Range Senator RFB006 6kW Guide

Models:
RFB006 6kW
RFB009 9kW
RFB011 11kW
RFB012 12kW
INSTALLATION AND
USER INSTRUCTIONS
March 2009
Issue No. 3
www.kingspanhws.com

INTRODUCTION
Introduction 2
Installer Detail 2
Description 3
Features 3
Models 3
Warranty 3
Basic Components Diagram 4
Basic Installation Dimensions 5
Operation and Indicators 6
Cleaning 6
Installation 6
Fitting 6
Plumbing / Heating installation 6
Basic Plumbing Layout 9
3 Boiler Plumbing Schematic 11
Wiring Instructions 12
Electrical Connections 12
Set up and test 14
Initial set up procedure 14
Main Test procedure 14
Parts location 15
Servicing 15
Fault Finding 15
Fault Reset Procedure 15
Fault Tracing chart one 16
Fault Tracing chart two 17
Fault Tracing chart three 18
Replacing the Main Powerboard 19
Powerboard Connections 20
Control Diagram 21
6 kW Boiler Wiring Diagram 22
9 kW Boiler Wiring Diagram 23
11 & 12 kW Boiler Wiring Diagram 24
Technical Specification 25
Heating Only Wiring Diagram 26
Typical Y Plan Wiring Diagram 27
Typical S Plan Wiring Diagram 27
Parts Listing 28
Limitations on Electrical Supply 29
Multiple Boiler Relay 30
2
Name:
Address:
Tel. No:
Date of installation:
Inhibitor used:
Model:
Serial Number:
CONTENTS
Every effort has been made to ensure the information contained in this manual is correct at the time of going to press, however Kingspan reserves
the right to change any information herein without notice. Senator is a Trademark of Kingspan Plc.
Range Senator
RFB 006
RFB 009
RFB 011
RFB 012
Your Electric Flow Boiler has been developed to provide many years of trouble free service when installed and maintained correctly. Every effort has
been taken to ensure the highest standards of reliability and safety from your purchase, however in the event of a suspected fault never attempt to
repair the boiler yourself. Consult your local installer as detailed below.
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision or instruction concerning use of the appliance by a competent person responsible for their safety.
Notes for the installer.
This document is specifically written for the Electric Flow Boiler. This manual must be read and explained to the householder by the installer and
left with the householder after installation. All boilers are packed in cardboard cartons. Inspect the boiler before installation. Any damage must be
reported to the supplier in writing within seven working days.
Installed by:
These instructions are applicable to the following models of electric flow boiler:

DESCRIPTION
The Electric Flow Boiler is designed to heat re-circulated water in wet central heating systems. The water is heated when it is passed over electric
immersion elements, which are contained within a stainless steel chamber. The temperature of the water is monitored and controlled by a modulation
technique switching the immersion elements. The switching of the elements is carried out by solid-state technology under the
control of a microcomputer contained in the control section of the boiler.
The operation of the boiler can be controlled by standard room thermostatic controls, etc. The pump MUST be connected to the boiler control, which
provides the run-on facility.
FEATURES
Domestic hot water is available via an indirect cylinder.
Can be used in pressurized installations or open vented systems.
No flue or fuel tank required.
Quiet in operation.
Operates from standard room thermostatic controls, etc.
Pump run-on facility.
Solid-state technology enables zero volt switching.
Soft start and soft modulation.
Front panel operation indicators.
Automatic self check every time it operates.
Optical isolation to enable connection of multiple boilers on single or 3 phase supply.
Electrical tails termination’s inside the boiler.
Safety trip for no water or no flow or excessive element current.
Warning of element failure.
WARRANTY
Your Electric Flow Boiler warranty covers defects originating from faulty workmanship and materials used in the manufacture of the boiler, for a period
of 5 years on the stainless steel chamber and 2 years on all other components. In the event of a potential warranty claim always quote the boiler serial
number. No claims will be considered without this number. The warranty covers the replacement of any faulty parts and our labour costs to replace
the faulty parts. It does not cover the cost of removing, returning and refitting the boiler or any secondary losses arising from the failure.
Under no circumstance should the boiler be dismantled prior to return. Failure to comply with this instruction will invalidate the warranty.
Defects arising from incorrect installation, water contaminates, harmful chemicals, system impurities, calcium build up, faulty ancillary equipment,
mechanical or electrical abuse, lightning or any other circumstances beyond our control, are not covered by the warranty.
The boiler is designed to operate the majority of wet central heating systems in domestic, commercial, industrial and public buildings. It must not be
used in any environment that has been classified as hazardous and could therefore cause a fire or explosion, or where their is a danger of ignition by
a flame path.
The warranty will be invalid if the boiler has not been installed correctly according to these instructions, standard codes of practice, including all
safety controls or if the recommended inhibitor is not used.
The warranty will be invalid if water leaks into the boiler from any external source. Ensure all joints and connections are water tight, pay particular
attention to those above the boiler. Under no circumstances is the case to have additional holes drilled into it. In the event of a potential warranty
claim, always quote the boiler’s serial number. No claims will be considered without this number.
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3

THE MAIN COMPONENTS OF THE ELECTRIC
FLOW BOILER
THE MAIN COMPONENTS OF SENATOR FLOW BOILER
Page 3 of 27
FLOW 22mm COMPRESSION
RETURN ( )NOT SHOWN
ELECTRICAL CABLE
ENTRY POINTS
TOP SEALING GROMMET
MAIN TERMINAL BLOCK
MAIN POWER BOARD
CONTROL PANEL
FRONT COVER
INSULATION
PRODUCT DATA
&
SERIAL NUMBER
MANUAL RESET
HIGH LIMIT
CUT OUT SWITCHES
Figure 1
4

BASIC INSTALLATION DIMENSIONS
120mm 120mm
100mm
900mm
Fixing Centres
8.5mm
1050mm
Cable Entry “Knock Outs”
1 x 25mm & 2x 20mm
Left, Right & Rear
Fixing Centres
Figure 2
5

6
OPERATION AND INDICATORS
The SUPPLY indicator (green) will remain illuminated whenever the supply is present to the boiler.
The DEMAND indicator (amber) will illuminate on demand from the programmer and thermostats. It will flash (amber) for 1 to 2 minutes during which
it automatically carries out self-tests before allowing the boiler to produce heat. At the end of this period it will remain on steady (amber), until the
heating demand is satisfied.
The HEAT indicator (green bar graph) will illuminate when the boiler actually produces heat when the DEMAND indicator (amber) is steady. The
gradual build up in heating power of the boiler can be seen on the front panel. The HEAT indicator (green bar graph) also shows the boiler modulating
when it reaches operating temperature.
The FAULT indicator (red) will only illuminate if there is a fault. The DEMAND indicator (amber) will turn off and the HEAT indicator (green bar graph)
will flash a fault code to assist with fault diagnosis. The boiler will remain in this tripped state until it is reset. To reset a FAULT follow the ‘Fault Reset’
procedure (see page 15).
Minimum operating temperature setting for the boiler is approximately 65oC Maximum operating temperature setting is approximately 80oC.
CLEANING
Use only a damp cloth and mild detergent to clean the boiler outer casing. Do not use abrasive cleaners. Do not allow water inside the boiler. Do not
immerse in water.
INSTALLATION
Care must be taken when handling and connecting the boiler not to damage or stress it in any way. Prior to installation the boiler must be stored in a
dry safe place.
FITTING
The boiler must be mounted in an UPRIGHT position only with the electrical connections uppermost. Any deviation from vertical is unacceptable. The
boiler must be fixed to a wall before connecting pipework. When choosing the position for the boiler, ensure sufficient clearances to house the unit
and for servicing, 50mm minimum clearance each side of the boiler is required. A drain valve at the base of the boiler is strongly recommended. It
must be sited in a dry, ventilated position, frost free and not subjected to extremes of temperature.
PLUMBING / HEATING INSTALLATION
IT IS THE INSTALLER’S RESPONSIBILITY TO ENSURE THE INSTALLATION DOES NOT CONTRAVENE THE
REQUIREMENTS OF THE WATER BYLAWS OR LOCAL AUTHORITY REGULATIONS.
The boiler must be installed by a qualified, competent tradesman who is aware of and will comply with all relevant standards that are applicable: e.g.
Building Regulations, the Local Building Regulations, the Bylaws of the Local Water Authority and Undertaking and the relevant codes of practice, the
system must be flushed in accordance with BS.7593 and in accordance with the supplied instructions and drawings to ensure correct operation.
In operation, the boilers contain a very small amount of water in relation to the power input and so require a good flow rate of water to ensure correct
operation. Six Kilowatt models require a minimum flow of 6 litres/minute, and nine to twelve Kilowatt models require a minimum flow of 12 litres/
minute. Insufficient flow of water through the boiler will cause nuisance trip outs. The maximum temperature differential between input and output of
the boiler must not exceed 20oC. If the temperature across the boiler exceeds this then the flow rate is too low and could cause permanent damage
to the boiler.
All Flow and Return pipework to be 22mm to ensure minimum flow rate.

7
BOILER
The Electric Flow Boiler is suitable for installation in either open vented or sealed system (max pressure 0.35Mpa/3.5 bar) primary circuits. The lower
cost and therefore most popular option will use the boiler to provide space heating only. Hot water provision will be via an unvented direct stainless
steel or open vented direct copper cylinder heated by immersion heaters.
If the boiler is to provide both space heating and hot water a conventional Y plan or S plan should be used in conjunction with an unvented indirect
stainless steel or open vented indirect copper cylinder. Where a three port valve is to be used a capacitor is required. Seek advice from Technical
Services 0845 260 7260.
The boiler is also compatible with under floor heating.
The boiler FLOW connection (22mm) is at the top of the boiler and the RETURN connection (22mm) is at the base. Ensure all connections to the
Senator boiler are made with 22mm Table X Copper Tube. Plastic pipework is not suitable.
PUMP
The circulating pump must be mounted in the return pipework pumping water upwards through the boiler. Size the pump in the usual way and set to
maximum to ensure sufficient flowrate. The pump fitted to this system and controlled by the boiler must have a thermal cut out device.
The boiler operates a pump overrun. Do not operate the boiler with the pump valves closed.
VENTING
To ensure a satisfactory clearance of air from the boiler mount an auto air release valve in the boiler flow pipework a minimum of 150mm horizontally
offset from the boiler. Do not mount directly above the boiler. see figs 3 & 4 (page 9).
For an open vented system the feed and vent pipes must be close coupled directly behind the pump. see fig 3 (page 9). The static head for the pump
should be between 2.5 mtr and 30 mtr.
BYPASS
The boilers incorporate a pump overrun. To meet Building Regulations all installations must include an automatic bypass within a
circuit of at least 2 meters of 22mm pipework when measured from the boiler flow connection, around the bypass to the boiler return
connection. see figs 3 & 4 (page 9).
Bypass radiators and gate valves are no longer acceptable alternatives.
The installations must include a room thermostat providing full boiler interlock.

8
SEALED SYSTEMS
Where used in sealed (pressurised) system, the system kit should be mounted in the return pipework behind the pump, see fig 4 (page 9). Use
standard calculations for an 82oc flow temperature when sizing the vessel. Max system pressure: 0.35Mpa/3.5 bar. Always mount the vessel in a
vertical upright position. Do not install a valve or other restrictive device between the boiler and the safety pressure relief valve.
THERMOSTATIC CONTROL
The installations must include a room thermostat providing full boiler interlock. Where the boiler is installed in a space heating only mode, a full
programmer providing independent control of hot water and space heating in conjunction with a room thermostat will normally be used.
Thermostatic radiator valves may be used on all radiators other than those in the room where the room thermostat control is situated.
CLEANSING / INHIBITOR
After installation the system must first be flushed out in accordance with BS7593:1992 before adding inhibitor. Fermox Superfloc or Betz Dearborn
Sentinel X300 or X400 are recommended for both new and existing systems. After flushing, the correct dosage of inhibitor must be added. Fernox
Superconcentrate or MB1 or Betz Dearborn Sentinel X100 can be used in most water areas, however consult manufacturer’s instructions and local
water conditions before use. Check inhibitor concentration after installation and annually to ensure correct protection. Failure to flush correctly or
inadequate inhibitor will invalidate the warranty.
MULTIPLE BOILER INSTALLATIONS
For multiple boiler installations (up to three number) mount each boiler side by side with a minimum gap of 50mm between each boiler casing.
Connect the pipework in parallel as fig 7 (page 11). Connect flows via swept tees together increasing pipework sizes from each tee to ensure full flow
through the system. EG. for 3 x 12kW boilers use a 22mm flow and horizontal pipe to the tee of the second boiler increasing to 28mm to the third
boiler increasing again to 35mm pipework for the system loop. Each pipe drop to the boiler flow connection is 22mm. Repeat the exercise for the
return connections.
Only connect to the boiler in 22mm Table X Copper Tube. Do not use plastics. Install the pump in the 35mm return pipework and size according to
overall system requirements ensuring sufficient flow to each boiler i.e. for 3 x 12 kW boiler require 3 x 12 litre per minute minimum flow = 36 LPM.

9
DRAIN VALVE
PUMP
Automatic Bypass
minimum of 2 metres
Radiators
Auto Air Vent
150mm
maximum
150mm
minimum
BASIC PLUMBING SCHEMATIC
SPACE HEATING ONLY - OPEN VENTED
DRAIN VALVE
PUMP
Automatic Bypass
minimum of 2 metres
Safety
Controls
Radiators
Auto Air Vent
150mm
minimum
BASIC PLUMBING SCHEMATIC
SEALED SYSTEM
Figure 3
Figure 4

DRAIN VALVE
PUMP
Radiators
150mm
minimum
Auto Air Vent
Automatic Bypass
minimum of 2 metres
Cylinder
BASIC PLUMBING SCHEMATIC
SPACE HEATING AND HOT WATER - Y PLAN SYSTEM
DRAIN VALVE
PUMP
Radiators
Auto Air Vent
Automatic Bypass
minimum of 2 metres
Cylinder
150mm
minimum
BASIC PLUMBING SCHEMATIC
SPACE HEATING AND HOT WATER - S PLAN SYSTEM
Figure 5
Figure 6
Open vented pipework or sealed system safety controls to be installed as fig. 3 on page 4
Open vented or sealed system safety controls to be installed as fig. 3 on page 4
10

11
22mm PIPE
FLOW =12L/MIN
28mm PIPE
FLOW =24L/MIN
35mm PIPE
FLOW =36L/MIN
RETURN
FLOW
DRAIN VALVE
AUTOMATIC
AIR VENT
150mm minimum
Automatic Bypass
minimum of 2 metres
35mm
35mm
3 BOILER PLUMBING SCHEMATIC
Figure 7

WIRING INSTRUCTIONS
ALL WIRING MUST BE CARRIED OUT IN ACCORDANCE WITH CURRENT IEE WIRING REGULATIONS.
The boiler must be installed by a qualified competent tradesman in accordance with these instructions and drawings to ensure correct operation.
Check the main incoming supply to the property to ensure there is sufficient current and voltage for the size of the boiler or boilers to be installed.
Remember to also take account of the supply requirements for the rest of the property. Ensure the correct cable size is used to feed the boiler.
Ensure the installation complies with current IEE regulations BS7671:2008.
A double pole RCD with a trip level sensitivity of 30mA and capable of breaking the full load current to BS EN 61008:1994, must be used.
In order to provide a means of isolation, the boiler must be connected to the supply through a double pole linked switch with a
minimum contact gap of 3mm in all poles. The RCD is suitable for this requirement if it is mounted in close proximity to the boiler.
A correctly rated MCB must be used in the supply, see Technical Specifications (see page 19). An additional 3A supply is required for
the controls etc. NOTE, a blank must be fitted between each MCB to provide ventilation, check with the MCB manufacturer/supplier.
NOTE: The high current mains supply MUST NOT be routed through the programmer, controls etc. Follow the wiring diagrams. Use a standard
programmer, room thermostat, etc.
The high current switching is carried out inside the boiler, only standard switched live (low current) control signals are supplied by the
programmer etc.
ELECTRICAL CONNECTIONS
Access can be gained to the boielrs electrical connections by removing the front panel. The earth lead is removed from the front cover by depressing
the release button on the connection to the cover.
IT IS IMPORTANT THAT THE EARTH CONNECTION SHALL ALWAYS BE RECONNECTED WITH THE RELEASE BUTTON
FITTED INWARDS AND EARTH BOND TESTED AFTER ANY MAINTENANCE HAS BEEN CARRIED OUT.
THESE CONNECTIONS MUST BE TIGHT. LOOSE CONNECTIONS COULD CAUSE A FIRE OR BURNING AT MAIN TERMINAL
CONNECTOR AND IS NOT COVERED BY THE WARRANTY.
1. MAIN POWER. Main power-supply cables. Using the correct rated cables, connect the main terminals live, neutral and earth directly to the isolation
switch,. Do not connect the power through the programmer, thermostats etc. The main power terminals in the boiler are suitable for cables up to 16mm.
2. CN1: CONTROL SIGNAL. Connect switched live to ‘D’ and neutral to ‘N’ on the control terminal block in the boiler to the switched live and neutral
from the programmer control circuit. A neutral must be connected, as this control signal is optically isolated from the main supply in the boiler and will
not run without a neutral.
3. CN2: PUMP CONNECTIONS. The supply to the pump must be connected to the ‘PUMP’ terminal on the control terminal block in the boiler. This
supply is fused in the boiler at 2A.
CONNECTIONS FOR 2 OR MORE BOILERS
1. Main power-supply cables. Connect each boiler to its supply live, neutral, and earth, as described above. The supplies to each boiler can be on
different phases if using a 3-phase supply.
2. CN1: Control signal. Join all the boiler ‘D’ terminals on the control terminal block together, and then connect them to the switched live control
signal to the programmer control circuit. Connect all the boiler ‘N’ terminals on the control terminal block together and then to neutral on the
programmer control circuit.
3. CN2: Pump connections. The pump must be connected through a relay assembly to ensure that the pump always operates if any one boiler is
running. Check the main electrical power connections are tight. Loose connections can cause a fire and will invalidate the warranty. The control
DEMAND signal is optically isolated from the main boiler supply to enable different phases to be used between boilers. The control signal required to
operate the boiler is 220v - 240v at a very low current typically 10mA.
12

13
WARNING: THIS APPLIANCE MUST BE EARTHED.
All exposed pipework must be earthed in accordance with IEE regulations.
After installation, preliminary electrical checks i.e. short circuit, earth continuity, resistance to earth and check for correct polarity etc.
must be carried out.
Before connecting the electrical supply, ensure the system is full of water and set to the correct pressure (pressurized systems), check
for leaks.
IT IS ESSENTIAL THAT ALL THE AIR IS PURGED FROM THE SYSTEM
Only then can the supply be switched on.
On completion of the work the installation must be tested to IEE regulations and an NICEIC inspection and completion certificate must be issued.
Please take note of the installation information. If in doubt please contact your local supplier.
Heating Controls To Comply With The Revised Building Regulations (Part L For England. Part J For Scotland.)
New Dwelling
1. Fully pumped system.
2. Independent temperature and time controls for both heating and domestic hot water.
3. Controls to interlock with the boiler. TRV’s alone do not comply.
4. An automatic bypass is required. Gate-valves do not comply.
5. Split heating circuits into zones:
a. Room thermostat or programmable room thermostats in all zones.
b. A room thermostat or programmable room thermostats in the main zone and TRV’s in all other zones.
6. Cylinder thermostat and zone valve to control stored hot water. Non-electric hot water controllers do not comply.
7. Timed controller for heating and hot water must be provided.
8. A minimum of 2 zones for heating floor spaces greater than 150m2.
9. Boiler management control systems meeting specific zoning, timing and temperature requirements are acceptable.
Existing Dwellings
1. When a new installation is fitted, the controls must be as for a new dwelling.
2. When replacing the boiler and/or hot water vessel, the opportunity to improve the controls should be considered to be confident that the
requirements of the Building Regulations are met.

SET UP AND TEST
The boiler controls are fully automatic, making the operation very simple.
Only after the system has been flushed through and then filled with water, inhibitor and set to the correct pressure (pressurized
systems), can the electrical supply be connected.
Check 1. When filling the system check for leaks. The warranty will be invalid if water leaks into the boiler. Ensure all joints and connections are water
tight. Pay particular attention to those above the boiler.
Check 2. Before connecting the mains supply, check the mains power connections are tight. Loose connections can cause a fire.
INITIAL SET UP PROCEDURE: ( AIR PURGE)
1. Ensure the main electrical supply and the programmer controls to the boiler are off and isolated.
2. Remove the pump live and neutral connection from the control terminal block in the boiler, and reconnect the pump live wire into
the control terminal ‘D’ together with the control signal wire. Connect the pump neutral wire into the control terminal ‘N’ together
with the control neutral wire.
3. Unplug the control block from the main PCB, ensure it is safe and not touching anything. The pump is now fed from the control
signal.
4. Check all air is purged from the system, and set the pump to maximum.
5. Switch on the RCD, and only the control (3 amp or 6 amp) MCB.
6. With the programmer and room thermostat on, check the pump is running and water is flowing. Ensure the whole system, valves
etc. are operating correctly. Continue to run the pump for some time to purge any air. Don’t forget to bleed the pump.
7. Switch off the main supply RCD and MCB. Ensure it is all safe before reconnecting the pump connections to the pump terminals as
originally wired. Reconnect the control terminal block onto the PCB. Check all connections are made correctly, check the main
supply terminals in the boiler are tight, close and secure the top front cover of the boiler.
MAIN TEST PROCEDURE
Only after a satisfactory initial test, proceed as follows;
1. Switch on the main boiler M C B. Switch on the programmer “control” (3 amp or 6 amp) M C B Switch on the R C D unit / Isolation
switch. Check the boiler front panel SUPPLY indicator is illuminated (green).
2. Set the programmer for central heating to ON. Set the room thermostat to be ON. The boiler front panel DEMAND indicator will
flash (Amber). This indicator will illuminate as a steady amber after approximately 1 minute. Following the steady amber, the HEAT
indicator will build up gradually.
3. Check the temperature of the FLOW pipework from the boiler. This pipework should start to rise in temperature. The rate of rise will
depend upon the size of the boiler and system.
4. Check the full system operates correctly. If at any time the temperature difference between the boiler return and flow is greater that
20 ° C, then there is a flow restriction problem, and must be rectified immediately. This function is automatic in boiler controls.
5. The pump is operated from the boiler control. It must be connected to the pump terminals on the boiler control panel. The pump
will run whenever the DEMAND indicator is illuminated (amber) either flashing or steady, and it will also continue to run if the boiler
is hot, even after the demand has ceased. It will turn off the pump when the temperature across the boiler falls below 5°C. A bypass
must be incorporated in systems where the heating load can shut down, i.e. when valves or thermostatic radiator valves are fitted.
See note on the bypass on page 7.
6. The FAULT indicator (red) will only illuminate if there is a problem. The HEAT (green bar graph indicator) and the DEMAND (amber) indicators will
turn off. The boiler will remain in this tripped state until the fault is corrected and the boiler is re-set.
14

15
SERVICING
IT IS ESSENTIAL THAT THE BOILER IS CHECKED ANNUALLY TO VALIDATE THE WARRANTY
Checks must include the electrical connections and inhibitor concentration.
Before any servicing or maintenance is carried out on the system, ensure that the electrical supply has been disconnected first. Care must also be
taken as the water may be scalding hot and at a high pressure.
Check the main electrical power connections are tight. Loose connections can cause a fire.
PART LOCATIONS
Fuse F1 is found near the top of the main Power Board assembly, See fig 8 (page 17).
The manual reset high limit cut out switches CN12 are left hand side and also the left hand side of the heatsink block, See fig 1 (page 4).
The control board assembly is mounted on the front, and plugged into the main power board at PL1
To change the main power board, follow ‘Replacing the Main Power Board’ procedure.
Each of the main electrical elements should have a resistance of approximately 19 ohms for a 3kW Element and 28 ohms for a 2kW element terminal
to terminal, (black to black, grey to grey, blue to blue and green to green) and an insulation resistance greater than 2 Meg ohms between terminal and
case. If the elements are open circuit terminal to terminal, or have short circuit insulation resistance terminal to case, the individual element needs to
be replaced (page 16).
FAULT FINDING
1. Should the RED FAULT indicator illuminate the fault can be traced using the fault code indicated by the flashing HEAT
indicator. The HEAT (green bar graph indicator) will flash a number of times and then pause, the fault can them be determined from the fault tracing
charts on pages 16,17 & 18.
2. Should the FAULT indicator flash then there is possibly a fault in one of the heater elements, this will not cause the unit to stop operating but
serves as a warning that one or more of the elements are not working. The unit’s heat output will be reduced The Boiler must NOT be operated if it is
known to have a fault.
FAULT RESET PROCEDURE
There are 3 steps to re-set a tripped condition:
1 - Switch Main Power Supply and Demand OFF.
2 - Correct the fault, check the system is full of water and set to the correct pressure (pressurized systems) and there is a good flow of water (i.e. all
the valves are open).
3 - Switch the supply back ON.

16
Fault Tracing
Chart One
Is the supply
(Green) LED
Illuminated?
Switch on Demand
Ensure call for
Heat
The Demand
(amber) LED will
flash in conjunction
with (green) bar
graph
(Self test mode)
Approx 1.5 minutes
To page 17
Is the demand
(amber) LED
Flashing?
Is there 230V
AC at main
terminals?
NO NO
NO
NO
NO
YES
YES
YESYES
APPROX 8 SECS
YES
Rectify, supply, fault
Is there 230V
AC at transformer
TX1 on powerboard?
Is Fuse F1 OK?
(rating 2.5A 20 X5)
Replace
powerboard
Replace
powerboard
Is there 5V DC at
PL1 Pin 1 to ground
on powerboard?
Is there 230V AC
at CN1 (demand) on
powerboard?
Replace
powerboard?
Rectify fault (s)
on demand
installation
Check / replace
FBP0307
(16 PIN cable)
or
FBS0321 - 06kW
FBS0331 - 09kW
FBS0341 - 11kW
FBS0351 - 12kW
(control panel)
Replace
Fuse
NONO
YES
YES
YES

17
Fault Tracing
Chart Two
Does the boiler
complete self test?
(amber LED solid
illumination)
From page 16
The Heat (Green)
bar graph & fault
(Red) LED will
flash NO’s 1 to
6 or 9
NO
YES
YES
NO
NO
YES
To page 18
No preheat current
Check FBS0116
preheat resistor
assembly for 2K OHMS
Replace FBS0116
preheat resistor
assembly
Temperature
sensor(s) fault
Replace fault sensor(s)
FBS0117 upper
FBS0118 lower
2 flashes
3 flashes
Temperature rise too
high on preheat
No water in heater
or no flow
Check for water
or flow
4 flashes
Excessive current
with relay(s) on Faulty Triac(s) Replace powerboard
5 flashes
Excessive current
with triac(s) on Faulty relay(s) Replace powerboard
6 flashes
Is temperature
differential between
flow & return greater
than 10˚C
Temperature
sensor(s) fault
9 flashes
Temperature not
stabilised before
preheat
Are flow & return
temperatures equal
Check pump
operation & valves
open
1 flash Excessive current
flow on switch on
Triac(s) or relay(s)
faulty
Replace
powerboard
YES
Check / replace
control panel or
powerboard
Replace faulty sensor(s)
FBS0117 upper
FBS0118 lower
YES
Refer to 7 flashes
see page 18
NO

18
Fault Tracing
Chart Three
Does the heat (Green)
bar graph illuminate &
stay on 1,2,3 or 4
From page 17
NO
NO
NO
Is the demand
voltage correct
Are elements within
specification (refer to
manual page 5)
Faulty Elements
Does the boiler
produce heat
NO Is the fault (red) LED
flashing
Is the boiler on
Y plan system?
Refer to manual
page 7 (capacitor
installed)
8 flashes
YES
YES
YES
YES
YES
YES
YES
YES
Check FBS0113
manual reset high limit
switch assembly
Is the fault (red)
LED flashing
NO Is the output
temperature less
than 60˚C
NO Adjust output
temperaure or flow
(minimum maintained)
Are elements within
specification (refer
to manual page 5)
NO Faulty elements Request service
exchange boiler
Have all individual
elements got a
current reading
NO
Check supply
voltage
YES
Check heating
requirement
calculations?
Does the boiler
run continually
Does the boiler
produce heat and
then fault
NO
Insufficent or no
water flow
Excessive temperature
drop across boiler
Excessive
heater current
Is there 230V AC at
CN2 (pump) on
powerboard boiler
on demand
Request service
exchange boiler
7 flashes
YES
Check pump
operation &
valves open
Replace powerboard
Replace powerboard
Replace powerboard

REPLACING THE MAIN POWER BOARD
NOTE. BEFORE ANY MAINTENANCE IS CARRIED OUT ON THE SYSTEM, ENSURE THAT THE ELECTRICAL SUPPLY HAS
BEEN DISCONNECTED FIRST. CARE MUST BE TAKEN AS THE WATER MAY BE SCALDING HOT AND AT HIGH PRESSURE.
Maintenance on the boiler can only be carried out by a qualified and competent tradesman in accordance with these instructions.
Removal of the Main Power Board
Switch OFF ALL electrical supply to the boiler. Both Main, “Live and Neutral”, and Control “D and N” must be isolated.
Remove the front panel and disconnect earth.
Disconnect CN1, CN2, CN3, CN13 at the top of the board, See fig 8 (page 17).
Disconnect CN12, CN14 & PL1 on the bottom of the board.
Remove manual reset high limit switch from heat sink block.
Clip restraining cable tie from top temp sensor wire to main power cables.
Disconnect inbound Live, Neutral and Earth cables and adjacent earth bond wire from main terminal block.
Remove 2 x screws from main terminal block to main terminal mounting.
Note the assembly position in relation to pipe.
Restrain power board assembly.
Remove four retaining screws from clamps at rear.
Withdraw assembly.
Disconnect all the heater element cables from the end of the heater unit, noting where each one goes.
Replacing the Main Power Board
Clean the top 22 mm pipe.
Adequately coat the power board pipe contact surface with heat sink compound.
Replace the heater cables in their original order as previously noted.
Position power board assembly as previously noted.
Replace the four retaining screws to the clamps at rear.
Replace the manual reset high limit switch to the heat sink block. (Clean and apply compound).
Reconnect all electrical connections on their original places.
Ensure both high limits are depressed.
Reconnect the main power connections. Ensure these connections are tight. Loose connections can cause a fire.
Re-attach the earth wire, refit front case and test.
Ensure all cables are restrained by ties as per original wiring.
19

L
N
CN2 CN1
CN3
CN13
NL
PL1
UPPER
TEMPERATURE
SENSOR
PRE HEAT
RESISTORS
DEMAND SIGNAL
PUMP
CONTROL PANEL
Page 18 of 27
E
LOWER TEMPERATURE
SENSOR
MANUAL RESET
HIGH LIMIT
CUT OUT SWITCHES
CN14
CN12
PUMP EARTH
TO ELEMENTS
(REFER TO INDIVIDUAL MODEL DIAGRAMS)
TO EARTH
BOND BOLT
NL
Black N1
Grey N2
Blue N3
Green N4
Black L1
Grey L2
Blue L3
Green L4
POWER BOARD CONNECTIONS
Figure 8
FUSE F1
20
TRANSFORMER
TX1
PIN 1