODEL 12 30010383B Electric Pump Assembly NHC-25B 30010388B Electric Pump Assembly NHC-30B 30010389B Electric Pump Assembly NHC-41B 13 30004241A booster pump ALL MODEL 14 30004377D Oil Filter Ass'y ALL MODEL 15 20010104D Flexible Hose ALL MODEL 16 30003745A Condensate Neutralizing Equipment ALL MODEL 17 30003760B Condensate Hose NHC-25B 20016346B Condensate Hose NHC-30,41B 18 30002556A High Limit Switch ALL MODEL 19 30002661A Low Water Level Sensor ALL MODEL 20 21 30003457A Silence Adaptor NHC-25B 30003491A Silence Adaptor NHC-30,41B 30005321A Oil Burner Assembly NHC-25B 30005328A Oil Burner Assembly NHC-30B 30005336A Oil Burner Assembly NHC-41B 47
Spare Parts List (Burner) NO. PART CODE DESCRIPTION MODEL 20010476A OIL Nozzle NHC-25B 1 20010484A OIL Nozzle NHC-30B 20010506A OIL Nozzle NHC-41B 2 30004397A Photocell (flame detector) ALL MODEL 3 30005541A Motor NHC-25,30B 30005542A Motor NHC-41B 30004721C Flame Holder NHC-25B 4 30004727C Flame Holder NHC-30B 30004728C Flame Holder NHC-41B 5 30004361D Ignition Transformer ALL MODEL 6 20010578A Ignitor ALL MODEL NO. PART CODE DESCRIPTION MODEL 1 30000670A Outdoor Sensor ALL MODEL 48
SATURN CONDENSING OIL BOILER ITEM UNIT NHC 25B NHC 30B NHC 41B HEAT OUTPUT HEATING kw 24.0 27.9 36.8 FOR USE(Combi only) FUEL Heating Light Oil BUILDING SIZE Less than 132 Less than 165 Less than 232 MAXIMUM WORKING PRESSURE Bar 3.5 (kpa) 343 HEAT TRANSFERING SIZE 1.60 2.08 2.40 FUEL CONSUMPTION kg/h 2.07 2.43 3.19 TYPE OF AIR / EXHAUST GAS FE HEATING EFFICIENCY % 97.6 96.8 97.2 ELECTRICITY CONSUMPTION COMBUSTION W 136 145 163 POWER V, Hz 220V, 50Hz WATER STORAGE CAPACITY l 34.0 41.0 48.0 BOILER HOUSE DIMENSIONS EXTERNAL CABIN PACK DIMENSIONS W L H mm 410 665 1,031 444 706 1,051 444 706 1,186 W L H mm 600 725 1,090 635 780 1,110 635 780 1,180 WEIGHT kg 59 64 72 PIPING HEATING A 1" HOT WATER A 1/2" DIAMETER FLUE Φmm EXHAUST : 75 Oil Nozzle Type 0.60 / 60 EH 0.75 / 60 ES 1.00 / 80 ES Oil Pressure Smoke Number Bar 10 10 10 0-1 0-1 0-1 Fuel Flow Rate kg/h 2.07 2.43 3.19 Flue Gas Temperature CO2 C 60-65 65-70 70-75 % 11.5 11.5 11.5 49
CE marking 1506 In accordance with the following European Standard EN 267, EN 304, EN 15034, EN 55014-2, EN 61000-3-2, EN 61000-3-3, EN 60335-1, EN 60335-2-102 In accordance with the following Directives Directive 92/42/EEC ErP Ecodesign : Directive 2009/125/EC 813/2013 ErP Labelling : Directive 2010/30/EU 811/2013 Low voltage : Directive 2006/95/EC Electoro-magnetic Compatibility : Directive 2004/108/EC Navien, manufactures its product using a Quality Assurance system in compliance with Standard EN-ISO 9001:2000. Warranty period begins from first day of operational use of boiler. The warranty of the application is conditional upon correct installation, completion of the passport document and returning the commissioning certificate to the appliance manufacturer - if you don't do this the warranty could be invalid. Boiler passport must be returned within 28 days of installation to validate warranty. 50
Saturn Heating Distributed exclusively by: Saturn Heating Ltd Shercock rd. Carrickmacross Co. Monaghan A81 HK09 Ireland Technical Helpline: (IRE) 1890 929 112 Sales: (IRE) +353 (0)42 9692032 E-mail : info@saturnheating.net www.saturnheating.net BO-E-M-10-3 20016914E