Saunier duval ISOMAX F 28 E User Manual

ISOMAX

IN WARRANTY

TECHNICAL HELPLINE

THIS IS A CAT I2E+ APPLIANCE

01773 828400

01773 828100

INSTALLATION AND OPERATING INSTRUCTIONS

ISOMAX F 28 E

Note!

The boiler serial number is marked on the label attached to the inside of the drop down door. Refer to the

'Introduction' section page 3 for a description of the basic functions of the boiler. The 'Users' section

describes how to safely operate the boiler.

USERS SECTION

Introduction.................................................... Page 3

Commissioning..........................................................3

Controls & lighting ....................................................4

Control options .........................................................5

Draining .....................................................................5

Servicing/maintenance ..........................................5

SERVICING SECTION

Routine cleaning and inspection ........................... Page 21 - 22

Replacement of parts ......................................................... 22 - 26

Boiler schematic .......................................................................... 27

Technical data ............................................................................ 28

Schematic wiring diagram ........................................................ 29

Fault finding...........................................................................30 - 32

Spare parts ................................................................................... 32

INSTALLATION SECTION

Introduction..................................................Page 3

Technical data ...................................................... 6

Dimensions ............................................................. 7

Heating system design ......................................... 7

Domestic hot water system design..................... 8

Boiler schematic .................................................... 8

Fixing jig .................................................................. 9

Piping system installation...............................9 - 10

Boiler location ...................................................... 11

Boiler installation.................................................. 12

Flue installation ............................................. 12 - 13

Electrical installation ........................................... 14

Commissioning..............................................15 - 18

Safety devices .............................................. 18 - 19

Settings.................................................................. 20

Mandatory warning for CEE countries Warning: This appliance is designed, approved and inspected to meet the requirements of the English market. The identification plate located on the inside of the appliance certifies the origin where the product was manufactured and the country for which it is intended. If you see any exception to this rule, please contact your nearest Saunier Duval dealer. Thank you in advance for your assistance.

INTRODUCTION

The

ISOMAX F

combination boiler with electronic ignition providing central heating and stored hot water.

The boiler is of the I2E+ category for use with Natural Gas (G20) as distributed in the United Kingdom, or Butane (G30), Propane (G31) or Towns Gas (G130) with the appropriate conversion kit.

boiler is a wall mounted modulating

The installation must be carried out by a qualified registered person in accordance with the relevant requirements of The Building Regulations, The Water Byelaws, The Building Standards (Scotland) Regulations and any applicable local regulations.

These instructions should be carefully followed for the safe and economical use of your boiler.

The boiler has a fan assisted balanced flue which both discharges the products of combustion to and draws the combustion air from the outside of the room. The boiler is suitable for top outlet flue connection only but, can be fitted with horizontal flue, vertical flue or twin-pipe flue. Refer to flue catalogue for further details.

Both the central heating and domestic hot water temperature are user adjustable from the boiler control panel. Domestic hot water demand always has priority over heating demand. The boiler is designed for use as part of a sealed water central heating system with fully pumped circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler .

The boiler can be installed against either an external wall or on an adjacent inside wall, that is, the flue system will pass directly to the rear or to either side to the terminal fitted on the outside wall face.

COMMISSIONING

Ancillary equipment

A range of flue accessories are available including vertical flues, twin-pipe flues, bends etc. For further information contact your supplier.

Substances Hazardous to Health The adhesives and sealants used in this appliance are cured and give no known hazard in this state.

INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL

These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaints you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handing should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the toilet. If you do suffer irritation to the eyes or severe irritation to the skin, seek medical attention.

Gas safety (Installation and use) Regulations

In your interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced by a qualified registered person in accordance with the above regulations.

Gas leak or fault

If a gas leak or fault exists or is suspected, turn the boiler off and consult the local gas supply company or your installation/service company.

Air in the heating system

Persistent air in the heating system may indicate leaks in the system or corrosion taking place. Call your Installation/Servicing company.

1-On/Off button 2-Summer/Winter mode selector 3-Hot water temperature adjuster 4-Hot water set point display 5-Graphic display 6-Heating temperature adjuster 7-Heating set point display 8-Display backlight

Overheating safety

In the event of a problem, the overheating safety devices cause safety shutdown of the boiler. If this happens, call your Installation/Servicing company.

Boiler controls

The control panel, located at the lower front of the boiler casing, see diagram 1, allows the boiler to be started, shut down, controlled and monitored during use.

Flue

Do not obstruct the outside terminal of the boiler.

158 7 26 34

mode

1.5

bar

Diagram 1

Hab 222

CONTROLS AND LIGHTING

Lighting the boiler :

Make sure that:

 The boiler is connected to the electrical supply.  The gas service cock is open.

Then follow the instructions below :

Press the On/Off button (1)

The pressure must be between 1 and 2 bar. If not, the system must be filled by a competent person.

1.5

bar

To stop the boiler : Press button (1)

mode

Hab 264

Setting to the SUMMER position

(Hot water only)

Appuyer sur mode pour sélectionner la position été

Press the mode button to select the summer symbol

mode

1.5

bar

The flame symbol appears

Apparaît lorsque le brûleur

when the boiler is running

est en fonctionnement

Adjusting the hot water temperature

Press + or - to adjust the maximum temperature

Appuyer sur + ou - pour ajuster la température

of the hot water (38°C to 60°C)

maximale de l'eau chaude sanitaire (38

Visual indication of set temperature

Visualisation de la température demandée

C à 60°C)

Setting to the WINTER position

Press the mode button to select the winter symbol

Appuyer sur mode pour sélectionner la position hiver

The actual temperature

Température actuelle

of the heating system

dans le circuit chauffage

Adjusting the heating temperature

Press + or - to adjust the maximum temperature

Appuyer sur + ou - pour ajuster la température

of the heating (38°C to 87°C)

maximale souhaitée du circuit chauffage

(Heating + hot water)

°C

Visual indication of set temperature

Visualisation de la température demandé

1.5

bar

Illuminates when

Apparaît lorsque le

the boiler lights

brûleur fonctionne

mode

°C

To obtain domestic hot water, open a hot water tap. Hot water always has priority over central heating.

mode

°C

mode

Hab 261

CONTROL OPTIONS

(a) Programmable room stat Part N° 40010, (b) Isocom combined boiler control & programmable room stat part N° 85915.

ISOCOM

Diagram 2

DRAINING

Protection against freezing

If the boiler is to be out of use for any long periods during severe weather conditions, it is recommended that the whole system, including the boiler , be drained to avoid the risk of freezing. If in doubt, consult your servicing company.

The

ISOMAX

that protects the boiler from freezing. If the boiler is to be left and there is a risk of frost, ensure that the gas and electrical supplies are left connected. The frost protection device will light the boiler when the temperature of the boiler water falls below 6°C. When the temperature reaches 16°C, the boiler stops. Note: This device works irrespective of any room thermostat setting and will protect the complete heating system.

has a built in frost protection device

SERVICING/MAINTENANCE

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.

Draining and filling

Caution: The boiler is installed as part of a sealed system which must only be drained and filled by a competent person.

Heating safety valve CAUTION: A heating safety valve with a discharge

pipe is fitted to this boiler. The valve MUST NOT BE TOUCHED except by a qualified registered person. If the valve discharges at any time, switch the boiler off and isolate it from the electrical supply. Contact your installation/service company.

Pressure/temperature relief valve CAUTION: A domestic hot water pressure relief

valve, with a discharge pipe is fitted to this boiler. The valve MUST NOT BE TOUCHED except by a qualified registered person. If the valve discharges at any time, switch the boiler off and isolate it from the electrical supply. Contact your installation/service company.

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.

TECHNICAL DATA

Heating

Heating output ajustable from 10,4 kW

to 27,6 kW

from 35,484 BTU/H

to 94,170 BTU/H Efficiency 91 % Maximum heating temperature 87 °C Expansion vessel effective capacity 8 l Expansion vessel charge pressure 0,5 bar Maximum system capacity at 75°C 180 l Safety valve, maximum service pressure 3 bar Products outlet diameter 60 mm Fresh air inlet diameter 100 mm

Hot water

Hot water output, automatically variable from 10,4 kW

to 27,6 kW

from 35,484 BTU/H

to 94,170 BTU/H Storage capacity 43 l Maximum hot water temperature 60 °C Minimum hot water temperature 37°C Specific flow rate (for 30°C temp rise) 13,2 l/min. Threshold flow rate 1 l/min. Nominal water flow rate 11,3 l/min. Temp./pressure relief valve opening pressure 7 bar Temp./pressure relief valve opening temperature 90°C Cylinder heat up time 7 min. Time to reheat 70% of storage to 60°C 3 min. Expansion valve setting 6 bar Maximum supply pressure 8 bar Minimum operating pressure 0,7 bar

Electrical

Electrical supply 230 V Maximum absorbed power 235 W Level of protection IP44

Natural Gas (G20)

Ø Burner injector 1,20 mm Inlet pressure 20 mbar Maxi. Burner pressure 13,8 mbar Mini. Burner pressure 2,16 mbar Gas rate maximum 3,20 m3/h Gas rate minimum 1,32 m3/h

Butane Gas (G30)

Ø Burner injector 0,77 mm Inlet pressure 29 mbar Maxi. Burner pressure 23,8 mbar Mini. Burner pressure 3,6 mbar Gas rate maximum 2,39 kg/h Gas rate minimum 0,99 kg/h

Propane Gas (G31)

Ø Burner injector 0,77 mm Inlet pressure 37 mbar Maxi. Burner pressure 30,8 mbar Mini. Burner pressure 3,6 mbar Gas rate maximum 2,35 kg/h Gas rate minimum 0,97 kg/h

Bypass fully shut

Open 1/4 turn

Open 1/2 turn

Open 1 turn

Open 2 turns

heating supply and return lines

Available pressure (kPa) between

(10 kPa = 1 m WG)

Pom 010 a

120010008006004002000

Flow rate through heating system (I/h)

DIMENSIONS

The

ISOMAX

- the boiler itself

- the fixing jig

- the flue system

Weight: 71 kg

is delivered in three separate packages:

131

234

890

Diagram 5

HEATING SYSTEM DESIGN

● The

ISOMAX

tallation.

● Heating surfaces may consist of radiators,

convectors or fan assisted convectors.

● The

ISOMAX

floor heating system without the need for a mixing bottle. The maximum central heating flow temperature can be set to 53°C on the boiler printed circuit board during commissioning.

● Pipe sectional areas shall be deter mined in ac-

cordance with normal practices, using the output/ pressure curve (diagram 4). The distribution system shall be calculated in accordance with the output requirements of the actual system, not the maximum output of the boiler. However, provision shall be made to ensure sufficient flow so that the temperature difference between the flow and return pipes be less than or equal to 20°C. The minimum flow is 400 l/h.

● The piping system shall be routed so as to avoid

any air pockets and facilitate permanent venting of the installation. Bleed fittings must be provided at every high point of the system and on all radiators.

is compatible with any type of ins-

can be piped directly to an under-

600

Hab322

480

● The total volume of water permitted for the heat-

ing system depends, amongst other things, on the static head in the cold condition. The expansion vessel on the boiler is pressurised at 0,5 bar (corresponding to a static head of 5 m w.g.) and allows a maximum system volume of 160 litres for an average temperature of 75°C and a maximum service pressure of 3 bar . This pressure setting can be modified at commissioning stage if the static head differs. An additional expansion vessel can be fitted to the system if required, see diagram 8.

● Provision shall be made for a drain valve at the

lowest point of the system.

● Where thermostatic radiator valves are fitted, not

all radiators must be fitted with this type of valve, and in particular, where the room thermostat is installed.

● In the case of an existing installation, it is ESSEN-

TIAL that the system is thoroughly flushed prior to

installing the new boiler.

Filling the system

A filling device must be fitted to the system to initially fill the system and replace water lost during servicing,see diagram 8.

DOMESTIC HOT WATER SYSTEM DESIGN

● Copper tubing or plastic Hep

the domestic hot water system. Unnecessary

0 may be used for

pressure losses should be avoided.

● A flow restrictor limiting the flow through the boiler

to a maximum of 16 l/min is fitted to the boiler.

● The boiler will operate with a minimum supply

pressure of 0,7 bar, but under reduced flow rate. Best operating comfort will be obtained from a supply pressure of 1 bar.

BOILER SCHEMATIC

1-Domestic thermistor 2-Three way valve 3-Gas valve 4-Gas valve ignition module 5-Temperatur sensor for accumulation vessel 6-Accumulation vessel 7-Burner 8-Ignition electrode 9-Combustion chamber 10 - Heating safety valve (3 bar) 11 - Main heat exchanger 12 - Air pressure switch 13 - Flow detector 14 - DHW pump 15 - Non return valve 16 - Bypass 17 - Domestic heat exchanger 18 - Heating pump 19 - Heating expansion vessel 20 - Heating thermistor 21 - Overheat safety ther mostat 22 - Flame sensor electrode 23 - Fan 24 - Domestic safety valve (6 bar) 25 - Loss of water sensor 26 - Domestic expansion vessel 27 - Pressure/temperature relief (7 bar) 28 - Domestic safety valve (10 bar)

A-Heating return B-Cold water inlet C-Heating flow D-Domestic hot water outlet E-Gas D1 - Discharge from HTG safety valves D2 - Discharge from DHW safety valves D3 - Discharge from temp/press (to tundish)

Diagram 6

'Hard Water Areas'

In areas where the water is 'hard', more than 200mg/litre, it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler.

10 28

AB C DE

Shy 163cUK

Valve

outlet size

Minimum

size of discharge to tundish

G 1/2 15 mm 22mm up to 9 m 0.8 m

G 3/4 22 mm 28 mm up to 9 m 1.0 m

G 1 28 mm 35 mm up to 9 m 1.4 m

Minimum

size of

discharge

pipe D2

from

tundish

28 mm up to 18 m 1.0 m 35 mm up to 27 m 1.4 m

35 mm up to 18 m 1.4 m 42 mm up to 27 m 1.7 m

42 mm up to 18 m 1.7 m 54 mm up to 27 m 2.3 m

Maximum resistance

allowed

expressed as a

length of

straight pipe

i.e. no elbows

or bends

Resistance

created by

each elbow or

bend

Discharge from HTG+ domestic prv on jig

D1 D3

Diagram 6a

Discharge from DHW safety valves

Tundish

Gully

FIXING JIG

The fixing jig is made up, from left to right, as follows: A- Heating return fitting with isolating valve(v) and drain knob (u). B- Cold water inlet fitting with isolating valve (m)and factory fitted flow regulator and filter (not shown).

Diagram 7

B C D E

➜

C- Heating flow fitting with isolating valve (q), drain knob (r) and safety valve (10). D- Domestic hot water outlet fitting with safety valve (28). E- Gas fitting.

Pla 213

PIPING SYSTEM INSTALLATION

● Heating system connections - Pipe diam. 22mm

● Hot water system connections - Pipe diam. 15mm

● Gas connection - Pipe diam. 22mm

● Domestic safety valve connection - Pipe

diam.15mm

● Heating safety valve connection - Pipe diam.

15mm

Water connection

Connect the copper connections supplied, to the fixing jig fittings, see diagram 7. Connect the sys-

Additional expansion vessel (if required)

Return

Heating circuit

Flow

control valve

Boiler

Bypass

valve

Filling device

Drain point

Domestic

water

Hot

Cold supply

Pressure reducing valve (supplied)

tem pipework to the boiler observing the correct flow and return format as shown in diagram 8. There are two sets of two safety valves fitted to this appliance. Two are located on the jig diagram 7, (10) heating safety valve 3 bar, and (28) DHW safety valve 10 bar . The other two are located inside the boiler (diagram 6,) (27) pressure/temperature relief safety valve 7 bar/90°C, and (24) DHW safety valve 6 bar.

Thermostatic

MIX

Temperature adjustment

mixing valve

Thermostaticaly

controlled

hot water

Boiler

"set temperature"

hot water

Diagram 8

Sch 173a

PIPING SYSTEM INSTALLATION

Step. 1

The internal safety valves have been tee'd together and the discharge pipe run so that it exits at the right hand bottom of the boiler (diagram 6) (D2). The tundish (supplied) must be used with this outlet within the normal guidelines and code of practice (diagram 6a).

Step 2

Tee the domestic safety valve (diagram 7) (28) outlet to the heating safety valve (10) outlet together. You can either extend this pipe horizontally to the outside wall. WARNING, It must not discharge above an entrance or window or any type of public access area, the discharge must be extend using no less than 15 mm o.d. pipe to discharge in a visible position outside the building, facing downard preferably over a drain. The pipe must have a continuous fall and be routed to a position so that any discharge of water, possibly steam, cannot create any danger to persons, damage to property or external electrical components and wiring. alternatively : The discharge pipe can be tee'd into the other discharge pipe after the tundish (diagram

6) provided that it has a continuous fall and that provisions are made for the size of discharge pipe immediately after the tundish (see diagram 6a)

Safety valve discharge

Domestic hot water supply options

Under normal circumstances, the domestic hot water storage temperature inside the boiler can be stored between 37 and 60° C. It is recommended that the boiler storage temperature is set by the user to the maximum of 60°C - this will ensure a more plentiful supply of hot water.

To pipe the hot water supply using the mixing valve, refer to diagram 8. This shows one outlet supplying hot water at the boiler hot water "set temperature" and one hot water outlet at a temperature pre-set at the mixing valve. The mixing valve can be set between 35 and 60°C. It is recommended that the valve is adjusted (and locked) by the installer to the desired temperature.

The connections to the mixing valve are : H - Hot water supply from boiler C - Reduced cold water supply MIX - Thermostatically controlled outlet

Warning : It is strongly recommended that the cold water supply to the mixing valve is taken from the reduced side of the pressure reducing valve (supplied) Note 1 : The mixing valve is fitted with two in-line strainer, one on the hot inlet and one on the cold inlet. For servicing details of these, refer to the separate instructions supplied with the mixing valve.

Note 2 : The mixing valve incorporates a "rapid failsafe" device which will automatically close the valve to safety in the event of supply failure on either hot or cold water. The discharge must be extended using not less than 22 m o.d. pipe, to discharge in a visible position outside the building, facing downward 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. Tighten all pipe connection joints.

It may be desirable to provide hot water to separate outlets at different temperatures (for example, to provide a limited temperature to prevent the risk of scalding). To be able to do this, a thermostatic mixing valve is supplied with the Isomax boiler (factory set to 43°C) and can be fitted during the installation procedure.

There are 2 options for the domestic hot water supply : 1 - Piping the hot water supply without the use of the mixing valve to provide hot water to all taps at the same temperature. 2 - Piping the hot water supply using the mixing valve (supplied) to provide hot water at boiler hot water “set temperature” to one tap and thermostatically controlled hot water to another tap(s).

Gas connection

● The supply from the governed gas meter must be

of adequate size to provide a constant inlet working pressure of 20 mbar (8 in w.g.). To avoid low gas pressure problems, it is recommended that the gas supply is connected using 22 mm pipe.

● On completion, the gas installation must be

tested using the pressure drop method and purged in accordance with the current issue of BS6891.

Gas Safety (Installation and use) Regulations

In your interests and that of gas safety, it is the law that ALL gas appliances are installed and serviced by a qualified registered person in accordance with the above regulations.

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