Saunier duval ISOFAST CONDENS F 35 E User Manual

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INSTRUCTIONS FOR USE, INSTALLATION AND SERVICING

FOR ISOFAST CONDENS F 35 E

4000135500-2 04/04

INSTRUCTIONS FOR USE

Lighting : make sure that:

• the boiler is connected

to the electrical supply,

• the gas service tap is open,

• Switch ON (I). Switch off the boiler : Switch

to OFF (0) : the electrical supply is off. Stop the gas supply if the boiler is to be out of use for a long time.

In case of fault, the red warning light will ﬂash and a code appears on the boiler display .

Code 21: Water pressure too low: open the blue tap (t) situated under the boiler until a pressure of 1.5 bar is obtained.

Other codes: press the key of the room thermostat and read the indications given by the display.

Lighting/switch off the boiler

Fault indication

1-On/Off switch. 2-Room thermostat disabled when the

button light is ON

3-Sanitary function enabled when the

button light is ON

4-Heating function enabled when the

button light is ON

5-Hot water temperature adjuster. 6-Heating temperature adjuster. 7-Graphic display. 8-Green running light. 9-Red, ﬂashing fault light.

10- Yellow running lamp for the burner.

➡

Operation without room thermostat

• Press the key (the key will light-up)

• Press the and/or buttons to activate the heating and/or hot water functions

• Use buttons and to determine the heating and hot water temperatures.

• To revert to the operating mode with room thermostat, again press the key (the light will turn OFF;

Important notice : The settings performed

on the boiler control panel are not transmitted to the room thermostat.

Perform the temperature settings from the wireless room thermostat supplied together with the boiler, strictly adhering to the instructions given in this manual, pages 10 through 17.

Contents

INSTRUCTION FOR USE

Controls and Lighting page 2 Important informations 3 - 5 Guarantee informations 6 - 7 Controls informations 8 - 17

INSTALLATION INSTRUCTIONS

General informations 18 Dimensions 19 Technical Data 20 - 23 Boiler coponents 24 Schematic layout of boiler 25 Boiler location 26 - 27 Flue location and Ventilation 28 - 31 Heating System 32 - 33 Domestic Hot Water System 33 Boiler Installation 34 Piping installation 35 - 38 Electrical Connection 39 Commissioning on boiler 40 - 43 Commissioning on room thermostat 44 - 51 Gas conversion 52 - 53

SERVICING INSTRUCTION

Routine Cleaning and Inspection 54 - 59 Wiring Diagram 60 - 61 Fault Finding 61 - 63 Replacement of Parts 64 - 72 Spare Parts 73

Important information

The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation.

General

This combination boiler is able to provide room heating as part of a central heating system, and domestic hot water direct from the cold water supply without the need for secondary storage. The central heating water temperature and domestic hot water temperature can both be adjusted on the boiler. Once the controls are set the boiler operates automatically. A frost protection program is also included.

Please read these instructions and follow them carefully for the safe and economical use of your boiler.

Gas Category

This boiler is for use only on Natural gas (G20) or propane (G31).

Gas Safety (Installation and Use) Regulations

In your own interests and that of safety, it is the Law that ALL gas appliances are installed by a competent person in accordance with the current issue of the above regulations.

Gas Testing and Certiﬁcation

The boiler is tested and certiﬁcated for safety and performance. It is, therefore, important that no alteration is made to the boiler unless approved, in writing, by Saunier Duval. Any alteration not approved by Saunier Duval, could invalidate the certiﬁcation, boiler warranty and may also infringe the current issue of the statutory requirements.

CE Mark

This boiler meets the requirements of Statutory Instrument, No. 3083 The Boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers ﬁred with liquid or gaseous fuels. Type test for purposes of Regulation 5 certiﬁed by : Notiﬁed body 0086. Product/production certiﬁed by : Notiﬁed body 0086.

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USERS

Important information

The CE mark on this appliance shows

compliance with :

1. Directive 90/396/EEC on

the approximation of the laws of the Member States relating to appliances burning gaseous fuels.

2. Directive 73/23/EEC on

the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits.

3. Directive 89/336/EEC on

the approximation of the Laws of the Member States relating to electromagnetic compatibility.

Control of Substances Hazardous to Health

Under Section 6 of The Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

Insulation Pads

These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not

cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.

Spare Parts

REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance speciﬁcation that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Saunier Duval.

Manual Handling Guidance

During the appliance installation and the replacement of the heat exchanger it will be necessary to employ caution and assistance whilst lifting as the appliance or component exceeds the recommended weight for a one man lift. In certain situations it may be required to use a mechanical handling aid. Take care to avoid trip hazards, slippery or wet surfaces.

Gas Leak or Fault

If a gas leak or fault exists or

is suspected, turn the boiler mains electrical supply off and turn off the gas supply at the meter. Consult your local gas company or your local installation/ servicing company.

Electrical Supply Failure

The boiler must be earthed. The boiler will not work without an electrical supply. Normal operation of the boiler should resume when the electrical supply is restored. Reset any external controls, to resume normal operation of the central heating. If the boiler does not resume normal operation turn the mains reset switch off and on. If the boiler does not resume normal operation after this the overheat stat may have operated. The overheat stat would only operate under abnormal conditions and, under these circumstances; it would be advisable to consult your installation / servicing company.

Boilers Installed in a Compartment or Cupboard

If the boiler is ﬁtted into a compartment or cupboard, it does not require any ventilation openings. Do not use the compartment or cupboard for storage.

Pluming from ﬂue terminal

Like all condensing boilers this appliance will produce a plume of condensation from the ﬂue terminal in cool weather. This is due to the high efficiency and hence low ﬂue gas temperature of the boiler. It is normal and not a fault indication.

Replacement Parts

If replacement parts are required contact Saunier Duval service using the telephone number on the back cover of this booklet. Please quote the name of the appliance this infomation will be on the front of the appliance.

Protection Against Freezing

The room thermostat automatically ensures a minimum installation temperature of 6°C. This protection is ensured by the room thermostat as long as it is active. This means that the button of the boiler must not be lit and that the batteries of the room thermostat must be in good condition.

If you are out of home for a few days, use the holidays mode of your room thermostat, and set the Start and End dates, as well as the desired temperature.

If the mains electricity and gas are to be turned off for any long periods during severe weather, it is recommended that the whole system, including the boiler, should be drained to avoid the risk of freezing.

Contact your installation/servicing company as draining, reﬁlling and pressurising MUST be carried out by a competent person.

As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions this may be due to the forming of ice in the condense drain external to the house. Release an ice blockage by the use of

warm cloths on the pipe. The boiler should then restart. Contact your installation/servicing company if the fault persists.

Draining and Filling

This boiler works in a pressurised system, which must only be drained, reﬁlled and pressurised by a competent person.

Pressure Relief Safety Valve

A pressure relief safety valve and discharge pipe is ﬁtted to the boiler. This valve must not be touched. Should there be any discharge from the pipe, isolate the boiler electrical supply and call your installer or Saunier Duval service using the telephone number on the back cover of this booklet.

Access to the user menu :

HOLIDAYS START DATE

END DATE

CANCEL

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To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough. Refer to Section «Routine Cleaning and Inspection».

If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by

the current issue of the Gas Safety (Installation and Use) Regulations, section 35. Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination.

To obtain service, please call your installer or Saunier Duval service using the telephone number on the back cover of this booklet.

Please be advised that the ‘Benchmark’ logbook

should be completed by the installation engineer on completion of commissioning and servicing. All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your boiler Logbook. You can check your installer is CORGI registered by calling CORGI direct on: 01256 372300.

Cleaning

The boiler casing can be cleaned with a damp cloth followed by a dry cloth to polish. Do not use abrasive or solvent cleaners.

Boiler casing

CAUTION. Do not remove or adjust the casing in any way, as incorrect ﬁtting may result in faulty operation. If in doubt, consult your installation/service company.

USERS

Servicing, all you need to know

Many thanks for choising Saunier Duval market leaders in boiler manufacture,

Your appliance is guaranteed for a period of 24 months from the date of installation or 30 months from the date of manufacture whichever is

the shorter and covers manufacturing defects only.

We, Saunier Duval, undertake to repair or replace parts free of charge which are recognised by us to be of faulty manufacture if necessary after return to our factory for examination on condition that : a) The appliance was installed by a qualiﬂed gas installer in accordance with installation instructions, and all the relevant codes of practice, standards and legislation in force. b) The appliance has been used for normal domestic purposes and in accordance with the manufacturer's operating and maintenance

instructions. c) The appliance has not been serviced, maintained, repaired dismantled or tampered with during the guarantee period, by anyone other than an engineer approved by Saunier Duval. d) The appliance is still in the possession of the original user, and proof of purchase in the form of a receipt or invoice is shown to the service engineer on request. The repair or replacement of parts during the guarantee period does not have the effect of extending the period.

This guarantee does not cover :

a) Any defects or damage resulting from incorrect or poor installation, inadequate servicing, or maladjustment of the gas or water used. b) Any defects in the system to which the appliance is connected. c) Any deterioration or maladjustment following changes in the nature or pressure of the gas or the water used, or a change in the characteristics of the electrical supply voltage.

Notiﬁcation of any fault should be made to the appliance installer. No repairs should be undertaken upon the

Welcome users

appliance, intending it to be covered by the product guarantee without prior authorisation from Saunier Duval.

IMPORTANT : The appliance serial number must be quoted on all correspondence/contact made with Saunier Duval.

This guarantee is in addition to your statutory and other legal rights, which will not be excluded or diminished by the return of the guarantee registration card.

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8 9

SYSTEM PRESSURE TOO LOW FILL IN AT 1,5 BAR

Ambient

temperature display

Time period for the

COMFORT temperature

Hot water mode indicator

Heating mode

indicator

Time display

Time period for the ECO temperature

Low battery indicator

1-Display. 2- Fault indicator. 3-Return to previous menu 4-Conﬁrm OK. 5-Access to the menus. 6 - Menu scrolling 7-Changing the mode 8-Wall bracket 9-Mains power plug

5 6

Fault description

Heating demand indicator

Indicators of the current temperature levels for “COMFORT or ECO” (Day/Night).

(Attention: this value may

vary when you hold the

thermostat in your hand).

Your Isofast boiler is factory set to operate within a customary installation.

Nevertheless, as many installations may incorporate speciﬁc features, feel free to contact your installer who will be able – by adapting the parameters of the boiler (maximum temperature and/or maximum power of the heating system) - to warrant you the best operating performance of your installation.

These settings being made, you still have the possibility of selecting the ambient temperature to suit your own requirements not only when you are at home, but also during nightime or when you are out

All these settings are achieved from the room thermostat supplied together with your boiler: if you accurately determine the temperatures that best suit to your needs, you will make signiﬁcant savings in terms of gas consumption.

Control as a source of savings

Essential adjustments to the wireless room thermostat : A – Setting the time B – Setting the date

The thermostat’s weekly programme functions enable you : C – To activate or deactivate the heating function.

D – To have a standard weekly programme by

activating the programme pre-set at the factory.

E – To bypass the current programme, temporarily, to increase or lower the temperature at any time during the day.

F – To set up a custom programme for each day of the week, with 2 temperature levels, for example:

• COMFORT for the periods you are present and.

• ECO at night or when you are away.

G – To have the same temperature 24 hours a day by deactivating the programme.

H – To leave on holiday, determining the desired temperature according to the date you leave and when you return.

I – To select the temperature of your domestic hot water from 38°C to 60°C. However, keeping the temperature below 50°C, reduces gas consumption and provides good protection against scalds.

J – To prevent undesired alterations to your settings by locking the thermostat’s buttons.

K – To be informed of any operating faults in the

boiler and be instructed in the procedure to follow.

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Control as a source of savings

A B

Progress of the operations :

at any time takes you back to the previous step

1 - Accessing the user menu

• Press to call up the next menu:

2 - Setting the time

• Use the buttons to select the "Set time" menu:

3 - Setting the date

• Use the buttons to select the "Set date" menu:

• Press to select the "ON/OFF heating " menu:

1 - Activate the heating

SET TIME

SET DATE

ON/OFF HEATING

Settings for the time and the dateand

Please note that pressing button

SET COMFORT T¡

SET ECO T¡ PROGRAMME SET HOT WATER T¡ ON/OFF HEATING HOLIDAYS SET TIME SET DATE

17:23

TUE 14/JUA/ 03

Activating/deactivating the heating function

PROGRAMME

OK OK

OFF

SET HOT WATER T¡ ON/OFF HEATING ...

Progress of the operations:

1 - Activating the weekly programme

PROG

• Press , the room thermostat shows this display:

• Pressing reverses ON and OFF mode every time

• When the ON mode appears, wait 5 seconds for the display to return to normal position and automatically validate the selection.

2 -Accessing the initial programme

• Press to select the "Programme" menu :

PROGRAMME

• Exit from the menu by pressing , which initiates the standard weekly programme pre-set at the factory :

Monday to Friday

• Pressing one of the scroll buttons calls up the menu for setting the ambient temperature :

PROG

ECO ECOCOMFORT COMFORT

11 PM >> 6 AM>> 8 AM >> 4 PM >> 11 PM

Temporarily bypassing the weekly programme

Activating the initial programme

Please note that pressing button at any time takes you back to the previous step.

PROGRAMME ON

PROGRAMME OFF

INITIAL PROGRAMME MONDAY

SET COMFORT T¡ SET ECO T¡ PROGRAMME ...

Weekends

ECO temperature 16°C COMFORT temperature 19°C

ECO COMFORT

11 PM >> 7 AM >> 11 PM

2 - Deactivate the heating

ON/OFF HEATING

OK OK

OFF

SET ROOM T¡

22¡C

This setting is automatically cancelled when the programme changes to Eco or Confort temperature level.

SET ROOM T¡

20¡C

Confirm by pressing

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PROG

MODIFY COPY TO

MONDAY TUESDAY

MONDAY

TUESDAY

OK OK OK

• Press to confirm the parameters you have set for the day.

• Follow the same procedure for every day of the week or use the duplication function, as explained below.

19.5

MODIFY TIME-SLOTS : T¡ CHOICE : PROG

19.5 16.5

Press to switch from COMFORT to ECO temperature

This symbol indicates the mode authorising deletion of black squares to set up operating periods at the stated ECO temperature using the buttons / .

E.g. :

In the case of the illustration opposite, each press of the button adds a blank from 6 AM onwards, corresponding to an extra 30 minutes heating at 16.5°C.

E.g. :

In the case of the illustration opposite, each press of the button adds a square from 11 PM onwards, corresponding to an extra 30 minutes heating at

19.5°C.

This symbol indicates the mode authorising additional operating periods at the stated COMFORT temperature (black squares) using the buttons / .

The squares indicate

the time periods when the boiler will provide the COMFORT temperature level (e.g.: 19.5°C between 4 PM and 11 PM and 6 AM and 8 AM)

The blanks indicate

the time periods when the boiler will provide the ECO temperature level. (e.g.: 16.5°C between 8 AM and 4 PM and 11 PM and 6 AM)

Duplicating a programme

• To save time, you can copy the parameters you have set onto another day via the menu :

MODIFY TIME-SLOTS : T¡ CHOICE : PROG

23:00 6:00

Control as a source of savings

OK OK

SET COMFORT T¡

SET ECO T¡ PROGRAMME ...

19.0¡C

19.5¡C

18.5¡C

20.0¡C

PROGRAMME

MODIFY COPY TO

MONDAY

TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAY SUNDAY INITIAL PROGRAMME

OK OK

/...

(to set the desired temperature during the day)

(to set the desired temperature during the night or while you are away)

OK OK

SET ECO T¡

16.0¡C

16.5¡C

16.0¡C

17.0¡C

/...

(to allocate time periods for the Comfort and Eco temperatures)

PROG

• When the ON mode appears, wait 5 seconds for the display to return to normal position and automatically validate the selection.

PROGRAMME OFF

PROGRAMME ON

• Press to call up the next menu:

• Press , the room thermostat shows this display:

• Pressing reverses ON and OFF mode every time.

Progress of the operations :

Setting the custom weekly programme

1 - Activating the weekly programme

2 - Access to the user menu

3 - Setting the Comfort temperature

4 - Setting the Eco temperature

5 - Programme

Please note that pressing button at any time takes you back to the previous step.

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1514

SET ECO T¡ PROGRAMME SET HOT WATER T¡ ...

OK OK

SET HOT WATER T¡

50¡C

51¡C 49¡C

52¡C

/....

(to set the hot water to the desired temperature)

• Press to call up the next menu :

Progress of the operations :

Setting the hot water temperature

1 - Access to the user menu

2 - Setting the hot water temperature

Please note that pressing button at any time takes you back to the previous step.

Locking/unlocking the thermostat’s buttons

• Holding down the and buttons simultaneously for 3 seconds locks the room thermostat’s buttons.

• Follow the same procedure to unlock the buttons.

Press for 3 seconds

OK OK

SET ROOM T¡

SET ROOM T¡ ...

19.0¡C

19.5¡C

18.5¡C

20.0¡C

/...

(to set the constant temperature desired)

PROG

• Press to call up the next menu :

• Pressing activates or deactivates the programme mode each time :

• Retain the

PROGRAMME OFF position. After 5 seconds, the display returns to its normal position

and automatically validates this selection.

Progress of the operations :

Setting the heating temperatures outside Programme mode

1 - Deactivating the weekly programme

2 - Access to the user menu

3 - Setting the ambient temperature

Please note that pressing button at any time takes you back to the previous step.

PROGRAMME ON PROGRAMME OFF

PROG PROG

Control as a source of savings

SET HOT WATER T¡ ON/OFF HEATING HOLIDAYS ...

HOLIDAYS

• Press to call up the next menu :

• Determine the temperatures you wish according to your departure and return dates.

Holiday programme

1 - Access to the user menu

2 - Activating the Holiday programme

START DATE END DATE SET ROOM T¡ CANCEL

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Glossary for the user menu

Control as a source of savings

Setting the ambient temperature when the programme has not been activated (Programme inactive).

Setting the Confort temperature for the periods set in “Programme” menu.

Setting the reduced temperature for the periods set in the “Programme” menu.

Allocating operating periods for Confort and Eco temperature for each day of the week. In the morning, for

example, you are recommended to start heating approximately 1 hour before you get up.

Displaying the external temperature when an external sensor is installed.

Setting the hot water temperature. Starting / stopping heating

On = Heating + hot water Off = Hot water only Outdoor T° = displayed when an external sensor is

connected. When “Driven by ext. T°” is selected, the boiler automatically cuts off the heating when the temperature is higher than 18°C (factory setting).

Displayed if your installer has selected "consigne ”manual“ in the “heating control” menu under the “installer” menu

Setting the ambient temperature for while you are away.

Setting the time. Setting the date.

Set room T°

Set comfort T°

Set eco T°

Programme

Outdoor T°

Set hot water T° ON/OFF heating

Set radiator T° or Floor heating T°

Holidays

Set time Set date

• If a fault occurs, the red lights on the boiler and on the room thermostat flash

and a pictogram is displayed on the thermostat : , , , or

• Press the button on the thermostat:

Fault level 1

• The thermostat shows the procedure to follow:

• At the same time, the boiler’s screen shows the code for the fault:

Fault indicators

SYSTEM PRESSURE TOO LOW FILL IN AT 1.5 BAR

Fault level 2

• The thermostat asks you to call your After-Sales service engineer, informing him of the fault code flashing on the boiler to assist in his diagnosis.

• At the same time, the boiler’s screen shows the code for the fault:

FLOW RATE FAULT CALL AFTERSALES TEL 00 00 00 00 00

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INSTALLERS

1918

Dimensions

The boiler is delivered in one package :

the boiler itself, the wireless thermostat, the ﬁxing bracket, the template and pipe connections .

The different packages relating to the ﬂue system will be ordered depending on the actual conﬁguration of the installation

418

890

510

232

Isofast F 35E Net weight (kg) 52 Gross weight (kg) 60

The “as delivered” package consists of :

- 1 wireless thermostat

- 1 ﬁxing bracket

- 3 x 1.5 V alkaline battery cells type LR6

- 1 access cover to the battery cells

ATTENTION: DO NOT FORGET TO RECOVER THE ROOM THERMOSTAT placed in a

polystyrene case in the bottom of the package.

General Information

IMPORTANT NOTICE

The boiler and pipes are supplied in one pack, the ﬂue is supplied seperately. This boiler is factory set for use only on G20 natural gas.

Where no British Standards exists, materials and equipment should be ﬁt for their purpose and of suitable quality and workmanship. Refer to Manual Handling Operations, 1992 regulations.

The installation of this boiler must be carried out by a competent person in accordance the rules in force in the countries of destination.

Manufacturer’s instructions must not be taken as overriding statutory requirements.

Sheet Metal Parts

WARNING: When installing the appliance, care should be taken to avoid any possibility of personal injury when handling sheet metal parts.

Statutory Requirements

The installation of the boiler MUST be carried out by a competent person in accordance with the relevant

requirements of the current issue of : Manufacturer’s instructions, supplied.

The Gas Safety (Installation and Use) Regulations, The Building Regulations, The Building Standards (Scotland) Regulations (applicable in Scotland), local Water Company Bylaws, The Health and Safety at Work Act, Control of Substances Hazardous to Health, The Electricity at Work Regulations and any applicable local regulations. Detailed recommendations are contained in the current issue of the following British Standards and Codes of Practice, BS4814, BS5440 Part 1 and 2, BS5449, BS5546, BS6700, BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671.

We also suggest that you have to hand a copy of the British Gas publication, “Guidance Notes for the Installation of Domestic Condensing Boilers”.

Manufacturer’s notes must not be taken as overriding statutory obligations.

Certiﬁcation

This boiler certiﬁcated to the current issue of EN 483 for

performance and safety. It is important that no alteration is made to the boiler, without permission, in writing, from Saunier Duval.

Any alteration that is not approved by Saunier Duval., could invalidate the warranty and could also infringe the current issue of the Statutory Requirements.

Electrical Supply

All system components shall be of an approved type and all wiring to current I.E.E. wiring regulations. External wiring must be correctly earthed, polarised and in accordance with the relevant standards.

In GB this is BS 6891. In IE this is the current edition of I.S.813 "Domestic Gas Installations". The boiler must be connected to a permanent 230V ac, 50Hz supply. Connection of the whole electrical system of the boiler, including any heating controls, to the electrical supply must be through one common isolator and must be fused 3 Amp maximum.

Wiring to the boiler must be PVC 85°C insulated cable, not less than 0.75mm2 (24/0.20mm).

Page 11

INSTALLERS

2120

Natural Gas (G 20) F 35 E

Ø burner injector (mm) 5,65 inlet pressure (mbar) 20 Sanitary ﬂow rate at maximum input (m

/h) 3,62

Heating ﬂow rate at maximum input (m

/h) 3,02

Flow rate at minimum input (m

/h) 0,85

Electricity F 35 E

Electrical supply (V) 230 Electrical rating (A) 0,9 Maximum absorbed power (W) 206 IP classiﬁcation IPX4D Class 1

Technical Data Isofast

Heating F 35 E

Heating output at 80°C/60°C (P) adjustable (kW) from 7,6 to 28

(BTU/H) from 25,930 to 95,536

Heating input min. (Q) (kW)/(BTU/H) 8 / 27,296 Heating input max. (Q) (kW)/(BTU/H) 28,6 / 97,583 SEDBUK efficiency (%) ? Heating output at 50°C/30°C adjustable (kW) from 8,6 to 30,6 Maximum heating temperature (°C) 80 Minimum heating temperature (°C) 22 Expansion vessel charge pressure (bar) 0,5 Maximum system capacity at 75°C (l) 215 Safety valve, maximum service pressure (PMS) (bar) 3,0

Hot water F 35 E

Heating output (P) adjustable from… (kW)/(BTU/H) 34,2 / 116,690

to… (kW)/(BTU/H) 7,6 / 25,931

Maximum hot water temperature (°C) 60 Threshold ﬂow rate (l/min.) 1 Speciﬁc ﬂow rate (D) (for 30°C temp rise) (l/min.) 16,3 Storage capacity (l) 4 Expansion valve setting (bar) 10 Minimum operating pressure (bar) 0,7 Maximum operating pressure (P

MW) (bar) 10

Combustion F 35 E

Product outlet diameter (mm) 60 Fresh air inlet diameter (mm) 100 Fresh air ﬂow rate (1013 mbar - 0°C) (m

/h) 43

Product outlet ﬂow rate (g/s) 15,3 Product outlet temperature (°C) 68 Values of product outlet CO (ppm o mg/kWh) 100 or 176

CO2 (%) 9,2

NOx (ppm o mg/kWh) 21,1 or 37,3

Gas Supply

The gas installation must be in accordance with the relevant standards. In GB this is BS6891. In IE this is the current edition of I.S.813 "Domestic Gas Installations".

The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler.

On completion, test the gas installation for soundness using the pressure drop method and suitable leak detection ﬂuid, purge in accordance with the above standard.

Technical Data

All dimensions are given in millimetres (except as noted).

The data label is positioned on the inner door.

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is Band 'A'.

The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated has been certiﬁed by B.S.I.

F 35 E

Gas category II2H3P

Page 12

INSTALLERS

2322

By-pass fully shut Open 1/2 turn

By-pass fully shut Open 1/4 turn Open 1/2 turn Open 2 turns

1 2

NB : Factory seeting : Speed II

III

Speed III

Bypass

The Isofast boiler has a built-in bypass. This must be adjusted according to the requirements of the system, refer to the ﬂow rate pressure curve. The boiler is supplied with the built-in bypass open a half a turn. It is adjusted by turning the bypass screw (a). Turn the screw clockwise to close the bypass. When using thermostatic radiator valves (TRV’s) on all of the radiators, it is essential that a separate, adjustable bypass of 15 mm minimum diameter is ﬁtted between the ﬂow and return

of the heating circuit.Any bypass must be ﬁtted before system controls.

By-pass fully shut Open 1/4 turn

Open 1/2 turn

70 60 50

40 30

20 10

500 14001000

Curve output/pressure

Available pressure (kPa)

between heating supply and return lines

Flow rate through heating system (l/h)

Technical Data

Speed II

Speed I

3 4

5 6

8 9

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INSTALLERS

2524

AB C DE

Isofast F 35 E

Schematic layout of boiler

1-Flue outlet 2-Main heat exchanger 3-Burner 4-Ignition and controle

electrode

5-Fan 6-Gas control valve 7-DHW storage vessel 8-Condensate drain 9-Overheat safety

thermostat.

10 - Temperature sensor for

DHW storage vessel

11 - Expansion vessel 12 - Heating return

thermistor

13 - Heating outlet

thermistor

14 - Ignition module 15 - Pump 16 - Water pressure sensor 17 - Domestic plate to plate

heat exchanger

18 - Three way valve 19 - Heating element 20 - Drain cock 21 - Water ﬂow sensor 22 - Discharge safety valve

3 bars

23 - DHW temperature

sensor

24 - Discharge safety valve

10 bar

25 - Isolating valve 26 - Filter on cold water inlet 27 - Filling system 28 - Filter on heating circuit 29 - Isolating valve 30 - Isolating valve 31 - Isolating valve 32 - Isolating valve

A-Heating return

B-Cold water inlet C-Heating ﬂow D-Domestic hot water

outlet

E-Gas

a-Flue outlet

b-Overheat safety

thermostat.

c-Combustion chamber d-Expansion vessel e- Air/Gas mixture inlet

f-Ignition and control

electrode

g-Fan h-Gas control valve

i-Ignition module j-Condensate drain

k-Heating ﬂow

thermistor

l-Heating return

thermistor

m-Water ﬂow sensor

n-Water pressure sensor o-Pump p-Filter on cold water

inlet

q-Domestic plate to plate

heat exchanger

r-Discharge safety valve

10 bar

s-Discharge safety valve

3 bar

t-Filling system u-Drain cock v-Room thermostat plug

w-Control panel

Boiler components

Isofast F 35 E

m n

Page 14

INSTALLERS

2726

installed in a timber frame building it should be ﬁtted in accordance with the Institute of Gas Engineers document IGE/UP/7/1998. If in doubt seek advice from the local gas undertaking or Saunier Duval.

• The boiler is room sealed, so when it is installed in a room or space, a permanent air vent is not required.

• Due to the high efficiency and hence low casing temperature of this boiler, cupboard or compartment ventilation is not necessary.

Boiler location

• This boiler is not suitable for outdoor installation.

• This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements. In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS. In IE reference should be made to the current edition of I.S.813 "Domestic Gas Installations" and the current ETCI rules.

• The boiler should be positioned so that at least the minimum operational and servicing clearances are provided, see diagram opposite. Additional clearances may be beneﬁcial around the boiler for installation and servicing. For ﬂue installations where external access is not practicable, consideration should be given for the space required to insert the ﬂue internally, which may necessitate clearance larger than those speciﬁed in diagram.

• If the boiler is to be

Leave existing air vents. A template is supplied with the ﬁxing bracket. Position setting of the assembly shall be performed in compliance with the indications shown on the template. Use two or three screws for the ﬁxing bracket.

The mechanical characteristics of the screws shall – at least – meet the requirements speciﬁed on the sketches below. Also, they shall be suited to the characteristics of the carrier wall.

16 kg mini

33 kg mini

16 kg mini

33 kg mini

If the boiler is not immediately installed, protect the different

couplings so that no plaster or paint could jeopardize the tightness of subsequent

connections.

232

GAS

70 102 702115

20 mini

160

11875066

160

Ø 105

890

510

Page 15

INSTALLERS

2928

Flue location and Ventilation

Flue Position and Length

The standard horizontal ﬂue is ﬁtted onto the top of the boiler using the ﬂue elbow. See diagrams to determine whether a standard ﬂue can be used.

An elevated ﬂue system can be installed with the addition of a vertical ﬂue adapter, extension kits and elbow, see section ﬂue options.

When extension pipes are used the ﬂue system must be designed to have a continuous fall to the boiler of at least 3% to allow condensate to run back into the boiler and out via the drain.

Internal Flue Installation

The ﬂue can be installed from inside the building, when access to the outside wall face is not practicale.

Additional accessories are available. See Saunier Duval "Flue Options Guide" for conﬁgurations available.

Minimum siting dimensions for fanned ﬂues terminals poritions Horizontal ﬂues A-directly below an opening, air brick,

opening windows . . . . . . . . . . . . . . . . . . . . . . . . .300

B-above an opening, air brick, opening windows . . . .300

C - horizontally to an opening, air brick,

opening windows . . . . . . . . . . . . . . . . . . . . . . . . .300

D- below gutter, drain/soil pipe . . . . . . . . . . . . . . . . . . .25

E-below eaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

F-below a balcony or car port . . . . . . . . . . . . . . . . . .25

G- from vertical drain pipes and soil pipes . . . . . . . . . .25

H- from internal/external corners . . . . . . . . . . . . . . . . .25

H*- to a boundary alongside the terminal . . . . . . . . . . .300

I-above adjacent ground or balcony level . . . . . . . . .300

J-from surface or a boundary facing the terminal . . .600

K-facing terminals . . . . . . . . . . . . . . . . . . . . . . . . .1200

L-from opening (door/window) in car port

into dwelling . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200

M - vertical from a terminal . . . . . . . . . . . . . . . . . . . .1500

N - horizontally from a terminal . . . . . . . . . . . . . . . . . .300

Vertical ﬂues

P-from another terminal . . . . . . . . . . . . . . . . . . . . . .600

Q- above roof level . . . . . . . . . . . . . . . . . . . . . . . . . . .300

R-from adjacent opening window . . . . . . . . . . . . . .1000

S-from adjacent wall to ﬂue . . . . . . . . . . . . . . . . . . . .300

H* and J* : These dimensions comply with the building regulations, but they may need to be increased to avoid wall staining and nusance from pluming depending on site conditions.

Warning notice :

Use only ﬂue accessories developed for

Saunier Duval condensing boilers.

Page 16

INSTALLERS

3130

Flue location and Ventilation

• Terminal Position

The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in page 29. For Ireland the minimum distances for ﬂue terminal positioning must be those detailed in I.S.813 "Domestic Gas Installations".

The terminal must be exposed to the external air, allowing free passage of air across it at all times.

Being a condensing boiler some pluming may occur from the ﬂue outlet. This

should be taken into consideration when selecting the position for the terminal.

It may be necessary to increase dimensions H & J if there is a risk that the boiler products could stain any adjoining surface.

Carports or similar extensions of a roof only, or a roof and one wall, require special consideration with respect to any openings, doors, vents or windows under the roof. Care is required to protect the roof if made of plastic sheeting. If the carport comprises of a

roof and two or more walls, seek advice from the local gas supply company before installing the boiler.

• Terminal Guard

A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage. If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal.

The ﬂue system pipes must feature a slope of 3% towards the boiler in order to recover any condensates.

Attention : The ﬂue system terminal supplied by Saunier Duval already integrates this slope. Therefore, it shall be

applied to any ﬂue system extensions.

Gasket

The maximum head loss is reached with an elbow and ﬂue system length (L) of 10 m.

Horizontal ﬂues (installation type C13)

Page 17

INSTALLERS

3332

Heating system

General

The boiler is for use only with sealed central heating systems. The safety valve is an integral part of the boiler and it cannot be adjusted. The digital readout on the controls fascia indicates the system pressure when there is no central heating demand. The circulation pump is integral with the boiler.

Expansion vessel

The boiler has an integral expansion vessel with a capacity of 10 litres, with a charge pressure of 0.5 bar. Note : The expansion vessel volume depends on the total water system volume and the initial system design pressure. Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition of I.S.813 "Domestic Gas Installations".

Flow rate

If it is necessary to alter the ﬂow rate, the system can be fitted with a lockable balancing valve in the main ﬂow or return pipes shown as valve "A" in diagram. The ﬂow rate through the boiler must not be allowed to fall below 14 l/min.

Bypass

The boiler is ﬁtted with an adjustable automatic bypass. Ensure that under no circumstances does the ﬂow rate drop below 14l/min.

The installation of the boiler must comply with the requirements of the current issue of BS6798, in Ireland, refer also to the current edition of I.S.813 "Domestic Gas Installations".

In GB it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland).

To comply with the Water regulations your attention is drawn to : The Water Regulations guide published by the Water Regulations Advisory Service (WRAS) gives full details of the requirements.

Heating system

In IE the requirements given in the current edition of I.S.813 "Domestic Gas Installations" and the current Building Regulations must be followed.

Water tratment

In the case of an existing installation, it is ESSENTIAL that prior to installing the new boiler the system is thoroughly ﬂushed. For optimum performance after installation of a new system, the boiler and its associated central heating system should also be ﬂushed. Flushing should be carried

out in accordance with BS7593: 1992 using a cleanser such as Sentinel X300 or X400, Fernox Superﬂoc or Salamander corrosion guard cleaner. For long-term corrosion protection, after ﬂushing, an inhibitor suitable for stainless steel heat exchangers should be used, refer to the current issue of BS 5449 and BS 7593 on the use of inhibitors in central heating systems. Examples are Sentinel X100 Fernox or Salamander corrosion guard inhibitor.

Draining Tap

A draining tap must be provided at the lowest points of the system, which will allow the entire system to be drained. A drain tap for the appliance is provided as an integral part of the hydroblock, see diagram page 24. General - All domestic hot water circuits, connections, ﬁttings must be in accordance with the relevant standards and water supply regulations.

Domestic Hot Water System

For GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. For IE: The current edition of I.S.813 "Domestic Gas Installations".

Water Pressure

The maximum working pressure of the domestic hot water circuit is 10 bar. If the cold water supply pressure exceeds this, then

a pressure-reducing valve must be ﬁtted in the supply to the boiler.

'Hard' Water Areas

The temperatures within the heat exchanger are limited by the boiler control system to minimise scale formation within the hot water pipework. However, in areas where the water is 'hard' (i.e. more than 200mg/litre), it is recommended that the hot

water setting is reduced and that a scale reducer is ﬁtted. Refer to the manufacturer's instructions or consult the local water company for additional advice.

Domestic Water Flow Rate

The water ﬂow rate is restricted to a maximum 16 l/min by a restrictor ﬁtted on the cold water inlet.

Page 18

INSTALLERS

3534

Boiler installation

Prior to performing any operation, it is essential that the piping systems be ﬂushed with a suitable product in order to eliminate any impurities such as ﬁllings, weld spatters, oils and greases.

Such foreign materials could be driven into the boiler, and could impair its operation. NB: Solvents may cause damages to the piping system. Remove the wooden beam placed behind the boiler.

Appliance Connection

IMPORTANT: With regards to the Manual Handling Operations, 1992

Regulations, the following lift operation exceeds the recommended weight for a one man lift, refer to Manual Handling section, on page 4. The appliance will contain a small amount of water, place a water container beneath the boiler connections before removing the protective caps.

1 - Lifting the boiler into position, lean the top of the boiler slightly to the wall and position just above the hanging bracket.

2 - Lower the boiler slowly and engage onto the hanging bracket.

Connect isolating valves using washers and domestic ﬂow restrictor supplied with the boiler.

3 - Do not forget to connect the blue extension on the ﬁlling tap, as shown on the picture below.

➡

GAS

115

250

223

WALL

102

Piping installation

Make connections to boiler, gas, water and heating cocks with the tube assemblies supplied in piping pack as shown in the diagram below :

A-Heating return with isolating tap (t) and (u), B-Cold water inlet with isolating tap (v) and water restrictor to 16 l/min, C-Heating ﬂow with isolating tap (w), D-Domestic hot water outlet, E-Gas inlet with isolating tap (x).

Water restrictor

16 l/min.

Pressure connection

Gas Connection

Before connection check supply of local gas. Refer also to page 18. Do not subject the gas service cock to heat. Fit the sealing washer into the union nut and make good the connection to the gas service cock on the wall.

Make sure the on / off lever is accessible. The whole of the gas installation, including the meter, should be inspected, tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 "Domestic Gas Installations".

A - C : Central heating

Ø 22 mm

B- D : Domestic hot

water Ø 15 mm

E : Gas supply Ø 15 mm

Page 19

INSTALLERS

3736

Water Connections

Flush out the domestic hot water and the heating systems before connecting to the boiler. Make the connections to the domestic hot water and heating systems by ﬁtting the sealing washers into the securing nuts and make good the connection to the isolating valves. Do not subject the isolation valves to heat. Make sure the drain point is accessible.

• The heating return coupling is equipped with a ﬁlter, accessible after removing the end nut.

•The proof-test pressure can be read on a pressure gauge screwed instead of the heating return coupling end nut (A).

Filter on heating return (A)

A pressure gauge can be screwed instead of the heating return coupling

Piping installation

Safety Discharge Valve

The pipes from the safety discharge valves S1 and S2 must not discharge above an entrance, window or any type of public access area. Take the short safety discharge tube, union nut and seal, supplied loose in the boiler ﬁttings pack and ﬁt as shown in diagram below. This must be extended, using not less than 15mm

o.d. pipe, to discharge, in a visible position, outside the building, facing downwards, preferably over a drain. The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly boiling, or steam cannot create any danger to persons, damage to property or external electrical components and wiring.

To ease future servicing it is advisable to use a compression type ﬁtting supplied with the boiler to extend the safety discharge valve tube.

Page 20

WARNING : This appliance

must be earthed.

This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Saunier Duval guarantee. All system components must be of an approved type.

Electrical components have been tested to meet the equivalent requirements of the BEAB. Do not interrupt the mains supply with a time switch or programmer. Connection of the whole electrical system and any heating system controls to the electrical supply must be through a common isolator.

Isolation should preferably be by a double pole switched fused spur box having a minimum contact separation of 3mm on each pole. The fused spur box should be readily accessible and preferably adjacent to the boiler. It should be identiﬁed as to its use.

Mains Cable

Important: If a replacement supply cable is required it must be purchased from Saunier Duval.

• The 630 mA fuse of the PCB must be connected to the neutral.

Electrical connection

INSTALLERS

Connect the A elbow Ø 22 mm to a discharge

system leading to the sewer, in compliance with the instructions below:

- Use a rigid PVC tube or a ﬂexible silicon pipe resistant to condensate.

- The pipe must have a continuous fall.

- Do not use copper pipes

Important notice :

The ﬂoat of the condensate recovery system also ensures fume tightness. Therefore, it is useless to add water in the condensate box.

Condensate discharge elbow.

Condensate box with access plugs for cleaning purposes.

Ø 22 mm

YES

Piping installation

Page 21

➡

Cold water inlet

Heating return

➡

Heating ﬂow

INSTALLERS

4140

Commissioning on boiler

Please ensure the "Benchmark" logbook is completed and left with the user .

Filling the system 1 to 8

The commissioning and ﬁrst ﬁring of the boiler must only be done by a qualiﬁed registered person.

Make sure that the boiler is connected to the electrical supply and the gas service cock is open.

Switch ON (I). Open the isolating

taps (t), (u), (v) and (w)

on boiler: slot in line wi th the lenght of the valve

Undo cap on automatic air vent on top of pump and leave undone.

Fill the system until the pressure

indicated on the display is between 1 and 2 bar. Close ﬁlling device.

Bleed each radiator to remove the air, re-tighten bleed screws.

Leave the cap on the pump auto air vent open.

➡

Open various hot water taps to bleed system.

Make sure the display indicates a system pressure of between

1 and 2 bar. Re-ﬁll system as necessary.

1,5 bar

Page 22

INSTALLERS

Commissioning on boiler

4342

Press the key to operate the boiler without room thermostat.

• Adjust heating temperature to maximum.

• Allow the temperature to rise to the maximum value, with all radiator valves open. The temperature rise will cause release of the gases contained in the water of the central heating system.

• Gases driven towards the boiler will be automatically released through the automatic air vent.

• The gases trapped at the highest point of the system must be released by bleeding the radiators. Check the burner gas rate required, ten minutes from lighting. Refer to Data Label on electrical controls box. Should there be any doubt about the gas rate it should be checked at

the meter. On reaching maximum temperature, the boiler should be turned off and the system drained as rapidly as possible whilst still hot.

• Reﬁll system to a pressure of between 1 and 2 bar and vent as before.

• Restart boiler and operate until a maximum temperature is reached. Shut down boiler and vent heating system. If necessary, top up heating system and make sure that a pressure of at least 1 bar is indicated when system is COLD. Flush the domestic hot water system by opening the hot water taps for several minutes.

Instruct the User

• Instruct and demonstrate the lighting procedure and advise the user on the safe

and efficient operation of the boiler.

• Instruct on and demonstrate the operation of heating system control.

• Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents.

• Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the installation conditions and usage, but in general, once a year should be enough.

• Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35,

which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK.

• The user shall not interfere with or adjust sealed components.

• It is the Law that any servicing is carried out by a competent person.

• Advise the user that, like all condensing boilers this appliance will produce a plume of condensation from the ﬂue terminal in cool weather. This is due to the high efficiency and hence low ﬂue gas temperature of the boiler.

• Advise the user of the precautions necessary to prevent damage to the system, boiler and the building, in the event of the heating system being out of

use during frost or freezing conditions.

• Advise the user that the permanent mains electrical supply SHOULD NOT be switched off, as the built in frost protection and pump/valve saver program would not be operable.

• Reminder, leave these instructions and the ‘Benchmark’ logbook with the user.

• For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813.

Page 23

INSTALLERS

4544

Settings

The description below speciﬁes the operations to be performed to make adjustments to an installation ﬁtted with radiators or for a direct ﬂoor system. For other types of

installation (for example with a ﬂoor-heating system) , follow the instructions in the appropriate accessories manual.

Your installation consists of a single radiator zone or direct ﬂoor system

1/3

Access to the boiler’s technical data (reserved for use by the installers and After-Sales service personnel). This enables adjustments to be made and any malfunctions to be analysed :

Commissioning on room thermostat

The wireless room thermostat (R.O.) has been specially developed for the Isofast.

• It is powered by 3 LR6

1.5V alkaline batteries.

• The boilers various functions are parametered from the room thermostat.

Installing the room thermostat

• Fasten the bracket for the room thermostat on an internal wall approximately

1.50 m from the ﬂoor, in an area sheltered from direct sunlight and any source of interference, such as television, lamps, draughts, etc.

• Insert the batteries in the thermostat.

When commissioning for the ﬁrst time, At initial

commissioning stage, the boiler automatically shifts to manual mode (the control panel keys are lit, and the key is blinking), thus meaning that the wireless room thermostat has not yet been acknowledged by the boiler. To do this :

• Open the control panel

• Locate connector (A) on the left-hand side and insert it in the thermostat for a few seconds as shown in the photo opposite.

When the red indicator light stops ﬂashing, this shows that the boiler has recognised the thermostat.

LCD display

Conﬁrm OK

Access to the menus

Weekly

programme

Scroll

Up/Down

Return

Mains power point or power cable

Fault indicator (red)

Wall

bracket

Your installation consists of a single radiator zone or direct floor system

Progress of the operations :

1 - Accessing the installer menu

• Connect connector (A) to the room thermostat as detailed on the previous page.

• Press for 5 seconds to call up the following menu :

• Select installer menu :

2 - Select the language

3 - Installation configuration

INSTALLER MENU

SELECT THE LANGUAGE

INSTALLATION TYPE

Please note that pressing button at any time takes you back to the previous step.

ACCESS CODE

INSTALLER MENU

AFTERSALES MENU FAULT HISTORY BOILER DATA

1 RADIATOR ZONE

CHOOSE LANGAGE

INSTALLATION TYPE RADIO SATELLITE HEATING REGULATION BOILER CONFIG.

ENGLISH

Page 24

INSTALLERS

4746

Your installation consists of a single radiator zone or direct ﬂoor system

3/3

Settings

Your installation consists of a single radiator zone or direct ﬂoor system

2/3

4 - Radio accessories

RADIO SATELLITE

5 - Heating control

HEATING CONTROL

Selecting is recommended so that you can benefit from automatic circuit temperature control.

However, if you wish to adjust the radiator temperature yourself, select Then return to the user menu to set the radiator temperature.

AUTO

a/ Press for 5 seconds

6 - Boiler configuration

BOILER CONFIG.

Warning : This menu must only be used when installing one or more of these accessories > please refer to the section on "Activating the accessories".

OK OK

SET RADIATOR T¡

IN OUTDOOR SENSOR OFF

REPEATER OFF THERMOSTAT 2 OFF MODEM OFF

HEATING SETPOINT

MAX OUTPUT

CHIMNEY SET MAX RADIATOR T¡ MIN RADIATOR T¡ PUMP MODE

MANUAL

SET RADIATOR T¡

50¡C

OK TO VALIDATE

AUTO MANUAL

6.2 Adapting the length of the vent

CHIMNEY SET

6.3 Selecting the maximum radiator temperature

MAX RADIATOR T¡

6.4 Selecting the minimum radiator temperature

MIN RADIATOR T¡

6.5 Selecting the pump’s operation

PUMP MODE

Operation WITH THERMOSTAT is recommended in all cases except for direct floor heating, in which case you should select:

6.6 Choice of preheat

In ON mode, the boiler holds the exchanger at the required temperature between 5 O’clock a.m. and 11 O’clock p.m. in order to warrant optimal reactivity for the supply of sanitary hot water.

In AUTO mode, the boiler memorizes the day to day requirements of the family, and triggers the pre-heating a few minutes before the first use of sanitary hot water of the day.

In OFF mode, the function is inhibited.

WITH THERMOSTAT

PREHEAT

No setting is required for this type of boiler. Codes displayed do not af functionning of the boiler.

PERMANENT

MAX 73¡C MAX 65¡C MAX 50¡C

MIN 50¡C MIN 38¡C MIN 28¡C MIN 22¡C

WITH BURNER WITH THERMOSTAT PERMANENT

OFF

AUTO ON

Warning : for direct floor systems, do not exceed a temperature of 50°C.

6.1 Limiting the maximum heating power

MAX OUTPUT

/...

16kW 15kW 14kW

/...

WHEN YOU HAVE COMPLETED PARAMETERS, press for approx. 5 seconds to return to the initial display.

Page 25

INSTALLERS

4948

EXT. SENSOR ON

HEATING REGULATION

BOILER CONFIG. CHOOSE LANGUAGE

• Reach into the Heating Set Point menu to select the desired regulating mode.

Select the code following curves given on diagram below. NB: Zone 2 settings are only displayed when two heating zones have been selected in the “config. Installation” menu.

MANUAL

AUTO

HEATING SETPOINT

T¡ HEATING OFF

HEATING SETPOINT

Note : we recommend selecting 17 or 18°C.

You may retain the advantages conferred by the external sensor, while setting yourself the slopes of the sensor. Select the setting and adapt the following parameters :

OK OK

CORRECT T¡ ZONE1

SLOPE ZONE 2

SLOPE ZONE 1

CORRECT T¡ ZONE2

0,70,80,60,2

......

OK OK

1,61,51,40,2

4,0 4,0

......

... ...

OK OK

... ...

OK OK

... ...

OK OK

Temperature setting curves.

-30 -20 -10 100

100

Heating temperature outlet (°C)

Outside temperature (°C)

b/ T° heating off

a/ Heating setpoint

2.2 Heating setpoint

0,2

0,5

0,7

1,0

1,2

1,5

1,7

2,0

2,2 2,5 2,7 3,0 3,5 4,0

MANUAL

The setting is recommended to obtain automatic regulation of circuit temperatures. In such case, no slope adjustment is required. The boiler will itself select, after a few days, the slope which is the most suited to the heating installation.

Accessories settings

2/3

Settings

Accessories settings

INSTALLER MENU

• Press for 5 seconds to call up the following menu:

Progress of the operations :

RADIO ACCESSORIES

HEATING REGULATION BOILER CONFIG.

INSTALLER MENU

AFTERSALES MENU FAULT HISTORY BOILER DATA

ACCESS CODE

RADIO ACCESSORIES

EXT. SENSOR OFF

REPEATER OFF THERMOSTAT 2 OFF MODEM OFF

EXT. SENSOR OFF

EXT. SENSOR ON

REPEATER OFF THERMOSTAT 2 OFF MODEM OFF

CONNECT

1 - Access to the Radio accessories menu

• Select the installer menu:

• Select the Radio accessories menu:

Please note that pressing button at any time takes you back to the previous step.

2.1 External sensor recognition

2 - External sensor

The external sensor is now operating

Hold the satellite button, situated on the backside of the external sensor box, depressed for 10 seconds. To establish connection, the sensor transmits signals – this may require several minutes – until it is acknowledged by the room thermostat which then validates the connection through the following display :

• Connect connector (A) on the room thermostat as described page 44.

1/3

Page 26

Selecting the language on the thermostat’s display. Selecting the type of heating installation. The ON position of this menu assigns the TA1

clock function to the radiator zone. In such case, the ambient temperature at ﬂoor level is selected from the TA1 user’s menu.

Activating the various radio accessories on the installation.

Selecting Automatic or Manual control mode. In Automatic mode, the radiator temperature adapts automatically to the heating requirements of the room in which the thermostat is located, operating between the maximum and minimum temperature values set.

Selecting the boiler’s main operating parameters (power and heating circuit temperatures, pump mode and airﬂow conﬁguration).

INSTALLERS

5150

Glossary for the installater menu

Select the language Installation conﬁg. Clock zone 2

Radio accessories

Heating regulation

Boiler conﬁg.

Settings

Accessories settings

REPEATER OFF

REPEATER ON

THERMOSTAT 2 OFF MODEM OFF EXT. SENSOR OFF

CONNECT

The repeater is now operating

3 - Repeater

THERMOSTAT2 OFF

THERMOSTAT 2 ON

MODEM OFF EXT. SENSOR OFF REPEATER OFF

CONNECT

The room thermostat 2 is now operating

4 - Room thermostat 2

Hold the satellite button situated on the back side of the radio relay box depressed for 10 s. To establish the connection, the radio relay transmits signals until it is recognized by the room thermostat which validate the connection by the following display :

Disconnect the cable of the zone 1 room thermostat, and connect it to thermostat

2. This is sufficient to have it recognized by the boiler. Take the cable and reconnect it to zone 1 room thermostat and press the key. The following display will confirm the connection:

3/3

Page 27

INSTALLERS

5352

2/ Minimum HEATING input setting, through the CO2 : a - Connect a CO2 analyser

to sample point B of the adapter or ﬂue elbow.

b - Adjust the boiler at its minimum heating power using the room thermostat menus described in the below.

c - Perform a heating demand and record the

CO2 value after stabilization (2 minutes or so).

d - Adjust the screw D to obtain the G31 CO2 value stated in the table, taking the following principle into account :

To increase the CO2 value,

turn the screw clockwise

To decrease the CO2 value, turn the screw

anti-clockwise

Note : After re-installation of the sealed front face, the CO2 value changes, and must correspond to that given in the table.

3/ After setting and reassembly, restore the maximum heating power to its initial value (20 kW) and stick the gas data tag close to the nameplate.

Gas conversion

Your Isofast boiler is factory-set to operate with G20 gas. For operation with G31 gas, some adjustments must be made on the gas valve after removal of the sealed front cover in order to obtain the CO2 values given in the adjacent table.

1/ Maximum hot water input setting, through the CO2. a - Connect a CO2 analyser

to sample point B of the adapter or ﬂue elbow.

b - Fully open a hot water tap.

c - Wait for 2 minutes or so, until the CO2 reading has stabilized.

d - Adjust the screw C to obtain the G31 CO2 value stated in the table, taking the following principle into account:

To increase the CO2 value,

turn the screw anti-clockwise

To decrease the CO2 value,

turn the screw clockwise

Note : After re-installation of the sealed front face, the CO2 value changes, and must correspond to that given in the table.

Isofast F 35 E G20 G31

Heating output max. hot water kW 34,2 34,2 Heating output max. heating kW 6,4 6,4 C02 case off % 9±0,2 10,3±0,2 C02 case on % 9,2±0,3 10,5±0,3

1 - Access to the installer menu

• Connect A connector on the room thermostat as indicated page 44.

• Press for 5 seconds to call up the following menu:

• Select the Installer menu:

INSTALLER MENU

2 - Access to boiler configuration

BOILER CONFIG.

• Set MAX OUTPUT on the minimal value:

MAX OUTPUT

WHEN YOU HAVE COMPLETED PARAMETERING, press for approx. 5 seconds to return to the initial display.

ACCESS CODE

INSTALLER MENU

AFTERSALES MENU FAULT HISTORY BOILER DATA

MAX OUTPUT

CHIMNEY SET MAX. RADIATOR T¡

6 kW

5 kW

CHOOSE LANGUAGE

INSTALLATION TYPE RADIO SATELLITE HEATING REGULATION BOILER CONFIG.

/...

Page 28

Push the gas pipe upwards further into gas valve connection and then rotate anti-clockwise (looking down) until the gas pipe end is over the large hole in boiler chassis. Withdraw the gas pipe from gas valve connection and remove. Note : When replacing ensure that the sealing grommet, situated below the gas valve is correctly re-seated. Disconnect the gas valve electrical plug at the gas valve. Disconnect the electrical leads from the fan. Remove the ﬁve combustion chamber front retaining nuts, see diag. 5. Gently remove the fan, gas valve and burner assembly from the combustion chamber, see diag. 5. Clean the burner with a soft brush taking great care not to damage the front insulation. DO NOT use

wire or sharp instruments to clean the holes of the burner. Inspect the burner for any signs of damage. Inspect the sealing rings and replace if necessary.

Removal of the burner is not necessary during a normal service. NOTE : IF THE BURNER HAS TO BE REMOVED IT WILL REQUIRE A NEW GASKET WHEN REFITTED.

INSTALLERS

5554

Servicing

Important Notes

To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation and usage, but in general once a year should be enough. It is the Law that any servicing is carried out by a competent person. When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance speciﬁcation that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Saunier Duval.

General

Measurement of the products of combustion can be achieved by connection of a probe to the combustion analyser test point, see diagram 1.

IMPORTANT NOTE :

Products of combustion will be discharged when the cap is removed. It is important to replace the cap immediately. Before commencing with a service or replacement of parts, the boiler should be

isolated from the electrical supply and the gas supply should be turned off at the gas isolation valve, see

page 35.

All routine servicing requirements can be achieved by the removal of the front panel and inner panel only. To remove simply undo the two screws on the underside of the front panel and lift off. Undo the two screws on the front of inner panel and lift off, see diag. 2. Unless stated otherwise any part removed during servicing should be replaced in the reverse order to removal. Servicing should always include the removal of any debris from the condensate pipe and siphon. After completing any servicing of gas carrying components, ALWAYS test for gas soundness and carry out a functional test of the controls.

Spark Electrode

Disconnect the electrode lead and two securing screws. Withdraw the spark electrode carefully from the combustion chamber, see

diagram 3.

Inspect the tips for damage. Clean away any debris and check the spark gap is 3.5 to 4.5 mm.

Check the electrode gasket for signs of damage and replace if necessary.

Burner

Drop down the control panel into the service position. Disconnect the gas supply at the gas service cock. Remove the two gas pipe retaining clips, one located below gas valve and the other one located on the underside of the boiler chassis. Pull sealing grommet down gas pipe diagram. 4.

Diagram 1

Combustion analyser test point

Diagram 2

Torx screws

Diagram 3

Diagram 4 Diagram 5

Sealing grommet

Gas pipe retaining clip

Electrode

Gasket

Spark Gap 3.5 to 4.5

Heat exchanger

Combustion chamber

Burner

Sealing ring

Gas valve

Fan

Securing Nut (5)

Page 29

Draining of Boiler Heating Circuit

Drain down the Heating Circuit of the boiler only, by closing the heating ﬂow and return isolating taps (t, u and w), on the boiler connections, see diag. 10. Attach a length of hose to the drain point and open the drain valve (r), see diag. 9. After servicing or replacing parts, close the drain valve and remove the hose. Open the heating ﬂow and return isolating valves and reﬁll, vent and pressurise the heating circuit. Check for leaks.

Draining of Boiler Hot Water Circuit

Drain the Domestic Hot Water circuit by closing the cold-water isolation tap (v) on the boiler connection. Open one or more hot water taps to drain the hot water circuit. After servicing or replacing parts open the cold-water isolation valve and slowly open a hot water tap to

remove air. Close the hot water tap and check for any leaks.

Inner Casing Panel Seal Check.

Check the condition of the seal, replace as required. To replace remove the old seal, thoroughly clean the casing sufaces. Fit the new seal, it is supplied to the correct length.

➡

Cold water inlet

Heating return

➡

Heating ﬂow

INSTALLERS

Servicing

5756

Combustion Chamber and Heat Exchanger

Remove loose debris from combustion chamber using a soft brush and vacuum cleaner. Carefully ﬂush by spraying water removing any remaining debris through the condensate trap (Ensure the water is kept away from electrical components).

Condensate Drain

The condense drain does not normally need removing during servicing. To ﬂush the condense drain carefully pour water into the heat exchanger and check that water ﬂows freely to drain.

Combustion Check.

If a gas carrying component has been replaced, the combustion of the appliance should be checked. Once the appliance has been re-assembled (apart from the front and inner casing panels) connect a CO2 combustion analyser to the test point on the ﬂue adapter, and follow indications given on page 52-53.

Domestic Cold Water Inlet Filter

If the water ﬂow rate through the appliance has reduced it may be necessary to clean or

replace the water inlet ﬁlter. Turn off the electrical supply to the boiler. Drain the domestic hot water circuit. Slide out the securing clip, and remove the ﬁlter to clean or renew if necessary,

see diag. 6.

Replace the ﬁlter into its housing and replace the securing clip. Open the cold water isolating valve and test the Domestic Hot Water circuit for soundness. Check for leaks.

“Mouss” Filter

Turn off the electrical supply to the boiler. Drain the heating circuit of the boiler. Remove the ﬁlter retaining clip under the pump see diag. 7, and ﬁlter clean or renew if necessary. Reﬁt the ﬁlter. Open the heating ﬂow and return isolating valves and reﬁll, vent and pressurise the heating circuit. Check for leaks.

Central Heating Return Filter

Turn off the electrical supply to the boiler. Drain the heating circuit of the boiler. Unscrew the ﬁlter placed on heating return, see diag. 8, and clean ﬁlter or renew if necessary. Reﬁt the ﬁlter. Open the heating ﬂow and return isolating taps and reﬁll, vent and pressurise the heating circuit. Check for leaks.

➡

Cold Water Inlet Filter

Diagramm 6

Diagramm 7

Diagramm 8

Heating Return Filter

Diagramm 10

Diagramm 9

Page 30

INSTALLERS

5958

• Press for 5 seconds to call up the following menu:

• Select Aftersales menu

INSTALLER MENU

AFTERSALES MENU FAULT HISTORY BOILER DATA

BOILER CODE

MIN. FAN SPEED MAX. FAN SPEED START FAN SPEED BURNER OVERRIDE FAULT RESET AFTERSALES TEL

TEST RADIO SIGNAL

AFTERSALES MENU

FAULT HISTORY BOILER DATA

ACCESS CODE

• Press for 5 seconds to call up the following menu :

The room thermostat then transmits signals every 10 s. Successive display of the numbers , , , means that the signals are properly routed.

Accessing the Aftersales menu

Communication test

BOILER CODE

MIN. FAN SPEED

MAX. FAN SPEED

START FAN SPEED

BURNER OVERRIDE

FAULT RESET

AFTERSALES TEL

OK OK

WHEN YOU HAVE COMPLETED PARAMETERS, press for approx. 5 seconds to return to the initial display.

• Connect boiler connector (A) to the room thermostat as described page 44 :

• DO NOT connect the boiler connector to the room thermostat.

1 2 3 4

Attention: The code is pre-recorded at the factory. Note: The code corresponding to the boiler is indicated on the nameplate.

This factory-set value corresponds to the minimum input.

This factory-set value corresponds to the maximum input.

Fan start-up speed selection

Allows analysing boiler operation at its minimum or maximum power.

Erases the fault log.

Recording of after sales service telephone No. This No. will be displayed on thermostat screen in case of malfunction requiring attendance by a professional.

The use of the menus described here after is exclusively reserved for the after-sales personnel.

Servicing

• Press for 5 seconds to call up the following menu:

• Connect boiler connector (A) on the room thermostat as described page 44.

Every validation through the OK key will cause display of the corresponding value during boiler operation.

INSTALLER MENU

AFTERSALES MENU FAULT HISTORY BOILER DATA

BOILER DATA

INSTALLER MENU AFTERSALES MENU FAULT HISTORY

WATER PRESSURE

RADIATOR SETPOINT FLOW T¡ RETURN T¡ DHW T¡ TANK T¡ FAN SPEED DHW FLOW BURNER PHASE POWER

Access to the data menu

1 - "Fault history" menu

2 - "Boiler data" menu

FAULT HISTORY

BOILER DATA INSTALLER MENU

FAULT HISTORY TUE 04/02/03 10

--/--/--

• Use the buttons to select the "Fault history" menu:

• Use the buttons to select the "Boiler data" menu

The display shows the fault N° and its date of occurrence.

The after-sales menus, accessible from the room thermostat, allow investigating possible malfunctions and modifying certain factory set values.

WHEN YOU HAVE COMPLETED PARAMETERS, press for approx. 5 seconds to return to the initial display.

Page 31

INSTALLERS

Fault ﬁnding

6160

NOTE

Before trying to operate the boiler make sure that :

• All gas supply cocks are open and that the gas supply has been purged of air.

• There is a permanent mains supply to the boiler.

• There is a heating demand from the external control.

WARNING.

Always isolate the boiler from the electrical supply before carrying out any electrical replacement work.

Always check for gas soundness after any service work.

Electrical Testing

Should there be any doubt about the voltage supply to any of the components, it is possible to carry out a simple electrical test.

Important. On completion of the Service/Fault Finding tasks which have required the breaking and remaking of the electrical connections the earth continuity, polarity,

short circuit and resistance to earth checks must be repeated using a suitable multimeter. To carry out the electrical test, gain access, as follows : Hinge down the control box and remove Torx screws and unhook the rear panel, refer diagram 2 page 54. Refer to the Wiring diagram and fault ﬁnding charts diagrams.

Wiring diagram

1-Overheat thermostat 2-Fan 3-Gas valve 4-Heating return

thermistor

5-Heating ﬂow thermistor 6-Water pressure sensor 7-Pump 8-Water ﬂow sensor

9-User interface 10 - Room thermostat 11 - Ignition and controle

electrode

12 - Ignition module 13 - DHW temperature

sensor

14 - Three way valve 15 - Fuse 630 mA

16 - Chassis earth 17 - Main reset switch

Wiring diagram

Page 32

INSTALLERS

Fault ﬁnding

6362

FOLLOWING PAGE

Page 33

INSTALLERS

6564

Replacement of parts

General

Replacement of parts must be carried out by a competent person. Before replacing any parts the boiler should be isolated from the mains electric supply and the gas should be turned off at the service cock on the boiler. Unless stated otherwise parts are replaced in the reverse order to removal. After replacing any parts always test for gas soundness and if necessary carry out functional test of the controls. For replacement of parts the front casing and the inner casing panel of the boiler will need to be removed. To remove undo the two screws on the underside of the front casing and lift off. Undo the two screws on the front of the inner front panel and lift off. The side panels can be hinged sideways to aid replacement of parts. To hinge a side panel undo and remove the three screws securing each side panel to the boiler, two at the front and one at the top.

Spark Electrode

For access, refer to section “General”. Remove the spark plug lead, earth lead and two

securing screws. Withdraw the spark electrode carefully from the combustion chamber, see diagram3

page 55.

Igniter Unit

For access, refer to section “General”. Remove ignition lead and electrical connections then remove igniter unit by removing two securing screws, see diagram 1.

Ignition Lead

For access, refer to section “General”. Pull the spark plug style connector off the spark electrode and the spade connector connected to the igniter unit, see diagram 1.

Gas Valve

For access, refer to section “General”. Remove the electrical plug from the gas valve, see

diagram 2. Refer to pages 54 and 55 for removal of the fan, gas valve and burner assembly. Before removing the gas valve note its position on the fan. Remove the three securing screws, which ﬁx the gas valve and plastic swirl plate to the venturi on the fan, see diagram 3. Remove the gas valve.

Diagram 1

Securing screws (2)

Spade connector

Igniter unit

When re-ﬁtting the gas valve take care as it can be ﬁtted more than one way. After re-ﬁtting check the combustion CO2 and adjust if necessary, see page

52-53.

After assembly test for gas soundness and purge in accordance with the current issue of BS6891or in IE, the current edition of I.S.813 "Domestic Gas Installations".

Fan

For access, refer to section “General”. Refer to pages 54 and 55 for removal of the fan, gas valve and burner assembly. Remove the gas valve. Remove the venturi plate secured with three screws, see diagram 3. Remove the two screws securing the fan to the gas manifold, see diagram 4, check the gasket and replace if necessary.

Burner

For access, refer to section “General”. Refer to pages 54 and 55 for removal of the fan, gas valve and burner assembly. Remove the four screws that secure the burner, see diagram 5. NOTE : THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED.

Front Insulation

For access, refer to section “General”. Refer to pages 56 and 57 for removal of the fan, gas valve and burner assembly. Remove burner as previous section. Remove spark electrode.. NOTE: THE BURNER WILL REQUIRE A NEW GASKET WHEN REFITTED.

Rear Insulation

For access, refer to section “General”. Refer to pages 54 and 55 for removal of the fan, gas valve and burner assembly. Remove securing screw and washer in the centre of the insulation and withdraw insulation, see diagram 6.

Viewing Window

For access, refer to section “General”. Refer to diagram 7. Remove circlip. Remove steel washer. Remove glass. Remove ﬁbre washer. Replace in reverse order.

Diagram 2

Electrical plug

Gas valve

Pressure test point

Diagram 3

Securing screws (3)

Venturi plate

Diagram 4

Diagram 5

Gas manifold

Securing screws (2)

Burner

Securing screws (4)

Insulation

Diagram 6

Washer

rear insulation

Securing screw

Circlip

Steel washer

Glass

Fibre washer

Diagram 7

Page 34

INSTALLERS

Replacement of parts

6766

Expansion Vessel

For access, refer to section “General”. Refer to page 57 and drain the boiler heating circuit. Undo the coupling at the base of the vessel, see diagram 8. While holding the vessel remove the securing bolt on the top panel of the boiler. Remove upper support bracket. Lift the vessel up, draw bottom out to the left, lower and remove. Fit the replacement unit. Fit a new gasket between the expansion vessel and coupling. Reﬁll, vent and pressurise the boiler. Check for leaks.

Heat Exchanger

For access, refer to section “General”. Refer to pages 54 and 55 for removal of the fan, gas valve and burner assembly. Drain the boiler heating circuit, and the hot water circuit see page 57. Remove the clip securing the clear condense pipe to heat exchanger. Pull to remove the clear condense pipe out of the bottom of the heat exchanger. Undo the two nuts of the ﬂow and return pipes from

the heat exchanger.

Move the pipes away from

the heat exchanger.

Loosen the three heat

exchanger securing screws

and clamps (two at the top

and one at the bottom) to

remove the heat exchanger,

see diagram 9.

CAUTION: There will be

water in the heat exchanger.

Remove condense pipe

connector from bottom of

heat exchanger.

Carefully ease heat

exchanger out.

Flue Hood

For access, refer to section

“General”.

Remove heat exchanger as

per previous section.

Remove the two securing

screws and pull the ﬂue

hood down and away from

the ﬂue hood bracket and

ﬂue elbow, see diagram 10.

Diverter Valve Motor

For access, refer to section

“General”.

Refer to diagram 11.

Remove the electrical plug.

Unscrew the retaining nut.

Remove the diverter valve

motor.

Pump (head only)

For access, refer to section

“General”.

Drain the boiler heating

circuit.

Diagram 8

Expansion vessel

Diagram 9

Securing screws and clamps

Flow and return pipe nuts

Diagram 10

Securing screws (2)

Flue hood

Flue hood bracket

Refer to diagram 12. Remove the four cap head screws. Carefully remove the pump head together with cable. Do not strain cable. Support the pump head, unscrew cable cover at the side of pump head and take off. Disconnect wiring from pump head. Reconnect wiring to new pump head and ﬁt cover. Fit the new pump head with 'O' ring. Reﬁll, vent and pressurise the boiler. Check for leaks.

Safety Discharge Valve

For access, refer to section “General”. Drain the boiler heating circuit. Refer to diagram 13. Undo the safety discharge valve union and remove from the pipework. Remove the securing clip and withdraw the safety discharge valve. Fit new 'O' ring. Reﬁll, vent and pressurise the boiler. Check for leaks.

Domestic Hot Water Thermistor

For access, refer to section “General”. Drain the boiler domestic

hot water circuit. Refer to diagram 14. Disconnect the domestic hot water thermistor electrical connections Remove retaining clip. Withdraw domestic hot water thermistor from its housing. Note : When reconnecting electrical connections, polarity is not important. Fit new 'O' ring. Carry out a functional test of the controls.

Heating Flow Thermistor

For access, refer to section “General”. Refer to diagram 15. Remove the electrical connections from the thermistor. Remove the retaining clip from the ﬂow pipe. Note: When reconnecting the polarity of the wiring to thermistors is unimportant.

Diagram 11

Diagram 12

cap head screw (4)

Cable cover

Pump head

Diagram 13

Diagram 14

Electrical plug

Diverter valve motor

Safety discharge valve

Domestic hot water thermistor

Page 35

INSTALLERS

6968

Heating Return Thermistor

Overheat Thermostat

For access, refer to section “General”. Refer to diagram 15. Remove the electrical connections from the overheat thermostat. Remove the retaining clip from the ﬂow pipe. Remove the overheat thermostat from the retaining clip. NOTE. When ﬁtting new thermostat, please ensure that it is located correctly onto the ﬂat area of the pipe and the retaining clip is secure.

Automatic Air Vent

For access, refer to section “General”. Drain the boiler heating circuit. Refer to diagram 16. Remove the retaining clip and remove the automatic air vent. Fit the new automatic air

vent and 'O' ring ensuring

the vent cap is left loose.

Reﬁll, vent and pressurise

the boiler.

Check for leaks.

Flow Sensor

For access, refer to section

“General”.

Drain down the hot water

circuit.

• Undo the union nut on the

cold water inlet isolating

valve.

• Pull out slotted metal clip

securing ﬁlling system tap

into housing, swing the tap

forwards.

• Pull out the two slotted

metal clips retaining the

domestic water inlet ﬁlter

housing.

• Remove domestic water

inlet ﬁlter housing.

• Remove electrical

connections from water ﬂow

sensor.

• Pull off slotted metal clip

and remove water ﬂow

sensor.

Replacement of parts

Diagram 15

Diagram 16

Automtic air vent

Retaining clip

Diagram 17

Low Water Pressure Sensor

For access, refer to section “General”. Drain the boiler heating circuit. Refer to diagram 18. Disconnect the electrical lead by pushing up retaining tab to withdraw the lead plug. Remove the retaining clip to remove the low water pressure sensor. Fit new 'O' ring. Fit the new low water pressure sensor. Reﬁll vent and pressurise the boiler. Check for leaks.

Bypass Valve

For access, refer to section “General”. Drain the boiler heating circuit. Refer to diagram 19. Remove the retaining clip to remove the bypass valve. Fit new 'O' rings. Replace the bypass valve, reﬁll, vent and pressurise the boiler. Adjust the bypass as described pages 22-23. Check for leaks.

Filling Loop Tube

For access, refer to section “General”. Drain the boiler hot water circuit. Refer to diagram 20.

Remove the retaining clips to remove the ﬁlling loop tube. Fit new 'O' rings. After replacing the ﬁlling loop tube open the coldwater isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.

Filling Loop Valve

For access, refer to section “General”. Drain the boiler hot water circuit. Refer to diagram 20. Remove the clip securing the ﬁlling loop valve to the domestic water ﬁlter housing. Disengage by pulling forward. Remove the clip securing the ﬁlling loop to the ﬁlling loop valve. Remove the ﬁlling loop valve from the ﬁlling loop. Fit new 'O' rings. After replacing the ﬁlling

loop valve open the cold water isolation valve and slowly open a hot water tap to remove air. Close the hot water tap and check for any leaks.

Diagram 18

Retaining clip

Flow sensor

➜

Water ﬂow sensor

Diagram 19

Bypass valve

Diagram 20

Retaining clip

Filling loop tube

Filling loop valve

Retaining clip

Return thermistor

Overheat thermostat

Flow thermistor

Reduced pressure zone valve

Page 36

INSTALLERS

Replacement of parts

7170

Reduced Pressure Zone Valve

For access, refer to section “General”. Refer to diagram 20. Drain the boiler hot water circuit. Remove the ﬁlling loop Remove the retaining clip to remove the reduced pressure zone valve. Fit new 'O' rings. Replace the reduced pressure zone valve, reﬁll, vent and pressurise the boiler. Check for leaks.

Domestic Cold Water Inlet Filter

For access, refer to section “General”. Refer to page 56. Fit new 'O' rings.

Central Heating Filter

Refer to section page 56. Fit new 'O' rings.

Heating Circuit Drain Point

Refer to page 57 to drain the boiler heating circuit. Refer to diagram 21. Remove the retaining clip to remove the drain point. Fit new 'O' rings. Replace the drain point, reﬁll, vent and pressurise the boiler. Check for leaks.

Inner Casing Panel Seal

For access, refer to section

“General”.

Remove the inner casing

panel.

To replace remove the old

seal, thoroughly clean the

casing surfaces. Fit the new

seal, it is supplied to the

correct length.

Reﬁt the inner casing panel.

NOTE: Ensure the seal is

ﬁtted correctly giving an

airtight joint.

Condense Drain

For access, refer to section

“General”.

Refer to diagram 22.

Remove the clips securing

the ﬂexible tubes to the

siphon adapter by twisting

the clips slightly to

disengage the clip jaws from

each other.

Remove black ﬂexible tubes

from siphon adapter.

Lift off the siphon adapter.

Remove the drain

connection downstream of

the condense trap.

Remove the two condense

trap securing screws. Lift

up and carefully remove the

condense trap taking care

not to spill any water which

may be left in the unit. As

the unit is lifted remove the

ﬂexible pipe on the outlet.

Remove the cap at the base

of the condense trap.

Remove any solids found.

Remove the ﬂoat to clean it. Flush water through the trap to remove any remaining solids. Check for any debris in the outlet pipe of the condensate drain and clean as necessary. Reassemble and reﬁt the condense trap. When reﬁtting the cap ensure that a watertight seal

Diagram 21

Diagram 22

Siphon adapter

Float

Condens trap

Screw

Seal

is achieved, but do not use excessive force. Remove the siphon adaptor from the ﬂexible tubes, using a suitable container, ﬂush the heat exchanger until the water appears clear in the container.

Plate-to-Plate Heat Exchanger

For access, refer to section “General”. Drain the boiler heating and hot water circuits. Remove the water ﬂow sensor, refer to previous section. Unclip the central heating thermistor. Unscrew the heating ﬂow pipe union nut, swing pipe forwards. Remove the system water pressure sensor. Supporting domestic hot water plate to plate heat exchanger, unscrew and remove two screws securing it onto pump mounting and 3-way valve/bypass housing. Remove plate to plate heat exchanger from boiler. Fit replacement plate to plate heat exchanger in reverse order to removal using new seals, supplied. Note: Plate to plate heat exchanger mounting screws are offset to ensure correct ﬁtting.

Domestic safety valve (10 bar BLUE), refer to diagram 24.

For access, refer to section “General”. Drain down the hot water circuit only. Undo discharge pipe union nut. Pull out slotted metal clip from valve body and remove valve.

Micro accumulator vessel thermistor, refer to diagram 25.

For access, refer to section “General”. For this operation the boiler must be removed from the wall. IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift.

Cap

Diagram 23

➜

Diagram 24

➜

Diagram 25

Micro accumulator vessel

Thermistor

Heating element

Electrical cable

Page 37

When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge.

Short parts list

No. Description Part No. G.C. No.

1 Central heating thermistor S5739800 ••••••• 2 Fan S152000 ••••••• 3 Domestic water ﬂow sensor S5720200 ••••••• 4 Printed circuit board - Main S1040000 ••••••• 5 Pump head S1024000 ••••••• 6 System water pressure sensor S5720500 ••••••• 7 Gas control valve S1043900 ••••••• 8 Overheat thermostat S1040100 ••••••• 9 Three way valve S1025500 ••••••• 10 Pressure relief valve S1006700 ••••••• 11 Heat exchanger S1041100 ••••••• 12 Burner S1042200 ••••••• 13 Micro accumulation vessel S1025000 ••••••• 14 Micro accumulation vessel thermistor S1027300 •••••••

Spare parts

INSTALLERS

Replacement of parts

Note : It is not necessary to drain down entire heating system to carry out this work. Disconnect the ﬂue system. Disconnect the boiler connections pipes . Disconnect the pressure relief valve discharge pipes. Disconnect the mains cable and any external controls cables. Lift up to remove the boiler from the wall. Locate micro accumulator vessel thermistor, on side of the micro accumulation vessel. Disconnect the inline electrical connection plug to the micro accumulator vessel thermistor. Pull out to remove the thermistor.

Micro accumulator vessel, refer to diagram 25.

For access, refer to section “General”. For this operation the boiler must be removed from the wall, see previous section.

From the rear of the boiler, disconnect the inline electrical connection plug to the micro accumulator vessel thermistor. Remove the heating element electrical cable. Unscrew the retaining nuts

pipes.

• Remove the vessel from

the boiler.

Micro accumulator vessel

heating element, refer to

diagram 25.

For access, refer to section

“General”.

For this operation the boiler

must be removed from the

wall, see previous section.

Disconnect the electrical

connection plug to the

micro accumulator vessel

heating element at the

control board PCB

connection.

• Release the micro

accumulator vessel heating

element cable from the

securing clips, note the

routing of the cable for

reassembly.

• Pull out micro accumulator

vessel heating element.

Printed circuit board (PCB), refer to diagram 26

For access, refer to section “General”. Gain access to rear of control panel. Undo and remove the two front retaining screws. Hinge up the control panel cover and ease forwards from the rear retaining lugs to gain access to PCB. Do not strain the cables attached to the PCB. Note the routing of the cables.

• Carefully pull off electrical connections to PCB. Unclip and lift out PCB. Fit replacement PCB in reverse order to removal. Be careful not trap any of the cables. Make sure that PCB connections are fully pushed onto replacement PCB.

Diagram 26

Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions.

Retaining clips

Page 38

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