Installation

& Servicing

Instructions

THESE INSTRUCTIONS

TO BE RETAINED

BY USER

SABRE

1SABRE

INTRODUCTION

Fig.1 General Layout

1 Flue Analysis Test Point2 Pressure Tube Negative3 Fan Assembly4 Heat Exchanger5 Secondary thermistor6 Combustion chamber7 Burner8 Expansion vessel9 Transformer10 Water pressure switch11 Domestic Hot Water Flow Switch12 Gas Valve13 Timeclock14 CH position15 Fault indicator led16 Mode selector switch17 DHW position18 Pressure gauge19 Safety valve20 Pump21 Auto air vent22 Electrode23 High limit thermistor24 Primary thermistor25 Air chamber (with cover removed)26 Air pressure switch27 Auto by pass (fig. 2)28 Water flow restrictor (fig. 2)

The Sabre range of appliances are combined central heat-

ing and domestic hot water boilers, which – by design –

incorporates full sequence electronic ignition, circulating

pump, expansion vessel, safety valve, pressure gauge,

automatic by-pass, and mechanical time clock.

Sabre is produced as a room sealed appliance, suitable for

wall mounting applications only. Sabre is provided with a

fan powered flue outlet with an annular co-axial combustion

air intake that can be rotated – horizontally – through 360

degrees for various horizontal or vertical applications.

This appliance is designed primarily for use with sealed

systems; consequently it is not intended for use on an

open vented system.

Fig. 1

�� ��

��� ��

���

2 SABRE

SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE

Fig. 2

1.1 PRINCIPLE COMPONENTS● A fully integrated, electronic control board fea-

turing mode selection switch, full sequence-electronic ignition, temperature control system,and appliance status indicator.

● A BI-thermal gas to water heat exchanger.● A multi-functional gas valve.● Two-stage, primary water pressure switch.

Integral pump, expansion vessel, pressure re-lief valve, pressure gauge, domestic water flowswitch, fan, differential air pressure switch, andtime clock.

MODES OF OPERATION

1.2 CENTRAL HEATING MODEWhen there is a request for central heating via thetime-clock and/or any external controls, the pumpand fan are started, the fan proves the differentialair pressure switch which in-turn, allows an ignitionsequence to begin.Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Once suc-cessful ignition has been achieved the applianceoperates al 75% of maximum for a fifteen-minuteperiod, and thereafter the appliance operates onmaximum output until the desired temperaturesetting is reached.

Once the desired temperature is reached, theburner will modulate to maintain that tempera-ture, however should the temperature within theappliance continue to rise, the burner will shutdown and the boiler will perform a three-minuteanti-cycle (timer delay).

1.3 HOT WATER MODEWhen there is a demand for domestic hot waterthe domestic hot water flow switch is proved bythe flow of water through the appliance, thisallows the fan to run, the fan proves the differen-tial air pressure switch which in-turn, allows anignition sequence to begin.

Ignition is sensed by the electronic circuitry toensure flame stability at the burner. Oncesuccessful ignition has been achieved the appli-ance will modulate burner gas pressure to main-tain the desired water temperature, should thetemperature of the domestic hot water exceedthe temperature setting by 5 ºC the burner willshut down until the water temperature dropsbelow the required setting.

1.4 SAFETY DEVICESIn both central heating and domestic hot watermodes, safe operation is ensured by.● A water pressure switch that monitors the sys-

tem pressure and will deactivate the pump andprevent burner ignition should the pressure orprimary flow rate fall below the rated tolerance.

● Differential air pressure switch that checks thecorrect operation of the fan and flue therebypreventing or interrupting burner operation.

● A high limit thermostat that overrides the con-trol circuit to prevent or interrupt burner ignition.

● A safety valve which releases excess pressurefrom the primary circuit.

1.5 FROST PROTECTIONThe appliance has built-in frost protection thatallows the pump to operate if the appliance tem-perature drops to 7 ºC, should the temperaturecontinue to drop the burner will light until theprimary circuit temperature exceeds 30 ºC.

return flow hwoutlet

coldinlet

27

5

910

26

19

8

23

4

20

18

3SABRE

SECTION 2 TECHNICAL DATA

Ref. Condition 15 °C , 1013,25 mbar, dry gasNOTE: L.P.G. data refer to section 10

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

SABRE 24 SABRE 28

2.1 Central heatingHeat input (kW) 26.3 31.0Heat output (maximum) kW 24.0 28.0Heat output (minimum) kW 9.4 10.5Minimum working pressure 0,5 barMaximum working pressure 3.0 barMinimum flow rate 350 l/h

2.2 Domestic hot waterHeat input (kW) 26.3 31.0Heat output (maximum) kW 24.0 28.0Heat output (minimum) kW 8.2 8.7Flow rate (35 °C rise) 9.8 l/min 11.5 l/minMaximum inlet pressure 6.0 barMinimum inlet working pressure 0.15 barMinimum flow rate 2 l/min.

2.3 Gas pressuresInlet pressure G20 20.0 mbarMaximum burner pressure 10.1 mbar 10.2 mbarMinimum burner pressure (central heating) 1.9 mbarMinimum burner pressure (domestic hot water) 1.5 mbar 1.3 mbarGross rate (maximum) 2.78 m3/h 3.28 m3/hInjectors size 12 x 1.35 mm 14 x 1.35 mm

2.4 Expansion vesselCapacity 8 litresMaximum system volume 76 litresPre-charge pressure 1.0 bar

2.5 DimensionsHeight 740 mmWidth 400 mm 450 mmDepth 328 mmDry weight 32 kg 34 kg

2.6 ClearancesLeft side 50 mmRight side 12 mmTop 150 mm from casing or 25 mm above flue elbow, whichever is applicableBottom 150 mmFront 600 mm

2.7 ConnectionsFlow & return 22 mmHot & cold water connections 15 mmGas 15 mmSafety valve 15 mm

2.8 ElectricalVoltage 230V/~ 50hzPower consumption 125 WInternal fuse 2 APCB fuse 2 AFExternal fuse 3 A

2.9 Flue detailsMaximum horizontal flue length (concentric) 4.25 m 3.4 mMaximum vertical flue length (concentric) 5 m 4.2 m

2.10 EfficiencySEDBUK band “D” 80,3% 80,3%

SABRE 24 SABRE 28

4 SABRE

2.11 PUMP DUTYFig. 3 shows the flow rate available – afterallowing for pressure loss through theappliance – against system pressure loss.When using this graph apply only thepressure loss of the system. The graph isbased on a 20 ºC temperature differential.

Fig. 3

Fig. 4

Wat

er p

ress

ure

(m

bar

)

Litres Per Hour (x100)

100

200

300

400

500

600

0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

SECTION 3 GENERAL REQUIREMENTS (UK)

Key Location Minimum distance

A Below an opening (window, air-brik, etc.) 300 mmB Above an opening (window, air-brik, etc.) 300 mmC To the side of an opening (window, air-brik, etc.) 300 mmD Below gutter, drain-pipe, etc. 75 mmE Below eaves 200 mmF Below balcony, car-port roof, etc. 200 mmG To the side of a soil/drain-pipe, etc. 150 mmH From internal/external corner or boundary 300 mmI Above ground, roof, or balcony level 300 mmJ From a surface or boundary facing the terminal 600 mmK From a terminal facing a terminal 1200 mmL From an opening in the car-port into the building 1200 mmM Vertically from a terminal on the same wall 1500 mmN Horizontally from a terminal on the same wall 300 mmP From a structure to the side of the vertical terminal 300 mmQ From the top of the vertical terminal to the roof flashing As determined by the fixed collar

of the vertical terminal

.

H

H

5SABRE

This appliance must be installed by a competentperson in accordance with the Gas Safety (In-stallation & Use) Regulations.

3.1 RELATED DOCUMENTSThe installation of this boiler must be in accord-ance with the relevant requirements of the GasSafety (Installation & Use) Regulations, the localbuilding regulations, the current I.E.E. wiring regu-lations, the bylaws of the local water undertaking,the Building Standards (Scotland) Regulation, andBuilding Standards (Northern Ireland) Regulations.

It should be in accordance also with any relevantrequirements of the local authority and the rel-evant recommendations of the following BritishStandard Codes of Practice.

3.2 LOCATION OF APPLIANCEThe appliance may be installed in any room orinternal space, although particular attention isdrawn to the requirements of the current I.E.E.wiring regulations, and in Scotland, the electricalprovisions of the Building Regulations, with re-spect to the installation of the appliance in a roomor internal space containing a bath or shower.

When an appliance is installed in a room orinternal space containing a bath or shower, theappliance or any control pertaining to it mustnot be within reach of a person using the bathor shower.

The location chosen for the appliance must permitthe provision of a safe and satisfactory flue andtermination. The location must also permit anadequate air supply for combustion purposes andan adequate space for servicing and air circulationaround the appliance. Where the installation of theappliance will be in an unusual location specialprocedures may beNecessary, BS 6798 gives detailed guidance onthis aspect.

A compartment used to enclose the appliancemust be designed and constructed specifically forthis purpose. An existing compartment/cupboardmay be utilised provided that it is modified to suit.

Details of essential features of compartment/cup-board design including airing cupboard installa-tions are given in BS 6798. This appliance is notsuitable for external installation.

3.3 GAS SUPPLYThe gas meter – as supplied by the gas supplier –must be checked to ensure that it is of adequatesize to deal with the maximum rated input of all theappliances that it serves. Installation pipes mustbe fitted in accordance with BS 6891.

Pipe work from the meter to the appliance mustbe of adequate size. Pipes of a smaller size thanthe appliance gas inlet connection must not beused. The installation must be tested for sound-ness in accordance with BS6891.If the gas supply serves more than one appliance,it must be ensured that an adequate supply ismaintained to each appliance when they are inuse at the same time.

3.4 FLUE SYSTEMThe terminal should be located where the disper-sal of combustion products is not impeded andwith due regard for the damage and discoloration

BS 5440 PART 1 FLUES

BS 5440 PART 2 FLUES & VENTILATION

BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS

BS5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES(2ND FAMILY GASES)

BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60kW

BS 6891 LOW PRESSURE INSTALLATION PIPES

BS 7074 PART 1 APPLICATION, SELECTION, AND INSTALLATION OF EXPANSION VESSELS ANDANCILLARY EQUIPMENT FOR SEALED WATER SYSTEMS

that may occur to building products located nearby.The terminal must not be located in a place whereit is likely to cause a nuisance (see fig. 4).

In cold and/or humid weather, water vapour maycondense on leaving the terminal; the effect ofsuch pluming must be considered.

If installed less than 2m above a pavement orplatform to which people have access (includingbalconies or flat roofs) the terminal must beprotected by a guard of durable material. Theguard must be fitted centrally over the terminal.Refer to BS 5440 Part 1, when the terminal is 0.5metres (or less) below plastic guttering or 1 metre(or less) below painted eaves.

6 SABRE

Fig. 5a

3.6.6 FILLING POINTA method for initial filling of the system and replac-ing water lost during servicing etc. must be pro-vided. This method of filling must comply with thecurrent Water Supply (Water Fittings) Regulations1999 and Water Bylaws 2000 (Scotland). Fig. 5shows an accepted method.

3.6.7 LOW PRESSURE SEALED SYSTEMAn alternative method of filling the system wouldbe from an independent make-up vessel or tankmounted in a position at least 1 metre above thehighest point in the system and at least 5 metresabove the boiler (see fig. 5a)

The cold feed from the make-up vessel or tankmust be fitted with an approved non-return valveand stopcock for isolation purposes. The feedpipe should be connected to the return pipe asclose to the boiler as possible.

3.6.8 FREQUENT FILLINGFrequent filling or venting of the system may beindicative of a leak. Care should be taken duringthe installation of the appliance to ensure allaspects of the system are capable of withstandingpressures up to at least 3 bar.

3.7 ELECTRICAL SUPPLYThe appliance is supplied for operation on 230V @50Hz electrical supply; it must be protected with a3-amp fuse. The method of connection to themains electricity supply must allow for completeisolation from the supply. The preferred method isby using a double-pole switch with a contactseparation of at least 3mm. The switch must onlysupply the appliance and its corresponding con-trols, i.e. time clock, room thermostat, etc. Alter-natively an un-switched shuttered socket with afused 3-pin plug both complying with BS 1363 isacceptable.

Fig. 5

control valvetemporaryconnection

control valve

supply pipe

double checkvalve

flow/returnpipe

Make-up vesselor tank

Automaticair-vent

Non-returnvalve

Stopcock

5.0

met

res

min

imum

Heatingreturn

3.5 AIR SUPPLYThe following notes are intended for general guid-ance only.This appliance is a room-sealed, fan-flued boiler,consequently it does not require a permanent airvent for combustion air supply.When installed in a cupboard or compartment,ventilation for cooling purposes is also not required.

3.6 WATER CIRCULATIONDetailed recommendations are given in BS 5449Part 1 and BS 6798. The following notes are forgeneral guidance only.

3.6.1 PIPEWORKIt is recommended that copper tubing to BS 2871Part 1 is used in conjunction with soldered capillaryjoints.Where possible pipes should have a gradient toensure air is carried naturally to air release pointsand that water flows naturally to drain cocks.Except where providing useful heat, pipes should beinsulated to avoid heat loss and in particular to avoidthe possibility of freezing. Particular attentionshould be paid to pipes passing through ventilatedareas such as under floors, loft space, and voidareas.

3.6.2 AUTOMATIC BY-PASSThe appliance has a built-in automatic by-pass,consequently there is no requirement for an externalby-pass, however the design of the system shouldbe such that it prevents boiler ‘cycling’.

3.6.3 DRAIN COCKSThese must be located in accessible positions tofacilitate draining of the appliance and all waterpipes connected to the appliance. The drain cocksmust be manufactured in accordance with BS 2879.

3.6.4 AIR RELEASE POINTSThese must be positioned at the highest points inthe system where air is likely to be trapped. Theyshould be used to expel trapped air and allowcomplete filling of the system.

3.6.5 EXPANSION VESSELThe appliance has an integral expansion vessel toaccommodate the increased volume of water whenthe system is heated. It can accept up to 8 litres ofexpansion from within the system, generally this issufficient, however if the system has an unusuallyhigh water content, it may be necessary to provideadditional expansion capacity (see 6.19).

7SABRE

3.8 SHOWERSIf the appliance is intended for use with a shower,the shower must be thermostatically controlledand be suitable for use with a combination boiler.

3.9 MOUNTING ON A COMBUSTIBLE SURFACEIf the appliance is to be fitted on a wall of combus-tible material, a sheet of fireproof material mustprotect the wall.

3.10 TIMBER FRAMED BUILDINGSIf the appliance is to be fitted in a timber framedbuilding, it should be fitted in accordance with theInstitute of Gas Engineers publication (IGE/UP/7)‘Guide for Gas Installations in Timber FrameBuildings’.

3.11 I NHIBITORSWe recommend that a neutral inhibitor is used toprotect the heating system from the effects ofcorrosion and/or electrolytic action. The inhibitormust be administered in strict accordance with themanutfacturers* instructions. *Fernox and Sentinel manufacture products thathave proved suitable for use with this appliance.We cannot comment on the suitability of any othersuch product with our appliances.

SECTION 3A GENERAL REQUIREMENTS (EIRE)

This appliance must be installed by a competent person inaccordance with and defined by, the Standard Specifica-tion (Domestic Gas Installations) Declaration (I.S. 813).

3A.1 RELATED DOCUMENTSThe installation of this boiler must be in accord-ance with the relevant requirements of the localbuilding regulations, the current ETCI NationalRules for Electrical Installations, and the bylawsof the local water undertaking.It should be in accordance also with any relevantrequirements of the local and/or district authority.

3A.2 LOCATION OF APPLIANCEThe appliance may be installed in any room orinternal space, although particular attention isdrawn to the requirements of the current ETCINational Rules for Electrical Installations, and I.S.813, Annex K.When an appliance is installed in a room or internalspace containing a bath or shower, the applianceor any control pertaining to it must not be withinreach of a person using the bath or shower.The location chosen for the appliance must permitthe provision of a safe and satisfactory flue andtermination. The location must also permit anadequate air supply for combustion purposes andan adequate space for servicing and air circulationaround the appliance. Where the installation of theappliance will be in an unusual location specialprocedures may be necessary, refer to I.S. 813 fordetailed guidance on this aspect.A compartment used to enclose the appliancemust be designed and constructed specifically forthis purpose. An existing compartment/cupboardmay be utilised provided that it is modified to suit.

This appliance is not suitable for external installa-tion.

3A.3 GAS SUPPLYThe gas meter – as supplied by the gas supplier –must be checked to ensure that it is of adequatesize to deal with the maximum rated input of all theappliances that it serves. Installation pipes mustbe fitted in accordance with I.S. 813.Pipe work from the meter to the appliance mustbe of adequate size. Pipes of a smaller size thanthe appliance gas inlet connection must not beused. The installation must be tested for sound-ness in accordance with I.S. 813.If the gas supply serves more than one appliance,it must be ensured that an adequate supply ismaintained to each appliance when they are inuse at the same time.

3A.4 FLUE SYSTEMThe terminal should be located where the disper-sal of combustion products is not impeded andwith due regard for the damage and discolorationthat may occur to building products located nearby.The terminal must not be located in a place whereit is likely to cause a nuisance (see I.S. 813).In cold and/or humid weather, water vapour maycondense on leaving the terminal; the effect ofsuch pluming must be considered.If installed less than 2m above a pavement orplatform to which people have access (includingbalconies or flat roofs) the terminal must beprotected by a guard of durable material. Theguard must be fitted centrally over the terminal.Refer to I.S. 813, when the terminal is 0.5 metres(or less) below plastic guttering or 1 metre (or less)below painted eaves.

Fig. 6

8 SABRE

highest point in the system and at least 5 metresabove the boiler (see fig. 5).The cold feed from the make-up vessel or tankmust be fitted with an approved non-return valveand stopcock for isolation purposes. The feedpipe should be connected to the return pipe asclose to the boiler as possible.

3A.6.8 FREQUENT FILLINGFrequent filling or venting of the system may beindicative of a leak. Care should be taken duringthe installation of the appliance to ensure allaspects of the system are capable of withstandingpressures up to at least 3 bar.

3A.7 ELECTRICAL SUPPLYThe appliance is supplied for operation on 230V @50Hz electrical supply; it must be protected with a3-amp fuse. The method of connection to themains electricity supply must allow for completeisolation from the supply. The preferred method isby using a double-pole switch with a contactseparation of at least 3mm. The switch must onlysupply the appliance and its corresponding con-trols, i.e. time clock, room thermostat, etc.

3A.8 SHOWERSIf the appliance is intended for use with a shower,the shower must be thermostatically controlledand be suitable for use with a combination boiler.

3A.9 MOUNTING ON A COMBUSTIBLE SURFACEIf the appliance is to be fitted on a wall of combus-tible material, a sheet of fireproof material mustprotect the wall.

3A.10 TIMBER FRAMED BUILDINGSIf the appliance is to be fitted in a timber framedbuilding, it should be fitted in accordance with I.S.813 and local Building Regulations.

The Institute of Gas Engineers publication (IGE/UP/7) ‘Guide for Gas Installations in Timber FrameBuildings’ gives specific advice on this type ofinstallation.

3A.11 INHIBITORSWe recommend that a neutral inhibitor is used toprotect the heating system from the effects ofcorrosion and/or electrolytic action. The inhibitormust be administered in strict accordance with themanufacturers* instructions.

*Fernox and Sentinel manufacture products thathave proved suitable for use with this appliance.We cannot comment on the suitability of any othersuch product with our appliances.

3A.12 DECLARATION OF CONFORMITYA Declaration of Conformity (as defined in I.S.813) must be provided on completion of the in-stallation.A copy of the declaration must be given to theresponsible person and also to the gas supplier ifrequired.

3A.5 AIR SUPPLYThe following notes are intended for general guid-ance only.This appliance is a room-sealed, fan-flued boiler,consequently it does not require a permanent airvent for combustion air supply.When installed in a cupboard or compartment,ventilation for cooling purposes is also not re-quired.

3A.6 WATER CIRCULATIONSpecific recommendations are given in I.S. 813.The following notes are for general guidance only.

3A.6.1 PIPEWORKIt is recommended that copper tubing be used inconjunction with soldered capillary joints.Where possible pipes should have a gradient toensure air is carried naturally to air release pointsand that water flows naturally to drain cocks.Except where providing useful heat, pipes shouldbe insulated to avoid heat loss and in particular toavoid the possibility of freezing. Particular atten-tion should be paid to pipes passing throughventilated areas such as under floors, loft space,and void areas.

3A.6.2 AUTOMATIC BY-PASSThe appliance has a built-in automatic by-pass,consequently there is no requirement for an exter-nal by-pass, however the design of the systemshould be such that it prevents boiler ‘cycling’.

3A.6.3 DRAIN COCKSThese must be located in accessible positions tofacilitate draining of the appliance and all waterpipes connected to the appliance.

3A.6.4 AIR RELEASE POINTSThese must be positioned at the highest points inthe system where air is likely to be trapped. Theyshould be used to expel trapped air and allowcomplete filling of the system.

3A.6.5 EXPANSION VESSELThe appliance has an integral expansion vessel toaccommodate the increased volume of waterwhen the system is heated. It can accept up to 8litres of expansion from within the system, gener-ally this is sufficient, however if the system has anunusually high water content, it may be necessaryto provide additional expansion capacity (see6.19).

3A.6.6 FILLING POINTA method for initial filling of the system andreplacing water lost during servicing etc. has beenprovided. You should ensure this method of fillingcomplies with the local water authority regula-tions.

3A.6.7 LOW PRESSURE SEALED SYSTEMAn alternative method of filling the system wouldbe from an independent make-up vessel or tankmounted in a position at least 1 metre above the

9SABRE

SECTION 4 INSTALLATION

4.1 DELIVERYThe appliance is delivered in a heavy-duty card-board carton. Lay the carton on the floor with thewriting the correct way up.

4.2 CONTENTSContained within the carton is:● the boiler● the wall mounting bracket● an accessories pack containing service valves

and sealing washers● the instructions pack containing installation &

servicing instructions, appliance logbook, userinstructions, guarantee registration card, 3 ampfuse and flue restrictor ring.

4.3 UNPACKINGAt the top of the carton pull both sides open – donot use a knife – unfold the rest of the carton fromaround the appliance, carefully remove all protec-tive packaging from the appliance, and lay theaccessories etc. to one side. Protective glovesshould be used to lift the appliance, the applianceback-frame should be used for lifting points.

4.4 PREPARATION FOR MOUNTING THE APPLI-ANCEThe appliance should be mounted on a smooth,non-combustible, vertical surface, which must becapable of supporting the full weight of the appli-ance. Care should be exercised when determiningthe position of the appliance with respect to hiddenobstructions such as pipes, cables, etc.When the position of the appliance has beendecided – using the template supplied – carefullymark the position of the wall bracket (fig. 6) andflue-hole (if applicable).

4.4.1 IMPORTANTPlease read these instructions carefully toensure correct and safe operation of the appli-ance

4.4.2 FLUE RESTRICTOR RINGTo ensure maximum efficiency and correct op-eration of the appliance, it may be necessary tofit one of the supplied flue restrictor rings to theappliance flue outlet (see tables below).

Sabre 24Total flue length Restrictor requiredLess than 1 metre 42mm diameterLess than 2 metres 44mm diameterLess than 3 metres 46mm diameterLess than 4.25 metres Not required

Sabre 28Total flue length Restrictor requiredLess than 0.75 metre 45mm diameterLess than 1.70 metres 47mm diameterLess than 2.70 metres 49mm diameterLess than 3.40 metres Not required

4.5 FITTING THE FLUEThe top flue outlet permits the appliance to beused for horizontal or vertical – concentric –applications without having to carry out any con-version of the appliance.

4.5.1 CONCENTRIC HORIZONTAL FLUEThe appliance flue outlet can be rotated through360 on its vertical axis. In addition the flue maybe extended from the outlet bend in the horizontalplane (see 2.9). However if additional bends areused, a reduction must be made to the maximumlength (see table).

Reduction for additional bends Bend Reduction in maximum flue length for each bend

45º bend 0.5 metre

90º bend 0.85 metre

Using the template provided, mark and drill a105mm hole for the passage of the flue pipe. Thehole should have a 1º drop from the boiler to out-side, to eliminate the possibility of rainwater en-tering the appliance via the flue.

The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropriatetype and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.

Horizontal flue terminals and accessories

Part No. Description Min-Max Length

2359029 Standardl flue kitFor use with add. Bends 833 mm& extensions (dimension ‘X’)

2359119 Telescopic flue kit. For usewith add. Bends and extensions

2359069 750 mm extension 750 mm2359079 1500 mm extension 1500 mm2359089 Telescopic extention 350-490 mm2359049 45º bend (pair) N/A2359059 90º bend N/A0225760 Wall bracket (5) N/A

Fig. 7

Dimension “Y”

Dimension “X”

135 mm7,5

110

10 SABRE

4.5.1.1 FITTING THE HORIZONTAL FLUE KIT (see4.5.1)Carefully measure the distance from the centreof the appliance flue outlet to the face of the out-side wall (dimension ‘X’ see fig. 7). Ensure theinner (60mm) pipe is fully inserted into the outer(100mm) pipe (when the inner pipe is fully inserted,it stands proud of the outer pipe by 7.5mm). Add32mm to dimension ‘X’ to give the overall fluelength (dimension ‘Y’).NOTEThe standard horizontal flue kit (part no. 2359029)is suitable for a distance (dimension ‘Y’) of up to865mm.The telescopic flue kit (part no. 2359119) is suit-able for a distance (dimension ’Y’) of up to 600mm.Dimension ‘Y’ is measured from the end of theterminal to the end of the outer (100mm) pipe.The internal trim should be fitted to the flue pipebefore connection of the 90º bend.

If the horizontal flue kit (2359029) requires to becut to the correct size (dimension ‘Y’), you mustensure that the inner (60mm) pipe stands proud ofthe outer (100mm) pipe by 7.5mm (see fig. 8).Ensure any burrs are filed or removed and that anyseals are located properly before assembly.

The telescopic flue terminal should be adjusted tothe appropriate length and then fixed using thesecuring screw supplied.

4.5.1.2 STANDARD FLUE KIT (2359029)Hold the inner (60mm) pipe of the terminal assem-bly and connect to the push-fit end of the 90º bend(supplied) using a twisting action. Insert theassembled flue into the previously drilled hole.Using the clips & screws supplied, connect theflue assembly to the boiler, ensuring that theterminal protrudes past the finished outside wallby the correct length (135mm).

4.5.1.3 TELESCOPIC FLUE KIT (2359119)Connect the 60mm push-fit connection of the fluebend (supplied) to the telescopic flue assemblyusing a twisting action. Insert the assembled flueinto the previously drilled hole. Using the clips &screws supplied, connect the flue assembly to theboiler, ensuring that the terminal protrudes pastthe finished outside wall by the correct length(135mm).

You must ensure that the entire flue system isproperly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that provides satisfac-tory weatherproofing. The exterior trim can nowbe fitted.

4.5.1.4 EXTENDING THE HORIZONTAL FLUEThe horizontal flue system can be extended usingbends and/or extensions (see 4.5.1).Connect the bend – supplied with the terminal kit– to the top of the boiler using the clips, screws, &gaskets supplied. The additional bends & exten-sions have an internal push-fit connection, careshould be taken to ensure that the correct seal ismade when assembling the flue system. Connectthe required number of flue extensions or bends(up to the maximum equivalent flue length) to theflue terminal using the clips, screws, & gasketssupplied (see fig. 8 & 8A). The interior trim shouldbe fitted at this point.

NOTEWhen cutting an extension to the required length,you must ensure that the excess is cut from theplain end of the extension, and that the inner(60mm) pipe is 7.5mm longer than outer (100mm)pipe (see fig. 8 & 8A). Remove any burrs, andcheck that any seals are located properly.

You must ensure that the entire flue system isproperly supported and connected.Seal the flue assembly to the wall using cementor a suitable alternative that will provide satisfac-tory weatherproofing. The exterior trim can now befitted.

4.5.2 CONCENTRIC VERTICAL FLUEThe vertical flue terminal can be connected di-rectly to the appliance flue outlet. Alternatively, anextension or bend can be connected to the appli-ance flue outlet if desired (see 2.9), however ifadditional bends are fitted, a reduction must bemade to the maximum flue length (see table).

Fig. 8a

Fig. 8

Boiler

Push-fit connection

Extension

7,5 mmOuter 100 mmclip

Inner 60 mmclip

11SABRE

Fig. 9

465 mm

300 mmmin.

150 mm

Bend Reduction in maximum flue length for each bend

45° bend 0.5 metre

90° bend 1.0 metre

Part No. Description Length

2359039 Vertical flue terminal 1.0 metre0225770 Pitched roof flashing plate N/A0225765 Flat roof flashing plate N/A2359069 750 mm extension 750 mm2359079 1500 mm extension 1500 mm2359049 45º bend (pair) N/A2359059 90º bend N/A0225760 Wall bracket (5) N/A

Vertical flue terminal and accessories

Using the dimensions given in fig. 9 as a reference,mark and cut a 105mm hole in the ceiling and/orroof.Fit the appropriate flashing plate to the roof andinsert the vertical flue terminal through the flashingplate from the outside, ensuring that the collar onthe flue terminal fits over the flashing.The fixing holes for the wall-mounting bracketshould now be drilled and plugged, an appropriatetype and quantity of fixing should be used toensure that the bracket is mounted securely.Once the bracket has been secured to the wall,mount the appliance onto the bracket.

IMPORTANTThe vertical flue terminal is 1.0 metre in lengthand cannot be cut; therefore it may be necessaryto adjust the height of the appliance to suit or usea suitable extension.Connect the vertical flue assembly to the boilerflue spigot using the 60mm & 100mm clips,gaskets, & screws (supplied), ensuring the cor-rect seal is made. The flue support bracket(supplied with the vertical flue kit) can now befitted.

If the vertical flue requires extension/s oradditional bend/s, connect the requirednumber of flue extensions or bends (up to themaximum equivalent flue length) betweenthe boiler and vertical flue assembly (see fig.8).

NOTEWhen cutting an extension to the requiredlength, you must ensure that the excess iscut from the plain end of the extension andthat the inner (60mm) pipe is 7.5mm longerthan outer (100mm) pipe (see fig. 8). Re-move any burrs, and check that any sealsare located properly.

You must ensure that the entire flue systemis properly supported and connected.

4.6 CONNECTING THE GAS AND WATERThe appliance is supplied with an accesso-ries pack that contains large and small seal-ing washers, service valves, and pipe con-nections.The service valves are of the compressiontype, the pipe connections have plain copperends. When connecting pipework to thevalves or connections, tighten the compres-sion end first, then insert the sealing washersbefore tightening the valve or connection tothe appliance. It will be necessary to hold thevalve or connection with one spanner whilsttightening with another.

4.6.1 GAS (fig. 6)The appliance is supplied with a 15 mmservice valve, connect a 15 mm pipe to theinlet of the valve, and tighten both nuts.

NOTEIt will be necessary to calculate the diameterof the gas pipe to ensure the appliance hasan adequate supply of gas.

4.6.2 FLOW & RETURN (fig. 6)The appliance is supplied with 22 mm servicevalves for the heating connections, connect22 mm pipe to the inlet of each valve andtighten both nuts.

4.6.3 SAFETY VALVE (fig. 6)The appliance is supplied with a 15 mmcompression coupling. Connect a 15 mmpipe to the coupling and tighten. It may benecessary to fit a non-return valve if theinstallation is subject to mains knock, inorder to eliminate false activation of thedomestic hot water flow switch.

4.6.4 COLD WATER INLET (fig. 6)The appliance is supplied with a 15mm stop-cock, connect a 15mm service pipe to theinlet of the service valve and tighten bothnuts. It may be necessary to fit a pressurereducing valve if the installation is subjecthigh-pressure fluctuations or high pressuresurges.

12 SABRE

Fig. 11

4.6.5 HOT WATER OUTLET (fig. 6)The appliance is supplied with a 15 mm copper tail,connect a 15 mm pipe and suitable coupling to thetail and tighten. The discharge pipe must have acontinuos fall away from the boiler to outside andallow any water to drain away thereby eliminatingthe possibility of freezing. The discharge pipemust terminate in a position where any water –possibly boiling – discharges safely without caus-ing damage or injury, but is still visible.

4.7 ELECTRICAL CONNECTIONSThe electrical supply must be as specified in 3.7/3.7a. The appliance is supplied, pre-wired with a1-metre length of flex. Should the supplied flex beunsuitable or insufficient see 4.8.3. other wiseconnect the wires as follows:●●●●● Connect the Brown wire to the L (Live) terminal

of the plug or fused isolator.●●●●● Connect the Blue wire to the N (Neutral) terminal

of the plug or fused isolator.●●●●● Connect the Green/Yellow wire to the E (Earth)

terminal of the plug or isolator.●●●●● Ensure the plug or fused isolator is fitted with a

3AMP fuse.If this method of connection is unsuitable, pleaserefer to section 4.7.3 and section 8. A qualifiedelectrician should connect the electrical supply tothe appliance. The electrical supply must be asspecified in Section 3.7/3.7a. A qualified electri-cian should connect the electrical supply to theappliance. If controls – external to the appliance– are required, a competent person must under-take the design of any external electrical circuits,please refer to Section 8 for detailed instructions.ANY EXTERNAL CONTROL OR WIRING MUSTBE SERVED FROM THE SAME ISOLATOR ASTHAT OF THE APPLIANCE. The supply cablefrom the isolator to the appliance must be 3-coreflexible sized 0.75mm to BS 6500. Wiring to theappliance must be rated for operation in contactwith surfaces up to 90ºC.

4.7.1 CASING REMOVALTo gain access to the appliance electrical connec-tions you must first remove the casing, proceed asfollows:●●●●● Locate and remove the 3 screws that secure the

outer casing to the appliance (see fig 10).●●●●● Gently pull one side of the casing then the other

to disengage it from the retaining clips.●●●●● Lift the casing upward to disengage it from the

top locating hooks and then remove.●●●●● Store the casing and screws safely until re-

quired. Re-fit in the reverse order.

Control panel screws and casing screws

Fig. 10

4.7.3 CONNECTING THE MAINS (230V) INPUT(see fig. 12)Remove the control PCB cover as described in4.7.2. Disconnect, remove, and discard thesupplied flex. Pass the (new) supply cable throughthe cable anchorage (see fig.10). Connect thesupply cable wires (earth, live, and neutral) to theircorresponding terminals on the terminal strip (seefig 12). Ensure that the EARTH wire is left slightlylonger that the others, this will prevent strain onthe Earth wire should the cable become taut.

Fig. 12

Do not interfere with any other wiring (fig 12)unless additional external controls are to be fitted(see section 8). Re-fit the electrical input boardcover.The securing screw on the cable anchorageshould now be tightened. This must be donebefore the control fascia is re-fitted in the uprightposition. The appliance casing and screws cannow be re-fitted.

4.7.2 ELECTRICAL CONNECTIONThe appliance terminal strip is located behind thecontrol fascia (see fig. 11). Locate and remove the4 screws securing the control PCB cover.NOTEThe appliance comes with a factory fitted link toallow basic operation of the boiler via the built-inclock. If it is anticipated that external controls willbe required please refer to the wiring diagrams insection 8 for more detailed information.

13SABRE

5.1 GAS SUPPLY INSTALLATIONInspect the entire installation including the gasmeter, test for soundness and purge.

5.2 THE HEATING SYSTEMThe appliance contains components that maybecome damaged or rendered inoperable by oilsand/or debris that are residual from the installa-tion of the system, consequently it is essentialthat the appliance is flushed in accordance withthe following instructions.

5.3 INITIAL FILLING OF THE SYSTEMEnsure both flow and return service valves areopen, remove appliance casing as described insection 4.7.1, identify the automatic air releasevalve, and loosen the dust cap by turning capanti-clockwise one full turn. IMPORTANT, THEREARE NO MANUAL AIR RELEASE VALVESLOCATED ON THE APPLIANCE. Ensure allmanual air release valves located on the heatingsystem are closed. Using the method of filling asdescribed in fig. 5, slowly proceed to fill thesystem, as water enters the system the pressuregauge will begin to rise, once the gauge hasreached 1 bar close the filling valve and beginventing all manual air release valves, starting atthe lowest first. It may be necessary to go backand top-up the pressure until the entire systemhas been filled. Inspect the system for watersoundness, rectifying any leaks.

5.4 INITIAL FLUSHINGThe whole of the heating system must be flushedboth cold and hot as detailed in section 5.9. openall radiator or heating valves and the appliancecentral heating valves. Drain the boiler and sys-tem from the lowest points. Open the drain valvefull bore to remove any installation debris fromthe boiler prior to lighting. Refill the boiler andheating system as described in section 5.3.

5.5 FILLING THE HOT WATER SYSTEMClose all hot water outlets, turn appliance stop-cock on (anti-clockwise), slowly open each outletuntil all air has been expelled and clear water isdischarged. Check pipe-work etc. for water sound-ness.

5.6 PRE-OPERATION CHECKSBefore attempting the initial lighting of the appliance,the following checks must be carried out:● Ensure all gas service valves from the meter to

the appliance are open and the supply pipe hasbeen properly purged.

SECTION 5 COMMISSIONING

● Ensure the proper electrical checks have beencarried out (section 7.11), particularly continuity,polarity and resistance to earth.

● Ensure the 3-amp fuse – supplied with theappliance – has been fitted.

● Ensure the system has been filled, aired, andthe pressure set to 1bar.

● Ensure the flue has been fitted properly and inaccordance with the instructions.

● Ensure all appliance service valves are open.

5.7 INITIAL LIGHTINGEnsure the electrical supply to the appliance isswitched on. Switch the time clock or programmerto an ‘on’ position and ensure all external controlsare also calling for heat.The appliance will now operate in as described insection 1.2. Should the appliance fail to ignite,refer to section 5.6 and/or section 7 (fault finding).

5.8 CHECKING BURNER PRESSURESAlthough burner pressures are set at the factory,it is necessary to check them during thecommissioning procedure. Isolate the appliancefrom the electrical supply and remove the casingas described in section 4.7.1.After attaching a manometer to the outlet testpoint of the gas valve (fig. 22), restore the electri-cal supply to the appliance, turn the selector to hotwater only (summer position), and rotate theDHW temperature selector to maximum.

Maximum burner pressureFully open a hot water outlet – preferably the bathtap – and check that reading on the manometercorresponds to the data given in section 2.3.

Minimum burner pressureAfter checking the maximum burner pressure,remove one of the black wires from themodulating coil on the gas valve. The burnerpressure will drop to the minimum setting. Checkthat the reading on the manometer correspondswith the data given in section 2.3.Once the gas pressures have been checked:●●●●● isolate the appliance from the electrical supply●●●●● close the hot water outlet●●●●● remove the manometer from the outlet test

point and tighten the test point screw●●●●● refit the appliance casing.Should either the maximum or minimum burnerpressure require to be adjusted, refer to section7.6 for the correct adjustment procedure.

Fig. 13

Gas pressure adjustmentprotective cover

Maximum pressureadjustment screw (a)

Minimum pressure ad-justment screw (b)

14 SABRE

5.9 FINAL FLUSHING OF THE HEATING SYSTEMThe system shall be flushed in accordance withBS 7593. If a cleanser is to be used, it shall befrom a reputable manufacturer* and shall beadministered in strict accordance with themanufacturers instructions.*Both Sentinel and Fernox manufacture productsthat have proved suitable for use with our appli-ances. We cannot comment on the suitability ofany other such product with our appliances.

5.9.1 INHIBITORSSee section 3 “General requirements”.

5.10 SETTING THE FLOW TEMPERATUREThe heating flow temperature selector can beadjusted from a minimum of 40 °C, to a maximumof 82 °C. In addition, when the selector is rotatedto the Auto position, the appliance willautomatically adjust the outlet flow temperatureto compensate for inclement weather

*When the selector is left within this range, the appliance willautomatically raise the outlet temperature during cold orinclement weather conditions

5.11 SETTING THE SYSTEM DESIGN PRESSUREThe design pressure should be I minimum of 1bar and a maximum of 1.5 bar.The actual reading should ideally be 1 bar plusthe equivalent height in metres to the highestpoint in the system above the base of the appli-ance. (Up to the maximum of 1.5 bar total).N.B. The safety valve is set to lift at 3 bar/ 30m/45psig.To lower the system pressure to the requiredvalue, pull lever on head of safety valve to releasewater until the required figure registers on thepressure gauge (fig.1).

5.12 REGULATING THE CENTRAL HEATING SYS-TEMFully open all radiator and circuit valves and runthe appliance in the central heating mode untilheated water is circulating. If conditions are warmremove any thermostatic valve heads. Adjustradiator return valves and any branch circuitreturn valves until the individual returntemperatures are correct and are approximatelyequal.

5.13 REGULATING THE DOMESTIC HOT WATERThe appliance is supplied with a built-in flowrestrictor that limits the amount of water passingthrough the heat exchanger, thereby ensuring areasonable temperature at the outlet.The outlet temperature can also be adjusted viathe DHW temperature selector.If the required outlet temperature cannot beobtained by rotating the DHW temperatureselector to its maximum setting, the adjustablestopcock should be used to limit the available flow

rate at the outlet. Slowly turn the adjustablestopcock clockwise until a satisfactory tempera-ture is obtained.Please note that it’s prudent to set the domestichot water outlet temperature at the lowestacceptable temperature, as higher temperaturescan be realised by reducing the flow rate at theindividual hot water outlets.

NOTEThe appliance will light to provide hot water whenthe domestic hot water flow switch senses a flowrate of 2.0 litres –per minute – or more.

5.14 FINAL CHECKS● ENSURE ALL TEST NIPPLES ON THE

APPLIANCE GAS VALVE ARE TIGHT ANDHAVE BEEN CHECKED FOR SOUNDNESS.

● ENSURE THE APPLIANCE FLUE SYSTEM ISFITTED CORRECTLY AND IS PROPERLYSECURED.

● ENSURE ALL PIPE WORK IS RE-CHECKEDFOR SOUNDNESS.

● RE-FIT APPLIANCE CASING.● COMPLETE APPLIANCE LOGBOOK.

Complete details of the boiler, controls, installation,and commissioning in the logbook supplied withthe boiler. This is an important document, whichmust be correctly completed and handed to theuser. Failure to install and commission theappliance to the manufacturers instructions mayinvalidate the warranty.

5.15 INSTRUCTING THE USERHand over all documentation supplied with thisappliance – including these instructions – andexplain the importance of keeping them in a safeplace.Explain to the user how to isolate the appliancefrom the gas, water, and electricity supplies, andthe locations of all drain points.Show the user how to operate the appliance andShow the user the position of the filling valve andhow to top-up the system pressure correctly, andshow the location of all manual air release points.Explain to the user how to turn off the appliancefor both long and short periods, and advise on thenecessary precautions to prevent frost damage.Explain to the user that for continued safe andefficient operation, the appliance must be servicedannually by a competent person.

Sector Range

Low sectorAuto sectorHigh sector

40° - 50°C55° - 65°C*65° - 82°C

Flow temperature selection

15SABRE

SECTION 6 SERVICING INSTRUCTIONS

6.1 GENERALTo ensure the continued safe and efficientoperation of the appliance, it is recommendedthat it is checked and serviced at regular intervals.

The frequency of servicing will depend upon theparticular installation conditions, but in general,once per year should be adequate.

It is the law that any servicing work is carried outby competent person such as an approved serviceagent, British Gas, or other CORGI registeredpersonnel.

The following instructions apply to the applianceand its controls, but it should be rememberedthat the central heating system will also requireattention from time to time.

Always use genuine spare parts

6.2 ROUTINE ANNUAL SERVICINGCheck the operation of the appliance in both ‘hotwater only’ and ‘heating and hot water’ modes.Ensure the appliance functions as described insection 7. Compare the performance of the appli-ance with its design specification. The cause ofany noticeable deterioration should be identifiedand rectified without delay.Thoroughly inspect the appliance for signs ofdamage or deterioration especially the flue sys-tem and the electrical apparatus.Check and adjust – if necessary – all burnerpressure settings (see section 7.6).Check and adjust – if necessary – the systemdesign pressure (see section 5.11).Carry out an analysis of the flue gases (seesection 7.7), and visually check the condition ofthe entire flue assembly. Compare the resultswith the appliance design specification. Anydeterioration in performance must be identifiedand rectified without delay.Ensure both flue venturis are clean and free fromany debris or obstruction.Ensure both the burner and heat exchanger areclean and free from any debris or obstruction.Inspect all joints for signs of leakage and repair ifnecessary.Refer to the commissioning section and/or re-placement of parts section for detailed instructionif required.

6.3 REPLACEMENT OF COMPONENTSAlthough it is anticipated that this appliance willgive years of reliable, trouble free service, the lifespan of components will be determined by fac-tors such as operating conditions and usage.Should the appliance develop a fault, the faultfinding section will assist in determining whichcomponent is malfunctioning.

6.4 MAIN HEAT EXCHANGER (de-scaling)The main heat exchanger may – when operatingunder certain conditions – become affected byscaling. Evidence of this will be a deterioration of

the hot water performance. The heat exchangercan be de-scaled using a proprietary de-scalantwithout having to remove it from the appliance.However the appliance must be disconnectedfrom the hot and cold service pipes, the de-scalant should be administered with strict adher-ence to the manufacturers instructions. Re-connect the hot and cold services only afterthorough flushing with clean water has takenplace.

6.5 COMPONENT REMOVAL PROCEDURETo remove a component, access to the interior ofthe appliance is essential. Isolate the appliancefrom the electrical supply and remove the fuse.And when necessary, close all service valves onthe appliance, remove the appliance casing asdescribed in section 4.7.1, drain the primarywater content from the appliance via the safetyvalve, and drain off secondary water content fromthe appliance via a hot water outlet. Ensure somewater absorbent cloths are available to catch anyresidual water that may drip from the appliance orremoved component. Undertake a completecommissioning check as detailed in section 5,after replacing any component. ALWAYS TESTFOR GAS SOUNDNESS IF ANY GAS CARRY-ING COMPONENTS HAVE BEEN REMOVEDOR DISTURBED.

6.6 PUMP HEAD fig. 14Carry out component removal procedure as de-scribed in section 6.5.Using a 4 mm Allen key or ‘T’ bar, unscrew andremove the four Allen screws that hold the pumpin position, pull firmly on the pump head to releaseit from the base. Disconnect the electrical leads.Replace in the reverse order.

6.7 SAFETY VALVE fig. 14Carry out component removal procedure as de-scribed in 6.5.Disconnect the outlet pipe from the safety valve,unscrew and remove the hex bush from thesafety valve outlet, remove safety valve lockingpin from appliance manifold. Replace in thereverse order

Fig. 14

Pump

Safety valve

16 SABRE

Fig. 17

Fig. 18

6.8 AUTOMATIC AIR RELEASE VALVE (AAV, fig.15)Carry out component removal procedure as de-scribed in 6.5.Remove the locking pins at the pump outlet, andthe flow & return connection of the heat ex-changer, disconnect both pipes from the heatexchanger, and remove the return pipe from thepump outlet. Remove the locking pin and expan-sion pipe from the pump base. Using a suitablepair of pliers, unscrew the AAV from the pumpbase. Replace in the reverse order.

6.9 WATER PRESSURE SWITCH fig. 16Carry out component removal procedure as de-scribed in 6.5.Remove locking pin from heating flow pipe at theheating manifold and withdraw the pipe from themanifold. Remove locking pin and the waterpressure switch from the heating manifold, pullback protective cover – and after taking note ofthe electrical connections – disconnect the wir-ing. Replace in the reverse order.

6.10 DOMESTIC WATER FLOW SWITCH fig. 17Carry out component removal procedure as de-scribed in 6.5.Remove black electrical plug from the domesticwater flow switch, disconnect and remove inletpipe between the domestic water flow switch andthe heat exchanger, remove locking pin from thedomestic water flow switch, the switch can now beremoved from the appliance. Replace in the re-verse order.

Fig. 15

AAV

Fig. 16

WATER PRESSURESWITCH

6.11 PRESSURE GAUGE (fig. 1)Carry out component removal procedure as de-scribed in 6.5.Remove pressure gauge locking pin, located onpump base, and withdraw the pressure gaugepipe, locate the spring tabs on the pressure gaugebody, push and hold tabs in, to enable extractionof the gauge from its location. Replace in thereverse order.

6.12 PRIMARY AND SECONDARY THERMISTORS(fig. 18-19)Carry out component removal procedure as de-scribed in 6.5.Pull back protective rubber cover from the ther-mistor, disconnect thermistor electrical plug, us-ing a 13 mm spanner slacken and remove thethermistor and sealing washer. Replace in thereverse order.

6.13 HIGH LIMIT THERMOSTAT fig. 18Carry out component removal procedure as de-scribed in 6.5.Pull off electrical plug from the high limit thermo-stat, slacken and remove retaining screws. Re-place in reverse order.

primary thermistor

high limit thermostat

Fig. 19secondary thermistor

17SABRE

6.14 PRINTED CIRCUIT BOARD (PCB, fig. 20)Carry out component removal procedure as de-scribed in section 6.5.Remove the PCB cover, after carefully takingnote off all wiring connections, disconnect allwiring from the PCB, locate and remove the PCBsecuring screws, remove PCB. Replace in thereverse order.

6.15 INTEGRAL TIME SWITCH (fig. 21)Carry out component removal procedure as de-scribed in 6.5.Remove the PCB cover, locate and remove thetime clock retaining screws, remove time clockafter carefully taking note off all wiring connec-tions. Replace in the reverse order.

6.16 GAS VALVE fig. 22Carry out component removal procedure as de-scribed in section 6.5.The gas valve must be changed as complete unit.Disconnect both electrical plugs from the gasvalve, disconnect silicone tube from gas valveregulator, slacken and unscrew gas valve inletand outlet connections, please note, the sealingwashers must be discarded and replaced withnew sealing washers, locate and remove gasvalve retaining screws on the underside of theboiler, the gas valve can now be removed. Replacein the reverse order. Check and adjust burnerpressure settings. WARNING, A GAS SOUND-NESS CHECK MUST BE CARRIED OUT.

Fig. 20

6.17 BURNER, INJECTORS AND SPARK/SENSEELECTRODE (fig. 23 & 24)Carry out component removal procedure as de-scribed in 6.5.Remove outer combustion cover by un-clippingthe two retaining clips located at the base of thecombustion cover, gently pull the cover towardsyou before lifting and disengaging it from the topretaining lugs. Locate and remove the two screwsat the base of the inner combustion cover, pull thecover towards you before lifting and disengagingit from the top retaining lugs.Disconnect both the electrode lead from its con-nector at the top of the control fascia, and theelectrode earth lead from the spade connector onthe appliance frame. Locate and remove the fourscrews which secure the burner in position, gen-tly ease the burner out of its location whilst alsoeasing the electrode sealing grommet from itslocation.Once the burner has been removed, locate theburner injectors – located to the rear of thecombustion chamber – and remove. Replace inthe reverse order. Please note, the injector sealingwashers must be replaced if the injectors havebeen removed, ensure all seals are in good condi-tion, taking care to ensure they are replacedcorrectly.

M

M

CLK-1

CLK-4

Fig. 22

Fig. 21

Fig. 23

Outlettest-point

Inlettest-point

Protectivecap

18 SABRE

Fig. 25

Fig. 26

6.18 FLUE FAN (fig. 24 & 27)Carry out component removal procedure as de-scribed in section 6.5.Remove outer combustion cover by un-clippingthe two retaining clips located at the base of thecombustion cover, gently pull the cover towardsyou before lifting and disengaging it from the topretaining lugs. Disconnect the electrical connec-tions and silicone tubes attached to the fan,noting their positions. Locate and remove thecombustion test point screws and the cross headscrew which retains the combustion analysis testpoint assembly, push the test point into the fanhousing, locate and remove the three screwswhich secure the fan to the flue hood, ease thefan from its location. Replace in the reverseorder. Ensure all seals are in good condition,taking care to ensure they are replaced correctly.

6.19 HEAT EXCHANGER fig. 25& 27Carry out component removal procedure as de-scribed in 6.5. Remove outer combustion coverby un-clipping the two retaining clips located atthe base of the combustion cover, gently pull thecover towards you before lifting and disengagingit from the top retaining lugs. Locate and removethe two screws at the base of the inner combustioncover, pull the cover towards you before liftingand disengaging it from the top retaining lugs.Remove locking pins and disconnect the hoses,from the flow and return connections on the heatexchanger. Disconnect the hot and cold connec-tions on the heat exchanger. Disconnect theelectrical plugs from the primary thermistor andhigh limit thermostat at the heat exchanger, theheat exchanger can now be withdrawn from theappliance. Replace in the reverse order. Ensureall seals are in good condition, taking care toensure they are replaced correctly.

6.20 AIR PRESSURE SWITCH (fig. 1, 27)Carry out component removal procedure as de-scribed in section 6.5.Remove outer combustion cover by un-clipping thetwo retaining clips located at the base of thecombustion cover, gently pull the cover towardsyou before lifting and disengaging it from the topretaining lugs. Locate and remove the two screwsholding the air pressure switch to the combustionchamber. Disconnect the electrical connectionsand silicone tubes attached to the air pressureswitch, noting their positions. Take-away the wiresbelt. Replace in the reverse order. Replace with anew belt. Ensure all seals are in good condition,taking care to ensure they are replaced correctly.

6.21 EXPANSION VESSELDue to the compact design of this appliance,removal and/or replacement of the expansionvessel requires the appliance to be removed fromthe wall, if this is deemed impractical, an externalexpansion vessel may be fitted to the return pipeas close to the appliance as possible.

6.22 EXPANSION VESSEL (removal) fig. 1Carry out component removal procedure as de-scribed in 6.5.Isolate gas, water and electrical supplies from theappliance. Disconnect and remove the electricalsupply cable from the appliance. Disconnect allservice valves and connections from the appli-ance. Disconnect the flue from the appliance.The appliance can now be lifted from its mountingbracket. Lay the appliance on its side and discon-nect the expansion pipe from the vessel, slackenand remove the locknut that secures the lowerpart of the vessel to the appliance frame. Locateand remove the six screws that secure the vesseltop holding plate, remove the plate. The expan-sion vessel can now be removed. Replace in thereverse order. Ensure all seals are in good con-dition, taking care to ensure they are replacedcorrectly. GAS AND WATER SOUNDNESSCHECKS MUST BE CARRIED OUT.

Fig. 27

Fig. 24

19SABRE

7.1 CHECKING APPLIANCE OPERATIONWhen carrying out any repairs or servicing to theappliance the relevant commissioning proceduremust be undertaken to ensure the continued safeoperation of the appliance. Particular attentionshould be made to ensure gas soundness, watersoundness, and the electrical integrity of theappliance.

7.2 AT REST MODEWhen the appliance is at rest, (no demand forheat or water) the green LED will be illuminatedto indicate there are no faults, if the appliance hasbeen inactive for aproximately 24 hours, it willenergise the pump for a short period to ensurethe pump does not seize due to inactivity. Theappliance also has built-in frost protection, whichwill operate even if the mode selector switch is inthe ‘off’ position.

7.3 HOT WATER MODEOpening a hot water outlet and enabling a flowrate of 2 litres or more, causes the domestic waterflow switch to activate. Activation of the domestichot water flow switch allows the fan to run. Whenthe fan is running it proves (switches) the airpressure switch. The air pressure switch deliverscurrent to the PCB and enables an ignition se-quence to begin. The ignition sequence beginswith the energising of the gas valve and a simul-taneous sparking at the spark/sense electrode.This will continue for aproximately 10 seconds oruntil successful ignition has been established. (Ifno ignition has been established within the tenseconds, the ignition attempt will be terminatedand the appliance will go to lockout). When ignitionhas been established, the appliance will quicklyachieve and maintain the desired hot water tem-perature (see 5.13). The appliance monitors thesetting of the hot water potentiometer against thetemperature of the secondary thermistor, andincreases or decreases current to the modulatingcoil, this in turn adjusts the burner pressure, thusenabling the temperature to be maintained towithin a few degrees. When the temperature ofthe secondary thermistor exceeds the setting ofthe hot water potentiometer, ignition will be termi-nated until the temperature drops.NOTEThe primary thermistor will overide the secondarythermistor if the temperature of the primarythermistor exceeds 80 ºC.When the mode selector switch is set to heatingand hot water, the pump will over-run for 30seconds after any demand for heating or waterhas been satisfied.When the mode selector switch is set to hot wateronly, the fan will over-run for one minute if thetemperature of the primary thermistor exceeds55 ºC.

7.4 HEATING MODEWith all controls calling for heat, the pump and fanwill run. When the fan runs it proves the air

SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING

pressure switch. The air pressure switch deliverscurrent to the PCB and enables an ignitionsequence to begin. The ignition sequence beginswith the energising of the gas valve and asimultaneous sparking at the spark/senseelectrode. This will continue for approximately 10seconds or until successful ignition has beenestablished. (If no ignition has been establishedwithin the ten seconds, the ignition attempt will beterminated and the appliance will go to lockout).The appliance monitors the setting of the heatingpotentiometer against the temperature of theprimary thermistor, and increases or decreasescurrent to the modulating coil, this in turn adjuststhe burner pressure, thus enabling thetemperature to be maintained to within a fewdegrees (see section 5.10). When the temperatureof the primary thermistor exceeds the setting ofthe heating potentiometer, ignition will beterminated and the appliance will anti-cycle forthree minutes (timer delay). When a new ignitionsequence begins the output of the appliance isset at minimum for two minutes.NOTEAny demand for hot water has the priority.If there is a demand for hot water whilst theappliance is anti-cycling, the timing will be can-celled once the demand for hot water has beensatisfied.

7.5 FROST PROTECTION MODEThe built-in frost protection system will operatethe appliance in the OFF, HOT WATER ONLYMODE, AND HEATING AND HOT WATERMODE. Should the temperature of the appliancefall to 7 ºC. the pump will run for fifteen minutes, thiswill be repeated every two hours. Should thetemperature rise above 10 ºC. the fifteen minuteswill be cancelled. Should the temperature fall below5 ºC. the boiler will fire at minimum output until thetemperature of the appliance exceeds 30 ºC.NOTEIf the appliance is at lockout the frost protectionmode is disabled.Although the frost protection mode is active evenwhen the appliance is switched off. The electricalsupply to the appliance must be maintained for itto function.Any demand for hot water or heating will resetany frost protection settings.

7.6 BURNER PRESSURE SETTINGSBurner pressure settings should be checked and/or adjusted whenever the appliance is beingserviced, commissioned, or the gas valve/controlPCB have been replaced.The procedure for setting or adjusting must becarried out in the following order:● set the maximum DHW gas pressure●●●●● set the minimum DHW gas pressure●●●●● set the maximum heating gas pressure●●●●● set the minimum heating gas pressure.

20 SABRE

7.6.1 SETTING THE MAXIMUM DHW GAS PRES-SURE (fig. 13 & 22)Isolate the appliance from the electrical supply,remove the appliance casing as described insection 4.7.1.● Attach a manometer to the outlet test point of the

gas valve.●●●●● Remove the protective cover from the gas valve

modulator, and disconnect the compensationtube from the gas valve.

●●●●● Fully open a hot water outlet (preferably the bathtap).

●●●●● Rotate the DHW temperature selector to maxi-mum.

●●●●● Restore the electrical supply to the appliance.●●●●● The appliance will now light and after 7-10

seconds, the burner will be at full power.●●●●● Observe the manometer, the reading for Sabre

24 should be 10.1 mbar, for Sabre 28 the readingshould be 10.2 mbar.

●●●●● If the reading is correct, proceed to section 7.6.2●●●●● If the reading is incorrect, turn the maximum

adjustment screw (fig. 13) clockwise to increasethe pressure, or anti-clockwise to reduce thepressure.

●●●●● Proceed to section 7.6.2

7.6.2 SETTING THE MINIMUM DHW GAS PRES-SURE (fig. 13 & 22)● After carrying out section7.6.1, disconnect one of

the black wires attached to the modulator coil.●●●●● The burner will now operate at minimum power.●●●●● Observe the manometer, the reading for Sabre

24 should be 1.5 mbar, for Sabre 28 the readingshould be 1.3 mbar.

●●●●● If the reading is correct, proceed to section 7.6.3.●●●●● If the reading is incorrect, turn the minimum

adjustment screw (fig. 13) clockwise to increasethe pressure, or anti-clockwise to reduce thepressure.

●●●●● Proceed to section 7.6.3

7.6.3 SETTING THE MAXIMUM AND THE MINIMUMCENTRAL HEATING BURNER PRESSURES● Isolate the appliance from the electrical supply.●●●●● Close the hot water outlet.●●●●● Re-attach the black wire to the modulator coil.●●●●● Remove the PCB cover and temporarily attach

a jumper tag to JP2.●●●●● Rotate the heating temperature selector to maxi-

mum, and ensure all radiators are turned on withany thermostatic radiator valves set to maxi-mum.

●●●●● Restore the electrical supply and ensure there isa call for heat via the appliance time clock and/or room thermostat.

●●●●● The appliance should now be operating in theheating mode at maximum output.

●●●●● Observe the manometer, the – maximum –reading for Sabre 24 should be 10.1 mbar, forSabre 28 the reading should be 10.2 mbar

●●●●● Using a small screwdriver, gently rotate the P5potentiometer if adjustment is necessary.

●●●●● To check and/or adjust the minimum heating

gas pressure, slowly rotate the heating tempera-ture selector until the burner pressure drops tominimum (should be 1.9 mbar).

●●●●● Using a small screwdriver, gently rotate the P4potentiometer if adjustment is necessary.

●●●●● Isolate the appliance from the electrical supply,and remove the jumper tag from JP2.

●●●●● Remove the manometer from the gas valve andtighten the outlet test screw.

●●●●● Refit the PCB cover and appliance casing.

7.7 COMBUSTION ANALYSIS TESTThe appliance has a built-in facility which enablescombustion analysis checks to be carried out. Toactivate the combustion analysis mode, proceedas follows.Locate and remove combustion test point screw,(fig. 1) insert flue gas analyser probe into combus-tion test point, remove mode selector switch androtate selector shaft clockwise until it can go nofurther, wait until the LED begins to flash, turn theselector shaft back to the heating position. Theappliance will now enter its combustion analysismode whereby it will fire at maximum output in theheating mode for fifteen minutes, without modulat-ing until the maximum operating temperature isrealised. To gain accurate information, ensure theflue gas analyser has been set properly, and thatthe analysis is carried out when the appliance is onmaximum output. Once the analysis has beencompleted, re-fit the mode selector switch, re-move the flue gas analyser probe and replace thetest point screw.

7.8 CHECKING THE EXPANSION VESSELCarry out procedure as described in section 6.5.Using a suitable pressure gauge, remove dust capon expansion vessel and check the charge pres-sure. The charge pressure should be between 0.7– 0.8 bar. If the charge pressure is less, use asuitable pump to increase the charge. Pleasenote, you must ensure the safety valve is in theopen position whilst re-charging takes place. Re-place dust cap and carry out the relevant commis-sioning procedures as detailed in section 6.21.

7.9 ELECTRO-MECHANICAL FAULTSBefore carrying out any fault finding or componentreplacement, ensure the fault is not attributable toany aspect of the installation, for example, exter-nal wiring fault, hot & cold services reversed,service valves closed, gas supply turned off, etc.

21SABRE

7.11 ELECTRICAL CHECKSAny electrical checks must be carried out by asuitably qualified person.

7.11.1 EARTH CONTINUITY TESTIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between anappliance earth point and the earth wire of theappliance supply cable. The resistance shouldbe less than 1 ohm. If the resistance is greaterthan 1 ohm check all earth wires and connectorsfor continuity and integrity.

7.11.2 SHORT CIRCUIT CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter, carry out a shortcircuit test between the Live & Neutral connec-tions at the appliance terminal strip (fig. 12).Repeat above test on the Live & Earth connec-tions at the appliance terminal strip (fig. 12).NOTEShould it be found that the fuse has failed but nofault is indicated, a detailed continuity check willbe required to trace the fault. A visual inspectionof components may also assist in locating thefault.

7.11.3 POLARITY CHECKWith the appliance connected to the electricalsupply and using a suitable multimeter, carry outthe following voltage tests. Connect test leadsbetween the Live & Neutral connections at theappliance terminal strip (fig.12); the meter shouldread aproximately 230V ac. If so proceed to nextstage. If not, see section 7.11.4.Connect test leads between the Neutral & Earthconnections at the appliance terminal strip (fig.12);the meter should read aproximately 0 – 15Vac. Ifso polarity is correct. If not, see section 7.11.4

7.11.4 REVERSED POLARITY OR SUPPLY FAULTRepeat the above tests at the appliance isolator,if testing reveals correct polarity and/or supply at

the isolator, re-check wiring and connections be-tween the isolator and the appliance.If tests on the isolator also reveal reversed polarityor a supply fault, consult the local electricitysupplier for advice.

7.11.5 RESISTANCE TO EARTH CHECKIsolate the appliance from the electrical supply,and using a suitable multi-meter carry out aresistance test. Connect test leads between theLive & Earth connections at the appliance terminalstrip (fig.12). If the meter reads other than infinitythere is a fault which must be isolated, carry outa detailed continuity check to identify the locationof the fault.IMPORTANTThese series of checks must be carried outbefore attempting any fault finding procedures onthe appliance. On completion of any task whichrequired the disconnection and re-connection ofany electrical wiring or component, these checksmust be repeated.

7.11.6 FUSESThe appliance is equipped with spare fuses.These fuses are located on the cover of the mainPCB. If a fuse has blown it is usually indicative ofan external wiring fault or a faulty componentsuch as the pump, fan, valve actuator, etc. Underno circumstances should a blown fuse be replacedwith one of a higher rating.

7.12 FAULT FINDINGBEFORE ATTEMPTING ANY FAULTDIAGNOSIS OR REPAIR THE FOLLOWINGPROCEDURE SHOULD BE CARRIED OUT:●●●●● Carry out the relevant electrical checks as

detailed in section 7.11●●●●● Disconnect any external wiring from the room

thermostat connections of the applianceterminal strip and replace with a solid link wire.

●●●●● Ensure the appliance is protected – externally– by a 3 amp fuse.

FAULT POSSIBLE CAUSES REMEDY

APPLIANCE FIRES THEN LOCKOUTS INCORRECT GAS PRESSURE CHECK INCOMING PRESSURE

AND/OR BURNER PRESSURES

FLUE BLOCKED OR BROKEN CHECK FLUE ASSEMBLY

APPLIANCE WON’T FIRE FOR HOT WATER HOT & COLD PIPES REVERSED CHECK EXTERNAL PLUMBING

FLOW REGULATOR BLOCKED REMOVE AND CLEAN

INSUFFICIENT FLOW RATE INCREASE FLOW RATE

APPLIANCE WON’T FIRE FOR HEATING EXTERNAL CONTROL OR

WIRING FAULT CHECK EXTERNAL CONTROLS

OR WIRING

APPLIANCE FIRES FOR HEATING FLOW & RETURN SERVICE

BUT NO CIRCULATION AROUND SYSTEM VALVES CLOSED OPEN SERVICE VALVES

AIR IN APPLIANCE OPEN DUSTCAP ON ‘AAV’

PUMP STUCK OPEN VENT PLUG ON PUMP AND

ROTATE SHAFT

DEBRIS IN SYSTEM FLUSH SYSTEM

APPLIANCE INACTIVE NO ‘LED’s ELECTRICAL SUPPLY FAULT CHECK SUPPLY TO APPLIANCE

SHOWING FOR 240V BETWEEN ‘L’ & ‘N’

BLOWN FUSE CHECK AND REPLACE

7.10 POSSIBLE INSTALLATION FAULTS

22 SABRE

7.12.1 FAULT FINDING TEST ‘A’: CHECKING OPERATION OF ELECTRONIC CONTROL BOARD ATSTART UP

MAINS ON FAN

REPLACE FAN

YES

NO

YES

REPLACE WIRINGOR CONNECTIONS

MAINS ON PUMP

REPLACEPUMP

NO

YES

YES

YESNO

NO

A1

A

CHECK &/ORREPLACE WIRING

ANDCONNECTIONS

MAINS ON FAN

CONNECTOR CN4.1 & CN4.2

ON PCB

MAINS ON PUMP CONNECTOR

CN2.1 & CN2.2ON PCB FAN RUNNING

PUMP RUNNING

GREEN LEDBLINKS

START

NO

NO

YES

REPLACE WIRINGOR CONNECTIONS

AIR FLOW SWITCH

OFF?

REPLACE AIRFLOW SWITCH ORCHECK FLUE GAS

TUBE

YES

REPLACECONTROL BOARD

ISTHERE 0 VCC

BETWEEN TERMINALS CN8.3 & CN8.5

ON PCB

NO

NO

YES

MADE A LINK BETWEEN BLACK &BLACK WIRES AT BOILER

TERMINAL STRIP AND CLOSE THETIMER CONTACT

SWITCH ON BOILER ANDSELECT MODE TO

WINTER C/HTHERMOSTAT AT MAX.

YES

LOOSE THE PUMPACTING WITH A

SCREWDRIVER ONTHE IMPELLER

RESTART THETEST

NO

NO

NO

NO

IS ROOM THERMOSTATINPUT LINKED

MADE A LINKBETWEEN THE ROOMTHERMOSTAT INPUT

CHECK IDRAULICCIRCUIT

WATERPRESSURE SWITCH

IS OK

NO

ISTHERE 24dc

BETWEEN TERMINALS CN8.3 & CN8.5

ON PCB

REPLACECONTROL BOARD

YESIS

THERE 24dc BETWEEN TERMINALS

CN9.1 & CN9.2 ON PCB

CHECK WIRING ANDCONNECTIONS ORWATER PRESSURE

SWITCH

MAINSBETWEEN PIN CN1.4 & CN1.5

ON PCB

REPLACECONTROL BOARD

RESTART THETEST

CHECK WIRING ORCONNECTIONS

BETWEEN TERMINALSTRIP AND CONTROL

BOARD

YES

YES

YES

YES

NO

NO

PUMP RUNNING

YES

23SABRE

7.12.2 FAULT FINDING TEST ‘A’

YES

NO

NO MAINS ON E.V.G.

NO

YES

NO

NO

YES

YES

YES

NO

IS THERE 24 Vdc

BETWEEN TERMINALSCN8.4 & CN8.5

ON PCB

A

REPLACESENSING/SPARKELECTRODE AND

LEADREPLACE PCB

SENSINGSPARK ELECTRODE

AND LEAD OK

CHEKSENSING/SPARKELECTRODE AND

LEAD

END

LOCKOUT

IGNITION

REPLACE EVGCHECK GAS

EVG OK

IGNITION

SPARK ATELECTRODE

CHECK WIRING ANDCONNECTIONS OR

HIGH LIMIT THERMOSTAT

CHECKSENSING/SPARKELECTRODE AND

LEAD

ISTHERE 230 Vac

BETWEEN TERMINALSCN5.1 & CN5.2

ON PCB

ISTHERE 0 Vdc

BETWEEN TERMINALS CN8.7 & CN8.8

ON PCB

NO

YES

NO

CHECK WIRINGAND

CONNECTIONS

NO

DO THEAIR FLOW SWTCH

TURN ON

CHECK WIRING ANDCONNECTIONS, AIR FLOW

SWITCH AND CONTROLBOARD

YES

NO

ARE THEVENTURI TUBE

AND THE SILICONE AIR TUBES

CLEANCHECK/CLEAN THEVENTURI TUBE AND

SILICONE AIRTUBES

ISTHE AIR DP >11 mmCH2O

CHECK THE FANAND/OR FLUE GAS

TUBE

CHECK REPLACEAIR FLOW SWITCH

NO

YES

YES

REPLACE THECONTROL BOARD

YES

NO

NO

IS THERE 230 Vac

BETWEEN TERMINALSCN6.1 & CN6.2

ON PCB

CHECK AND/ORREPLACE PCB

IS THERE 24 Vdc

BETWEEN TERMINALSCN8.4 & CN8.8

ON PCB

CHECK AND/ORREPLACE PCB

IS THERE 24 Vdc

BETWEEN TERMINALSCN8.4 & CN8.7

ON PCB

NO

CHECK WIRING ANDCONNECTIONS OR

HIGH LIMITTHERMOSTAT

NO

YES

YES

YES

AFTER

24 SABRE

7.12.3 FAULT FINDING TEST ‘A1’

NO

YES

A1

REPLACECONTROL BOARD

FUSE OK

CHECK FUSE F1ON CONTROL

BOARD

RED LEDBLINKS

MAINS PRESENT BETWEEN

TERMINALS CN1.2&CN1.3 M2.2 ON

CONTROL

YES

NO

RESTART THETEST

REPLACE FUSE

NO

NO

REPLACE CONTROLBOARD

RED LEDLIGHT

YES

YES

SWITCH ON/OFFSELECTOR ON OFF

POSITION

SWITCH ON/OFFSELECTOR TO

WINTER POSITION

GREEN LEDBLINKS

RESTART THETEST

YES

YES

NO

CHECK CH NTCSENSOR OR WIRINGAND CONNECTIONS

YELLOW LEDLIGHT

NO

CHECK WIRING ANDCONNECTIONS, WATERPRESSURE SWITCH AND

HYDRAULIC CIRCUIT

NO

RECHECK SUPPLYFUSE &

CONNECTORS TOBOILER

TERMINALS

MAINS PRESENT BETWEEN

BLUE & BROWN WIRES ATBOILER TERMINAL

STRIP

NO

REPLACE WIRING ORCONNECTIONS

TERMINAL STRIP ANDCONTROL BOARD

YES

YELLOW LEDBLINKS

CHIMNEYSWEEPER CYCLE.

RESET ANDRESTART TEST

NO

ISTHERE 0 VCC

BETWEEN TERMINALS CN9.1 & CN9.2

ON PCB

ISTHERE 24 Vdc

BETWEEN TERMINALS CN8.4 & CN8.7

ON PCBIS

THERE 24 Vdc BETWEEN TERMINALS

CN8.4 & CN8.8 ON PCB

REPLACECONTROL BOARD

CHECK WIRING ANDCONNECTIONS OR

HIGH LIMIT THERMOSTAT

ISTHERE 24 Vdc

BETWEEN TERMINALS CN8.4 & CN8.6

ON PCB

REPLACECONTROL BOARD

ISTHERE 24 Vdc

BETWEEN TERMINALS CN8.4 & CN8.5

ON PCB

CHECK WIRING ANDCONNECTIONS OR

AIR PRESSURE SWITCHREPLACE

CONTROL BOARD

YES

YES

YES

YES

YES

NO

NO

NO

NO

YES

BOARD

25SABRE

7.12.4 FAULT FINDING TEST ‘B’: CHECK CONTROL IN DHW MODE

NO

NO

NO

NO

NO

YES

YES

YES

ISVOLTAGE

ACROSS TERMINALSOF MODULATOR

COIL >10 VDC

REPLACE WIREAND

CONNECTIONS

REPLACECONTROL BOARD

REPLACEMODULATOR COIL

IS THE RESISTENCE OF

MODULATOR COIL ABOUT 70/80

OHM

ISTHERE A

VOLTAGE >10 VDCBETWEEN TERMINALS

CN9.7 & CN9.8 ON PCB

DOES BURNER LIGHT

CHECK BOILERSTARTUP: TEST A

TURN ON TAP

SWITCH ON BOILER ANDSELECT MODE TO

SUMMER. DHWTHERMOSTAT AT MAX.

START

YES

SWITCH DHWTHERMOSTAT AT MIN.

DO BURNER AND FAN

SWITCH OFF

IS

TEMPERATURE >40 ûC

WAIT D.H.W.TEMPERATURE

>40 ûC

REPLACECONTROL BOARD

YES

NO

YES

NO

ISTHERE 24 Vdc

BETWEEN TERMINALS CN9.7 & CN9.8

ON PCB

REPLACECONTROL

BOARD

YES

CHECK WIRING ANDCONNECTIONS OR

DHW SWITCH

YES

NO

ISTHERE 0 Vdc

BETWEEN TERMINALS CN9.7 & CN9.8

ON PCB

NO

WAIT TILL THEVOLTAGE BETWEEN

TERMINAL CN9.3 & CN9.4 ON PCB IS < 1.2 Vdc

IS THEVOLTAGE BETWEENTERMINAL CN9.3 &CN9.4 ON PCB IS

< 1.2 VdcIS

TEMPERATURE >60 ûC

WAIT D.H.W.TEMPERATURE

>60 ûC

YES

YES

NO

ISD.H.W. NTC

OK

REPLACE D.H.W. NTC

REPLACECONTROL BOARD

YES

B

NO

D.H.W.

D.H.W.

26 SABRE

7.12.5 TEST ‘B’ CONT’D

NO

END

DO BURNER, FAN AND

PUMP SWITCH OFF

TURN OFF TAP

SWITCH DHWTHERMOSTAT AT MAX.

DO BURNER AND FAN

SWITCH ON

IS

TEMPERATURE >60 ûC

WAIT D.H.W.TEMPERATURE

< 60 ûC

REPLACECONTROL BOARD

YES

CHECK WIRING ANDCONNECTION ORCONTROL BOARD

REPLACE DHWFLOW SWITCH

IS DHW FLOW

SWITCH OK

YES

YES

NO

NO

YES

NO

B

D.H.W.

27SABRE

7.12.6 FAULT FINDING TEST ‘C’: CHECK CONTROL IN C/H MODE

NO

YES

NO

YES YES

NO

YES NO

REPLACECONTROL BOARD

REPLACECONTROL BOARD

REMOVE JUMPER

IS TIMER JUMPER

ON

ISVOLTAGE

ACROSS TERMINALS OFMODULATOR COIL

>10 VDC

ISVOLTAGE

ACROSS TERMINALS OFMODULATOR COIL

< 8 VDC

CHECK BOILERSTARTUP TEST A

SET TIMERJUMPER ON

DOES BURNER

LIGHT

MADE A LINK BETWEENBLACK & BLACK WIRES AT

BOILER TERMINALSTRIP AND CLOSE THE

TIMER CONTACT

SWITCH ON BOILERAND SELECT MODE

TO WINTER C/HTHERMOSTAT AT

MAX.

START

RESTART THETEST

NO

NO

YES

REPLACE WIREAND

CONNECTIONS

REPLACECONTROL BOARD

REPLACEMODULATOR COIL

IS THE RESISTENCE OF

MODULATOR COILABOUT 70/80

OHM

ISTHERE A

VOLTAGE <8 VDCBETWEEN TERMINALS

CN9.3 & CN9.4 ON PCB

YESC

ISVOLTAGE

ACROSS TERMINALS OFMODULATOR COIL

>10 VDC

SWITCH CHTHERMOSTAT AT MIN.

NO

YES

NO

WAIT TILL THEVOLTAGE BETWEEN

TERMINAL CN9.3 & CN9.4 ON PCB IS < 1.2 Vdc

IS THEVOLTAGE BETWEENTERMINAL CN9.3 &CN9.4 ON PCB IS

< 1.2 Vdc

IS

TEMPERATURE >80 ûC

WAIT D.H.W.TEMPERATURE

>80 ûC

YES

NO

YES

NO ISC.H. NTC

OK

REPLACE C.H. NTC

REPLACECONTROL BOARD

YES

D.H.W.

28 SABRE

7.12.7 TEST ‘C’ CONT’D

YES

WAIT 3 MIN.

C

NO

DO BURNER AND FAN

SWITCH OFF

ISWATER FLOWTEMPERATURE

>40 ûC

WAIT WATER FLOWTEMPERATURE

>40 ûC

REPLACECONTROL BOARD

SWITCH CHTHERMOSTAT AT MAX.

DO BURNER AND FAN

SWITCH ON

ISWATER FLOWTEMPERATURE

>80 ûC

WAIT WATER FLOWTEMPERATURE

< 80 ûC

NO YES

REPLACECONTROL BOARD

REMOVE JUMPER

IS TIMER JUMPER

ON

RESTART THETEST

DO BURNER AND FAN

SWITCH ON

OPEN THE TIMERCONTACT

REPLACECONTROL BOARD

DO BURNER

AND FAN SWITCH

OFF

DOPUMP SWITCH

OFF

END

REPLACECONTROL BOARD

YES

YES

YES

NO

NO

NO

NO

NO

NO

YES

YES

YES

WAIT30 SECS.

NO

ISC.H. NTC

OK

REPLACE C.H. NTC

REPLACECONTROL BOARD

YES

29SABRE

Fig. 28A

SECTION 8 WIRING DIAGRAMS

8.1 CONNECTION OF A ROOM THERMOSTAT (Fig. 28)

Isolate the appliance from the electrical sup-ply. Remove the appliance casing and PCBcover.

Connect the room thermostat as shown infigure 28. We recommend the use of a “volt-age-free” type room thermostat. Should an-other type of room thermostat be preferred,please contact the technical help-line fordetailed advice and guidance.

8.2 CONNECTION OF AN EXTERNAL TIMECLOCK (Fig. 28A)Should the integral time clock be unsuitable,additional or alternative controls must be con-nected to the appliance terminal strip asshown in Fig. 28 or 28A. The external timeclock or control must be of the “voltage-free”type.

Carry out the electrical checks as describedin 7.11 prior to refitting the PCB cover andappliance casing.

NOTEGuidance on the recommended practice forthe in stallation of external controls, can befound in CHeSS – HC1/HC2 (www.energy-efficiency.gov.uk).

Fig. 28

30 SABRE

FUNCTIONAL DIAGRAM

NOTE: L-N-E CONNECTION IS ADVISABLE

Key

R.T. Room thermostatS.F.S. Domestic hot water flow switchP.S. Pressure switchP.D.S. Differential pressure switchH.L. High limit thermostatS.R. Heat thermistorS.S. Domestic hot water thermistorMOD ModulatorF FanP PumpSP/SE E. Spark\Sense electrodeOPE Gas valve solenoidsB.C.B. Burner control boardCP08X Boiler control boardJP2 Setting timerJP3 Natural gas or L.P.G. selector

JP4 Jumper disable/enable DHW absolut thermostatP1 Domestic hot water temperature controlP2 Central heating temperature control

P3 Off/summer/winter selectorP4-P5 Setting trimmerF External fuse 2 A F (on 230 V circuit)F2 (CP08X) Fuse 2 A F (on 230 V circuit)RL1 Ignition relayRL2 Fun relayRL4 Pump relayTRF1 TrasformerTRX Ignition trasformerACF01X Ignition control boardLED Led OK (green)

Led alarm (red)Combustion test (blink orange)

Fig. 29

31SABRE

NOTE: L-N-E CONNECTION IS ADVISABLE

FUNCTIONAL DIAGRAM

Fig. 30

32 SABRE

SECTION 9 EXPLODED DIAGRAMS

34

270

13

26

20

12

21

27

28

27

226

18

19

76

49

31

226

90

1

300

301

302

POS. DESCRIPTION 24 28

1 Frame assembly 01005282 0100533012 Quick primer pressure gauge 2564 256413 Pin 10023044 1002304418 Cover 10024976 1002497619 Ignition module 10022174 1002217420 Printed Circuit Board 10023537 1002353721 Led Light Guide 10023816 1002381626 Instrumental panel 10025726 1002572627 Knob 10023937 1002393728 Knob 10023936 1002393631 Case 10025728 1002573934 Fixing flange 10025731 1002573149 Converter 10023935 1002393576 Timer 10023938 1002393890 3 A fuse 3478 3478

226 Edge clip 5128 5128270 Transformer 10021272 10021272300 Wiring harnes 10023840 10023840301 Wiring harnes 10023939 10023939302 Wiring harnes 10023940 10023940

33SABRE

POS. DESCRIPTION 24 28

2 Connection 10022658 100226583 Pressure switch 2044 20447 By-pass valve 2047 2047

22 Safety valve 2907 290723 Connection 10022499 1002249924 Flow governor* 8009 9430

8008 800925 Pipe 10020714 1002395026 DHW actuator 10022349 1002234927 Heating cock 1789 178928 Connection 1790 179030 Water supply stop cock 10025733 1002573331 Venting plugs kit 01005137 0100513736 Pipe 10020612 1002394963 Pipe 10020898 10020898

201 Washer 5026 5026285 NTC sensor 8484 8484288 O ring 6898 6898289 Clip 2223 2223290 Clip 2165 2165299 Washer 10022726 10022726300 Clip 2222 2222303 Connection 2217 2217351 Ogive 1823 1823353 Ogive 1824 1824

27

28

35130

27

353

26

3 2

7

288

288

288

300303

289

28922

289

303

289

31

289

290

23

283

201

299

285

36

25

201

353

63

24

* White flow governor 8008 Blue flow governor 8009 Red flow governor 9430

34 SABRE

POS. DESCRIPTION 24 28

1 Expansion vessel 2204 22042 Flexible pipe 2164 21643 Pump 2225 22254 Automatic air vent bottle 0439 04397 Flexible pipe 10022000 100239478 Heat exchanger 10021419 100236619 Flexible pipe 10022002 10023948

12 Washer 2226 2226201 Washer 5026 5026285 NTC sensor 8484 8484287 High limit thermostat 2258 2258289 Clip 2223 2223290 Clip 2165 2165299 Washer 10022726 10022726

1

2

201

7

9

3

12

8

289

290

289

290

285

299

287

4

12

35SABRE

POS. DESCRIPTION 24 28

1 Roomsealed chamber 10024669 100239042 Clip 0402 04023 Main burner injector manifold 10023799 100239024 Burner 10023798 100239015 Spark electrode 10021398 10021398

12 Pipe 10023996 1002399613 Gas valve 10025074 1002507415 Gas cock 10020897 1002089716 Cover assembly 10024779 1002392818 Glass 10021558 1002155827 Air box hole cap 10023805 10023805

200 Washer 5023 5023295 Silicone tube 1457 1457

- LPG conversion kit 01005297 01005297

200

15

13

295

12

200

200

4

5

18

3

1

27

27

2

16

POS. DESCRIPTION 24 28

2 Back insulating panel 2230 100239093 Lateral insulating panel 2231 22314 Front insulating panel 2232 10023910

10 Fan 10020793 1002390712 Connection 10021972 1002197220 Fumes testing connection pipe 10021973 1002197325 Pressure diff. switch 01005272 1002390828 Stop clip 10020626 10020626

212 Screw 5080 5080295 Silicone tube 1457 1457300 Wiring harnes 10024157 10024067

4

212

2

3

12 28

20 295

10

25

3

300

10.1 TECHNICAL DATA

SECTION 10 L.P.G. INSTRUCTIONS

10.3 GAS SUPPLYThe gas supply must be connected to the appli-ance by a competent L.P.G. installer and must beof sufficient size to supply the appliance at itsmaximum output. An existing supply must bechecked to ensure that it is of adequate size todeal with the maximum rated input of this and anyother appliances that it serves.

10.4 GAS SUPPLY INSTALLATIONThe entire installation including the meter, must bepurged and checked for gas soundness.

10.5 BURNER PRESSURESBurner pressure settings should be checked and/or adjusted whenever the appliance is being serv-iced, commissioned, or the appliance gas typehas changed.

NOTEEnsure the jumper tag has been fitted to the con-trol PCB (JP3).The procedure for setting or adjusting must becarried out in the following order:● set the maximum DHW gas pressure.●●●●● set the minimum DHW gas pressure.●●●●● set the maximum heating gas pressure.● set the minimum heating gas pressure.

10.5.1 SETTING THE MAXIMUM DHW GAS PRES-SURE (fig. 13 & 22)Isolate the appliance from the electrical sup-ply, remove the appliance casing as describedin 4.7.1.●●●●● Attach a manometer to the outlet test point of the

gas valve.●●●●● Remove the protective cover from the gas valve

modulator, and disconnect the compensationtube from the gas valve.

●●●●● Fully open a hot water outlet (preferably the bathtap).

●●●●● Rotate the DHW temperature selector to maxi-mum.

●●●●● Restore the electrical supply to the appliance.●●●●● The appliance will now light and after 7-10

seconds, the burner will be at full power.●●●●● Observe the manometer, the reading should be

36.0 mbar.●●●●● If the reading is correct, proceed to 10.5.2●●●●● If the reading is incorrect, turn the maximum

adjustment screw (see fig. 13) clockwise toincrease the pressure, or anti-clockwise to re-duce the pressure.

●●●●● Proceed to 10.5.2.10.5.2 SETTING THEMINIMUM DHW GAS PRESSURE (fig. 15 & 23)

● After carrying out section 10.5.1, disconnectone of the black wires attached to the modulatorcoil.

●●●●● The burner will now operate at minimum power.●●●●● Observe the manometer, the reading for Sabre

24 should be 5.1 mbar, for Sabre 28 the readingshould be 4.8 mbar.

● If the reading is correct, proceed to section10.5.3.

● If the reading is incorrect, turn the minimumadjustment screw (fig. 15) clockwise to increasethe pressure, or anti-clockwise to reduce thepressure.

●●●●● Proceed to section 10.5.3.

10.5.2 SETTING THE MINIMUM DHW GAS PRESSURE(see fig. 13 & 22)

●●●●● After carrying out 10.5.1, disconnect one of theblack wires attached to the modulator coil.

●●●●● The burner will now operate at minimum power.●●●●● Observe the manometer, the reading for Com-

pact 24 should be 5.1 mbar, for Compact 28 thereading should be 4.8 mbar.

●●●●● If the reading is correct, proceed to 10.5.3.●●●●● If the reading is incorrect, turn the minimum

BS 6798 INSTALLATION OF BOILERS OF RATED INPUT NOT EXCEEDING 60 Kw

BS 5449 PART 1 FORCED CIRCULATION HOT WATER SYSTEMS

BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES

BS 5440 PART 1 FLUES

BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS

10.2 RELATED DOCUMENTS

For details of converting appliances to LPG please refer to the instructions supplied with the relevant conversation kit.

BURNER PRESSURES SABRE 24 SABRE 28Inlet pressure 37 mbar 37 mbar

Gas rate 2,04 Kg/h 2,41 Kg/h

Injectot size 12 x 0.77 14 x 0.77

Maximum burner pressure DHW & Heating 36 mbar 36 mbar

Minimum burner pressure DHW 5.1 mbar 4.8 mbar

Minimum burner pressure Heating 6.5 mbar 6.5 mbar

Jumper tag for LPG Inserted across JP3 Inserted across JP3

adjustment screw (see fig. 13) clockwise toincrease the pressure, or anti-clockwise to re-duce the pressure.

●●●●● Proceed to 10.5.3

10.5.3 SETTING THE MAXIMUM AND MINIMUM CEN-TRAL HEATING BURNER PRESSURES

●●●●● Isolate the appliance from the electrical supply.●●●●● Close the hot water outlet.●●●●● Re-attach the black wire to the modulator coil.●●●●● Remove the PCB cover and temporarily attach

a jumper tag to JP2.●●●●● Rotate the heating temperature selector to maxi-

mum, and ensure all radiators are turned on withany thermostatic radiator valves set to maxi-mum.

●●●●● Restore the electrical supply and ensure there isa call for heat via the appliance time clock and/or room thermostat.

●●●●● The appliance should now be operating in theheating mode at maximum output.

●●●●● Observe the manometer, the – maximum –reading should be 36.0 mbar.

●●●●● Using a small screwdriver, gently rotate the P5potentiometer if adjustment is necessary.

●●●●● To check and/or adjust the minimum heatinggas pressure, slowly rotate the heating tempera-ture selector until the burner pressure drops tominimum (should be 6.5 mbar).

●●●●● Using a small screwdriver, gently rotate the P4potentiometer if adjustment is necessary.

●●●●● Isolate the appliance from the electrical supply,and remove the jumper tag from JP2.

●●●●● Remove the manometer from the gas valve andtighten the outlet test screw.Refit the PCB cover and appliance casing.

●●●●● Remove the manometer from the gas valve andtighten the outlet test screw.

Refit the PCB cover and appliance casing.

CO

D. 1

0025

735

- 06

/04

- E

d. 1

COLLECTIVE MARK

We Service Support provide after-sales assistanceand Technical advice for Sabre Boilers

Service Support: 0870-333-0220Technical Advice: 0141-945-6810

We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected