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ROC COMBI HE 2802 Manual For Installation, Operation & Maintenance Download Page 50

50

Dismantle the combustion 

chamber sealing cover 

following the basic 

dismantling method.

Heat exchanger dismounting

Time: 23 min

1.

Heat exchanger dismounting

2.

Dismantle the 4 nuts 

connected with fan by 

8mm spanner, and then 

dismantle the connected 

gas pipe by 24mm 

spanner.

Take out the whole fan 

and silencer.

Unscrew the 4 nuts on 

the mix air inlet elbow by 

10mm spanner.

Take out the mix air inlet 

elbow upwardly.

Tools:

Tools:

Take out the combustor 

upwardly.

Main heat exchanger

Summary of Contents for COMBI HE 2802

Page 1: ...tion Personnel Service Provider Manual for Installation and Maintenance Condensing Wall Mounted Gas Fired Combination Boilers ROC COMBI HE 2802 ROC COMBI HE 2810 ROC COMBI HE 4010 G C N 47 492 01 28 KW G C N 47 492 02 40 KW ...

Page 2: ......

Page 3: ...lief valve 21 Gas connection 21 Water connection 21 22 Flue system 23 25 Instruction and precautions for power connection 26 Connecting additional controls 27 Appliance commissioning 28 Appliance adjustment Check the circuit and power 29 Cleaning of heating system 29 Checks before operation 30 31 First operation 31 33 ECS Control Operations 33 ECS parameter chart 34 Flue gas analysis 35 Capacity a...

Page 4: ...ed Improper installation may cause damage or injury to individuals animals and personal property for which the manufacturer will not be held liable To ensure efficient and safe operation it is recommended that the boiler is serviced annually by a GAS SAFE engineer All GAS SAFE registered installers carry a GAS SAFE ID card and have a registration number Both should be recorded in your boiler Servi...

Page 5: ...n can harm persons animals and possessions the manufacturer shall not be held responsible for any damage caused as a result The boiler is delivered in a carton Once you have removed all packaging make sure the appliance is intact and that no parts are missing If this is not the case please contact your supplier Keep all package materials clips plastic bags polystyrene foam etc out of reach of chil...

Page 6: ...y 2006 95 CEE relating to electrical safety Clean using a cloth dampened with soapy water Do not use aggressive detergents insecticides or toxic products If the appliance is used in full compliance with current legislation it will operate in a safe environmentally friendly and cost efficient manner If using kits or optional extras make sure they are authentic Turn the boiler off and turn the exter...

Page 7: ...nt make sure in particular that the tool is not worn out and that its handle is fixed properly use them correctly and make sure they do not fall from a height Replace them once you have finished using them Personal injury from the falling splinters or fragments inhalation of dust shocks cuts pricks and abrasions Damage to the appliance or surrounding objects caused by falling splinters knocks and ...

Page 8: ...city supply open all windows and contact the technician Personal injury caused by burns smoke inhalation asphyxiation Personal injury caused by falling from a height During all work carried out at a certain height generally with a difference in height of more than two metres make sure that parapets are used to surround the work area or that individual harness are used to prevent falls The spare wh...

Page 9: ...r flashes when performing hot water function 4 Central heating icon indicator flashes when performing heating function 5 Temperature Error icon hot water and heating temperature indicate error code indicator when error occurs 1 2 3 4 5 4 ON OFF Power button Central heating Hot Water only mode 5 Heating temperature up down button 6 Pressure gauge 1 Timer 2 D H W temperature up down button 3 Display...

Page 10: ... inlet pipe burner 10 Expansion tank 11 Heating water temperature sensor 12 Drain point 13 Pressure gauge 14 Overheat protector 15 Ignition needle 16 Burner 17 Flame detection needle 18 Three way motor 19 Domestic heat exchanger 20 Gas valve 21 Pressure switch 22 Hot water temperature sensor 23 Water flow volume sensor 24 Safety valve 25 Air exhaust valve 26 Pump ...

Page 11: ...D Inlet of central heating water E Outlet of central heating water F Pressure relief valve pipe A Gas B Domestic hot water C Cold water D Inlet of central heating water E Outlet of central heating water F Pressure relief valve pipe ROC COMBI HE 28 ROC COMBI HE 40 ...

Page 12: ...ion the boiler must be in accordance with the clearances stated below The following minimum distance should be left for equipment s installation and maintenance Distance on the bottom 300mm Distance on the side position 5mm Distance on the top 300mm Distance on the front 500mm 5 300 300 5 ...

Page 13: ...ure Minimum domestic hot water volume Sanitary water maximum pressure Sanitary water minimum pressure Expansion tank capacity Expansion tank preset pressure Heating system maximum pressure NG normal pressure Performance Heating water maximum temperature Hot water maximum temperature Hot water rate T 35 C Electrical Electric supply Input electric power Protection level Weight Dimension Lx H x D KW ...

Page 14: ... Code of Practice Appliance installation BS 7593 BS 5546 BS 5440 1 BS 5440 2 Treatment of water in domestic hot water central heating systems Installation of hot water supplies for domestic purposes Flue Air supply BS EN 12828 2003 BS EN 12831 2003 BS EN 14336 2004 BS 6798 BS 6891 BS 7671 BS 4814 BS 5482 Heating systems in buildings Design for water based heating systems Heating systems in buildin...

Page 15: ...size is adequate for demand including other gas appliances on the same supply Power supply The gas boiler requires 230V 50Hz supply in accordance with IEE regulations and must also allow the appliance to be electrically isolation The connection should be via 3 amp double pole fuse isolating switch and the contacts separated by at least 3 mm on both poles Alternatively a fused 3 amp 3 pin plug and ...

Page 16: ...hermic exchanger because small areas of scale cause a high increase of the temperature of the metallic walls and therefore add to the thermal stress of the heat exchanger Deminieralised water is more aggressive so in this situation it is necessary to treat the water with an appropriate corrosion inhibitor Any treatment of water by additives in the system for frost protection or for corrosion inhib...

Page 17: ...ailed recommendations are given in BS 5440 Part 2 If it is proposed that it is to be installed in a timber framed building then reference should be made to IGEM Document IGE UP 7 or advice sought from Gas Safe When a room sealed appliance is installed in a room containing a bath or shower the appliance and any electrical switch or appliance control utilizing mains electricity should be situated sp...

Page 18: ... meters Some examples of the type of condensate terminations can be found below 1 Internal termination of condensate drainage pipe to internal stack Condensate Discharge Push fit the flexible condensate pipe into the outlet spigot on the appliance Cut to length and locate outlet into a tundish 2 External termination of condensate drainage pipe via internal discharge branch e g sink waste and conde...

Page 19: ...ation bag Hanging plate Expansion screws used to fix the hanging plate Accessory bag User s manual Installation manual and warranty card Sealing cushion Paper template Installation noise Please comply with the relevant national or region standard or guidelines when installing the wall mounted gas boiler The noise of installation should be controlled within the local standard requirement pay specia...

Page 20: ...d plug the wall and secure the hanging bracket using the screws provided ensure the hanging bracket is level Remove all the protective packaging from the gas boiler and place the boiler on the hanging bracket Installation of pipework Remove the caps and valves from the boiler Connect the valves to the boiler has shown below and the valves to the heating system We would recommend that a street elbo...

Page 21: ...lushed completely before connecting the cold supply to the boiler Please check the maximum water pressure and make sure it does not exceeds 6 bar if it exceeds 6 bar then a pressure reducing valve should be equipped Before connecting the heating pipe to the gas boiler wash the pipe and radiator cleaning all foreign body in the pipes otherwise these foreign bodies may cause obstructions Please ensu...

Page 22: ...ch steaming must be considered If the terminal is less than 2 meters above a balcony above ground or above a flat roof to which people have access then a suitable stainless steel terminal guard must be fitted The minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in diagram below A Directly below an opening window etc 300mm B Horizontally to a windo...

Page 23: ... Standard 100mm flue system includes Key 1 Horizontal flue duct with external wall seal 2 90 elbow 3 2X30mm flue duct clamp 4 Internal trim ring 5 External wall seal Standard flue installation Flue system ...

Page 24: ...n old appliance the flue system must be changed Important Ensure that the flue is not blocked Ensure that the flue is supported and assembled in accordance with these instructions Fitting the Coaxial Flue Ø 60 100 Horizontal Contents 1x Silicone O Ring 60mm 1x Elbow 90 2x Wall Seals Internal External 1x Flue Pipe including Terminal 1 metre 60 100 2x Flue Clamps 4x Screws 2x Seals ...

Page 25: ...8mm clamp to fix the flue duct to the elbow Fix the internal trim ring to the internal wall Attach the outer wall seal to the flue duct from the outside wall If the flue requires extending the connections are push fit but ensure each meter is secured with a flue bracket Before installing the flue ensure the maximum length of flue ducting does not exceed 10m for the 28Kw and 5m for the 40Kw You sho...

Page 26: ...e the power cable For electrical safety please make the correct earth connection with accordance to local safety rules The above safety requirements must be checked If you have any questions please ask the installer engineer to check the appliance carefully The manufacturer will not take any responsibility for any losses caused by not earthing the appliance Ask the installer engineer to check the ...

Page 27: ...27 Connecting additional controls ...

Page 28: ...omestic hot water DHW to a certain temperature Before supplying heating domestic hot water to the users the boiler should be connected to a heating supplying network heat dissipation device and or domestic hot water supplying network which match the function and capacity of the gas boiler Before connecting the gas boiler to the system please ask the installer engineer to make the following operati...

Page 29: ...oop immediately after filling the system Gas Supply Inspect the entire installation including the gas meter and test for tightness The entire installation should be in accordance with the relevant standards In the UK this is BS 6891 The connection on the appliance is a 15mm 22mm on the 40kW nut and olive located at the rear of the gas service cock Check the circuit and power Check if the voltage m...

Page 30: ... of electricity water and gas supply Flue pipes should be unobstructed and installed as instructed Ensure the minimum space for maintenance when there is furniture walls or other obstacles surrounds Make sure all the heating system pipes and DHW pipes connecting to the boiler have been cleaned carefully Check the gas pipe line and water pipe connection to see if there is any leakage Note Strictly ...

Page 31: ...nd regulations Instruction of gas use The gas pipe cannot be used as the earth connection of electrics Please close gas main valve when the user is not at home for long periods you should also drain out the water from heating and hot water system to avoid water freezing in the system What to do if you smell gas If there is a smell of gas in the building proceed as follows Avoid rooms that smell of...

Page 32: ...lose the hot water tap it will continue to supply heating as requested The boiler can be switched from mode Hot water Central heating by pressing the heating up button and the hot water up button together for 3 seconds Heating The display will show when the boiler has power Press ON OFF button for 5 seconds the boiler will be turned on and work under Central heating and the display will show If yo...

Page 33: ...n use Heating temperature up and Heating temperature down button to select a parameter then press ON OFF and Heating temperature up at the same time to show the real valve of the selected parameter See ECS Parameter Chart Change the parameter on the menu To change the actual value of the selected parameter users can use Heating temperature up and Heating temperature down button refer to the ECS pa...

Page 34: ... both the values after setting 01 12 External temperature factor option 10 15 20 25 C 50 55 60 C 00 pulse signal 00 water pressure switch 01 two heat exchangers Pr07 Pr09 Pr10 Pr12 Pr13 Pr14 Pr15 Pr20 Pr21 Pr22 Pr23 Pr24 Highest heating temperature setting Scanning test function activation Anti circulating time Max heating power Working mode of heating pump Ignition power OTC option Heating return...

Page 35: ...9 2 0 2 8 8 0 2 Power Max power Min power ROC COMBI HE 40 Air speed rpm 7200 7800 1700 2400 CO2 9 2 0 2 8 8 0 2 Power Max power Min power Warning It is forbid to operate power adjustments when the gas inlet pressure is not between 17 25 The tightness of all the control points must be checked after adjusting the power Capacity adjustment 1 Preparation unscrew the gas valve inlet and connect the pre...

Page 36: ... the required point CO2 9 2 0 2 4 Minimum power adjustment enter ECS menu and select Pr09 parameters 01 adjust the screw picture A and make the value of CO2 achieve the required point CO2 8 8 0 2 you may have to reenter this menu several times as the program only lasts for 20 seconds 5 Due to the interactional effect you should recheck the maximum and minimum power to ensure the CO2 levels are sti...

Page 37: ...ation please contact the supplier or local after sales service department Please use a wet cloth and soapy water to clean the externals of the appliance Other cleaning liquids should not be used Anti freeze function The gas boiler has anti freeze function If the gas and power is on the boiler will start to work automatically when the heating water temperature is below 5 C and heat the water in the...

Page 38: ...ol fault Air pressure switch fault flue system fault NTC temperature sensor fault Heating NTC temperature sensor fault DHW External temperature sensor fault Flue system temperature sensor fault Overheat 90 C of flue exhaust system Fake flame flame can be detected before the boiler is turned on Return back water temperature sensor fault EEPROM fault The heating water is overheated 93 C Gas valve ci...

Page 39: ... by the fan please check the fan and the connecting wires to see if they are loose or damaged Er 06 Fault Er 06 indicated that the temperature of heating water is unusual it could be caused by extremely cold water or damage of the heating NTC temperature sensor Check if the water temperature less than 20 C Else the NTC temperature sensor maybe damaged Er 07 Fault Er 07 indicated that the temperatu...

Page 40: ...ult Er14 means the temperature of heating water is 93 C please check if the heating pipeline is blocked or if all the valves in the heating pipeline are opened or if the discharge of condensing water is normal Er 15 Fault Er15 means the gas valve circuit inside the circuit board is out of order Check if the circuit is damp Er 16 Fault If flameout occurred during the combustion operation process th...

Page 41: ...ime 3 min 1 General access 2 Use screw driver unscrew the two screws of bottom plate Lift the plastic panel from bottom Turn around the plastic panel Unscrew the 4 screws of plastic panel from the bottom plate Dismantle the facing cover from front Tools Unlock the upper buckle ...

Page 42: ...42 Unscrew the 4 screws of the sealing cover of combustion system Dismantle the facing cover from front General access 3 Tools ...

Page 43: ...t the screws on the both sides of Electrical box Electrical box operation Time 4 min 1 Fuse replacement Time 4 min 1 Take out the Electrical box back cover upward Open the Electrical box as shown above Remove the fuse Tools Tools ...

Page 44: ...shown above PCB replacement Time 6 min 1 Display Replacement Time 7 min 1 Dismantle the 4 screws on the PCB Operate PCB as shown above Dismantle the 4 screws on the PCB Remove the PCB Remove the display Tools Tools PCB and Display ...

Page 45: ...ee way valve dismounting Time 5 min 1 Bypass valve dismantling Time 5 min 1 Unscrew the motor connector by spanner take out the inside three way component axially Spin and take out the water pressure switch manually Unscrew the bypass valve cover axially by spanner and take it out Tools Tools ...

Page 46: ...e clip Safety valve dismantling Time 5 min 1 Exhaust valve dismantling Time 5 min 1 Take out the safety valve manually Take out the exhaust valve clip Take out the exhaust valve manually Tools Tools Safety valve and Exhaust valve ...

Page 47: ...12 min 1 Plate heat exchanger dismantling Time 3 min 1 Separate the bottom plate and water system Dismantle the 2 screws on plate heat exchanger by 5mm Hex key Take out the pump from right side Tools Tools Pump and Plate heat exchanger Pull the domestic heat exchange out of the bottom plate ...

Page 48: ...ombustion system dismounting 2 Dismantle the 4 screws of maintain cover on top and take out the maintain cover Dismantle the 2 installation screws flame testing needle or ignition needle as shown above then take out the flame testing needle or ignition needle manually Unscrew the Heating temperature sensor by 15 mm spanner and take it out Tools Tools ...

Page 49: ...n dismantling 2 Dismantle the 4 nuts connected with fan by 8mm spanner and then dismantle the connected gas pipe by 24mm spanner Unscrew the Heating temperature sensor by 15 mm spanner and take it out Take out the silencer after dismantled the 3 screws connected with it Take out the whole fan and silencer Tools Tools Fan ...

Page 50: ...changer dismounting 2 Dismantle the 4 nuts connected with fan by 8mm spanner and then dismantle the connected gas pipe by 24mm spanner Take out the whole fan and silencer Unscrew the 4 nuts on the mix air inlet elbow by 10mm spanner Take out the mix air inlet elbow upwardly Tools Tools Take out the combustor upwardly Main heat exchanger ...

Page 51: ...e clip and unscrew the nut on A and take out the siphon pipe Dismantled the 2 screws on the bottom of siphon pipe Dismantled the 4 screws on the smoke pipe outlet by screwdriver and take out the outlet flange Tools Tools Unscrew the 2 heating outlet water pipe connection nuts by 30mm spanner take heating outlet water pipe out Take out the inside smoke pipe connection pipe upwardly ...

Page 52: ...tled the 2 screws on heat exchanger Heat exchanger dismounting 5 Take out the whole heat exchange and smoke collector Dismantle the screws connected with heat exchange and smoke collector and separate them Tools ...

Page 53: ...nterval Yearly Method Visual inspection Clean if necessary Check the flow Expansion tank Maintenance interval Yearly Method The pressure should be 1 bar in the air system drainage Flame test needle and ignition needle Maintenance interval Yearly Method Visual inspection clean if necessary distance with combustor electric ion current larger than 1 µ A Fan Maintenance interval Yearly Methods Visual ...

Page 54: ... water before clean Pump Maintenance interval Yearly after the first ignition Method Check the AAV if it s open visual inspection clean if necessary Burner combustion chamber Maintenance interval Yearly or after cleaning the main heat exchanger Method Visual inspection clean or replace if necessary inspect the seals and replace the seals if needed ...

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Page 60: ...60 ROC UK UK HD Ltd 14 Lenton Business Centre Lenton Boulevard Nottingham NG7 2BY Support Number 08452268261 Email info rocboilers co uk ...

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