Saunier duval ISOMAX F 28 E User Manual

Page 1
ISOMAX
IN WARRANTY
TECHNICAL HELPLINE
THIS IS A CAT I2E+ APPLIANCE
01773 828400
01773 828100
1
Page 2
INSTALLATION AND OPERATING INSTRUCTIONS
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.
2
Page 3
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
IO
mode
1.5
bar
Diagram 1
Hab 222
3
Page 4
e
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)
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)
IO
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
2
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
3
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
10
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
50
To obtain domestic hot water, open a hot water tap. Hot water always has priority over central heating.
4
mode
60
°C
mode
Hab 261
Page 5
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.
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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
1
Open 1/4 turn
2
3
Open 1/2 turn
Open 1 turn
4
Open 2 turns
5
60
50
40
1
2
3
4
5
30
20
10
heating supply and return lines
Available pressure (kPa) between
0
(10 kPa = 1 m WG)
Pom 010 a
120010008006004002000
Flow rate through heating system (I/h)
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Page 7
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.
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Page 8
DOMESTIC HOT WATER SYSTEM DESIGN
Copper tubing or plastic Hep
the domestic hot water system. Unnecessary
0 may be used for
2
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)
19
16
25
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.
23
12
27
11
21
22
15
18
17
14
7
20
9
8
3
4
2
1
6
5
26
24
13
10 28
AB C DE
D1
D1
D2
D1
D3
D1
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
8
bend
Discharge from HTG+ domestic prv on jig
D1 D3
Diagram 6a
Discharge from DHW safety valves
D2
Tundish
Gully
Page 9
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
A
B C D E
u
m
10
v
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.
r
q
28
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
HC
Temperature adjustment
mixing valve
Thermostaticaly
controlled
hot water
Boiler
"set temperature"
hot water
Diagram 8
Sch 173a
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Page 10
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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Page 11
BOILER LOCATION
Clearances
The position of the boiler must be such that there is adequate space for servicing. The recommended clearances are: 20 mm either side of the boiler. 600 mm at the front of the boiler. 300 mm below the boiler.
Place template on wall in required position, mak-
ing allowances for the necessary clearances etc. Note: It is permissible to install the boiler with smaller clearances than those quoted above PROVIDING that adequate consideration is given for Servicing/ Repairs at a later date. If any doubt exists, contact the Saunier Duval T echnical Helpline 01773 828400.
Mark the position of the holes for the hanging
bracket and jig.
Drill, plug and fix the hanging bracket to the wall
using suitable screws.
Check that the hanging bracket is level.
Drill plug and fix the fixing jig to the wall.
For horizontal flue system, mark the position for
the flue hole as follows:
Flue to rear of boiler
Mark correct position of hole from template.
Diagram 9
Ø 105 pour sortie ventouse (type F)
Ø 105 or 125 core drill
169
65
900
2,10 m au sol (pour les modèles type C)
==
20 mm
mini
120
600
234
20
per metre of flue DOWNWARD towards the termi­nal. There must NEVER be a downward incline to­wards the boiler.
Ins 090a
Flue to side of boiler
Mark the horizontal centre line for the hole on the
rear wall. Extend the horizontal centre line to the side wall and mark the vertical centre line of flue hole as shown in diagram 9.
Terminal position
The minimum acceptable spacings from the ter­minal to obstructions and ventilation openings are shown in diagram 10. The boiler must be installed so that the terminal is exposed to the external air.
Cutting the flue hole
Making allowance for the slope of the flue, cut
hole in external wall, preferably using a core drill.
Should any doubt exist as to the permissible posi­tion of the terminal, contact the Saunier Duval
Technical Helpline 01773 828400.
For installations with internal and external access use a 10 5 mm diameter core drill. For installations with internal access only use a 125 mm diameter core drill.
Terminal guard
If a terminal guard is required, a suitable guard can be obtained from your supplier , Saunier Duval part number 85373.
Important
When cutting the flue hole and when extending the flue centre line to a side wall, remember that the flue system must have a fall of about 35 mm
Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or compart­ment without the need for permanent ventilation.
Minimum dimensions (in mm) for the positioning of flue terminals
A-Under a window .................................................... 300
B-Under an air vent .................................................. 300
C-Under a gutter ......................................................... 75
D-Under a balcony ................................................... 300
E-From an adjacent window .................................. 300
F-From an adjacent air vent................................... 300
G-From vertical or horizontal air pipes.................... 300
H-From an external corner of the building............ 300
I-From an internal corner of the building ............. 300
L-From the ground or from another floor .............. 300
M-Between two terminals vertically ...................... 1500
N-Between two terminals horizontally .................... 600
G
C
N
E
F
M
A
B
D
I
L
H
Diagram 10
Ven 060b
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Page 12
BOILER INSTALLATION
Rear flue outer pipe E+55mm, inner pipe E+217mm RHS flue outer pipe E+A+290mm, inner pipe E+A+452mm LHS flue outer pipe E+A-48mm, inner pipe E+A+114mm
Statutory requirements
The installation of this boiler must be carried out by a qualified registered person in accordance with the relevant requirements of the current issue of: The Gas Safety (Installation and Use) Regulations The Building Regulations The local water company Byelaws The Building Standards Regulations (Scotland) The Health and Safety at Work Act
Sheet metal parts
WARNING. When installing or servicing this boiler, care should be taken when handling the edges of sheet metal parts to avoid the possibility of personal injury.
FLUE INSTALLATION
Top outlet flue - kit 85090
The boiler is only suitable for top outlet flue connection.
Rear flue systems
The calculate the lenght when flueing to the rear measure e (diagram 11) plus 25 mm outer flue pipe and e plus 125 mm to inner pipe measurement.
Installing the boiler
Prior to starting work, the system must be thoroughly flushed using a propriety cleanser such as Sentinel X300 to eliminate any foreign matter and contami­nation e.g. metal filings, solder particles, oil, grease etc. Note. Solvent products could cause damage to the system.
Engage boiler upper part onto the hanging
bracket.
Fit the washers between the boiler pipes and the
inlet and outlet fittings on the fixing jig and con­nect the various couplings between the boiler and jig.
Calculation of cutting lengths when flueing to the right or left
Measure wall thickness e (mm), see diagram 11.
For right hand applications
Measure distance from inside face of wall to side
of the boiler a (diagram 11) add 350 mm to outer pipe measurement and 445 mm to inner pipe mesurement.
For left hand applications
Measure distance from inside face of wall to side
of the boiler a (diagram 11) subtract 25 mm for outer pipe length and add 75 mm to inner pipe length measurement.
Refer to table 2 for cutting lengths of both inner
and outer flue pipes for each of the various flue options available.
Important: All flue cutting lengths must be meas­ured from the terminal end of the flue pipes, see
diagram 12.
When the dimension X measured on site is greater than that given in table 2. Extensions will be required as necessary.
Important: All cutting lengths should be measured from the push fit joint end of the extension pipe. Do not leave any burrs or sharp edges on the cut ends of the pipes. Note : maximum horizontal flue lenght without bends is 3 m.
ee
a
X
Diagram 11
Diagram 12
Table 2 Flue cutting lengths (mm)
Rear flue Outer pipe : e + 25, inner pipe : e + 120
Comment : maximum distance 'x' without extension 770 mm
Right side flue Outer pipe : e + a + 350, inner pipe : e + a + 450
Comment : maximum distance 'x' without extension 515 mm
Left side flue Outer pipe : e - 25, inner pipe : e + 125
Comment :
maximum distance 'x' without extension 1087 mm
Outer pipe
Cutting length
Inner pipe
Cutting length
a
X
Hab 210a
Ven 089
12
Page 13
FLUE INSTALLATION
Installation of flue assembly
Fit rubber sealing collar (F), see diagram 13, into
groove at the outer end of pipe (A).
Fit outer pipe (A) into wall with groove to the out-
side.
Pull pipe inwards to bring rubber sealing collar
hard up against external wall, see diagram 14.
Fit internal plastic flange (G) onto outer pipe. Push
along the pipe until engaged against internal wall.
From inside, insert inner pipe (B) into outer pipe.
Fit both O rings (J) into the flue elbow (C), one
at the inlet, one at the outlet. By necessity, they are a loose fit, apply a small amount of silicone grease to each ‘O’ ring when fitting.
Wrap sleeve (D) over outer pipe (A) and elbow
(C) ensuring it is the correct way round.
Take hold of the inner flue and push gently onto
the elbow outlet taking care not to tear the ‘O’ ring.
Open fixing collard (D) and locate between
elbow and outer pipe (A). Close fixing jig.
Engage the two fixing clips (E) onto the colar
onto (D) and press down to lock into position. Secure clips with screws provided.
Important: If the flue has been cut, ensure that there are no burrs that could damage the ‘O’ ring.
For flue systems less than 1,5 m long, leave the
restrictor (a) fitted in the fan outlet, see diagram
15.
Remove the backing from the self adhesive gas-
ket (H) and carefully fit gasket to base of flue el­bow.
Fit elbow onto boiler and secure with the four
screws (I).
Diagram 13
A
B
E
C
D
H
The flue kit 86285 is 1000 mm long and comprises:
- Outer pipe .............................................................. A
- Inner pipe ................................................................B
- Flue elbow ..............................................................C
- Fixing collar............................................................. D
- Locking clips............................................................E
- External rubber sealing collar ............................... F
- Internal flange .......................................................G
- Gasket..................................................................... H
- Scre w s ....................................................................... I
- 'O' rings..................................................................... J
Diagram 14
F
I
J
G
Pho 451
Pho 087
Concentric flue system
The maximum permissible length (L) for the concentric flue system is 3 m. For flue systems up to 1,5 m length, the restrictor (a) supplied fitted to the boiler , inside the fan outlet, must be left in place. For longer flue systems, the restrictor must be removed. For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced by 1 metre.
L
Gasket
a
Diagram 15
65
234
13
Hab 249a
Page 14
ELECTRICAL CONNECTION
Warning. This boiler must be earthed All system components must be of an approved type.
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 3 mm 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. A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that: a) They are not used in a room containing a fixed bath or shower. b) Both the plug and socket comply with the cur­rent issue of BS1363. The mains electrical supply must be maintained at all times in order to provide domestic hot water. Do not interrupt the mains supply with a time switch or programmer.
WARNING: ON NO ACCOUNT MUST ANY EXTERNAL VOLT AGE BE APPLIED TO ANY OF THE TERMINALS ON THE HEATING CONTROLS CONNECTION PLUG.
The boiler will work for heating without a room ther­mostat being connected provided that the wire link fitted between the two terminals of the con­nector (E) is left in place, see diagram 17.
Alternatively, a 230V room thermostat can be used but do not make any connection to the compen­sating resistor, see diagram 17. ON NO ACCOUNT must any electrical voltage be applied to any of the terminals of the external con­trols plug.
Note: For further information, see the building regulations 1991 - Conservation of Fuel and Power
- 1995 edition - appendix G, Table 4b.
The boiler is supplied with a mains lead at­tached. Connect this to the electrical supply.
Warning: This appliance must be wired in accord-
ance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Saunier Duval guarantee.
External controls
The ISOMAX boiler is designed to operate at maxi- mum efficiency at all times, but will be most effi­cient and economical when connected to a room thermostat. A suitable room thermostat is available as an ac­cessory, Saunier Duval part number 40011. Please contact your supplier.
Also available :
For extra control or if the boiler is to be sited in a garage or utility room an optional remote control unit with programmable roomstat can be obtained part number 85915 (Isocom), diagram 2. This is a dual function unit (a) boiler control (same as boiler facia) (b) programmable room stat. Full fitting instructions supplied with the unit.
Isocom only
F
Diagram 16
Leave link in place for no external controls.
F
Diagram 17
IMPORTANT
With voltage free room thermostat
Without room thermostat
E
¡C
Ins 060
Sch 171
14
Sch 172
E E
Page 15
COMMISSIONING
d
The commissioning and first firing of the boiler must only be done by a qualifed registered person.
Gas installation
It is recommended that any air is purged from the supply at the gas inlet test point on the gas valve, see diagram 18.
Filling the system
Press the mains 'On/Off' button
1
Le témoin lumineux clignote
The warning light will illuminate
L'afficheur indique 0 bar de pression et clignote
The display will indicate 0 bar pressure in the system
0.0
bar
Diagram 18
Reg 018
IO
1
mode
v
m
Open the boiler isolating valves (v and q), the slot of the screw corre-
2
sponds to flow direction. Fully open valve m by turning anti­clockwise.
4
Open filling device fitted previously, fill the system
until the pressure indicated on the display is between
1 and 2 bar. Close filling device.
q
3
Undo cap on auto­matic air vent on top of pump and leave un-
Pla 213
done.
The pressure must be between 1 and 2 bar
Hab 260
Reg 008
mo
1.5
bar
Hab 265
15
Page 16
COMMISSIONING
Bleed each radiator to re-
5 76
move the air, re-tighten bleed screws.
Ins 061
Make sure the display indicates a system pressure of between 1 and 2 bar. Re-fill system as
8
necessary.
The pressure must be between 1 and 2 bar
Leave the cap on the pump auto air vent open.
Reg 008
Open various hot water taps to bleed system.
Ins 062
IO
1.5
bar
mode
Hab 265
16
Page 17
COMMISSIONING
e
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)
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)
IO
1
mode
Hab 264
Setting to the WINTER position
(Heating + hot water)
Press the mode button to select the winter symbol
Appuyer sur mode pour sélectionner la position hiver
2
°C
10
The actual temperature
Température actuelle
of the heating system
dans le circuit chauffage
1.5
bar
Illuminates when
Apparaît lorsque le
the boiler lights
brûleur fonctionne
mode
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
Visual indication of set temperature
Visualisation de la température demandé
Adjust heating temperature to maximum .
Check that any external controls, if fitted, are
calling for heat (set room thermostat 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 automati-
cally released through the automatic air vent.
The gases trapped at the highest point of the sys-
tem must be released by bleeding the radiators. 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 tem-
perature 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.
3
60
°C
mode
Hab 261
17
Page 18
COMMISSIONING
Setting the heating output
The heating output can be set without the use of a pressure gauge; proceed as follows:
Press the display light button
and keep pressed for 5 seconds, see diagram 20. Note:The boiler has now been put into 'Service
Mode', allowing certain adjustments to be made and diagnostic fault codes to be displayed. Refer to the 'Servicing Instructions' for further details. The heating output, in kW , is shown on the left hand side of the display, see diagram 21.
Remove the blanking plug from the front of the
control panel to gain access to the heating ad­justing screw.
Adjust the heating output by turning the screw
clockwise to increase, anti-clockwise to decrease.
Refit blanking plug.
Note: Adjustment of the heating output does not affect the domestic hot water output.
For kW to Btu/hr conversion refer to table 5.
Table 5 kW to Btu/hr conversion
kW Btu/hr
10 34,120 12 40,940 14 47,770 16 54,590 18 61,420
kW Btu/hr
20 68,240 22 75,060 24 81,890 26 88,710 28 95,540
1
Diagram 20
Adjustment screw
Diagram 21
Setting the heating output
2
mode
20 01
5 s
Reg 051/UK
Setting the heating output
The heating output, in kW , is shown on the display.
Reg 052
kW Btu/hr
30 102,360 32 109,180 34 116,000 35 119,420
Setting the maximum heating temperature
The maximum heating temperature can be preset at commissioning stage to suit the type of heating system. For example, for use with underfloor heating, the maximum heating temperature can be set to 53°C. To adjust the maximum temperature, proceed as follows:
Remove the blanking plug (b) from the rear of
the control panel to gain acess to selector switch SW1 (see diagram 22). Adjust toggles 1 and 2 to give the desired maxi­mum heating temperature, see diagram Note: T o adjust the maximum heating temperature it is only necessary to change toggles 1 and 2. Do NOT touch any other toggles.
Refit blanking plug.
b
Diagram 22
1=ON, 2=ON 53 °C. Maximum. 1=OFF, 2=OFF 73°C. Maximum. 1=OFF, 2=ON 87°C. Maximum.
Factory setting ➜ 73°C.
O N
1234567
Reg 053
SW1
SAFETY DEVICES
The
ISOMAX
cates fault conditions, should they occur. In the event of a fault, the display will indicate, by means of pictograms and/or letters and numbers, exactly in which area the fault lies.
18
incorporates a visual display that indi-
Should the boiler fail to operate during Commis­sioning, the most likely fault is that the gas supply to the boiler has not been turned on or purged suf­ficiently or that there is no pressure in the heating system. These are indicated as follows :
Page 19
SAFETY DEVICES
No gas supply
This will be indicated
on the display as a pictogram of a spark. To rectify this, pro­ceed as follows:
Switch off the boiler at the On/
Off push button.
Rectify the gas supply problem.Restart the boiler by pressing the
On/Off button.
IO
1
--------------------------
Insufficient system pressure
This will be indicated on the display as a
0.3
bar
To rectify this the system must be re-filled, refer to 'Commissioning'.
flashing warning indi­cating the system pressure is low.
--------------------------
Other faults
These are indicated on the display by a fault code and a telephone symbol. Further information on the fault codes can be found in the 'Servicing Instruc-
tions'.
General safety devices
Air flow rate safety device
If an obstruction, even partial, of the flue occurs, for any reason whatsoever, the built in safety sys­tem of the boiler will turn the boiler OFF and the fan will continue to run. The boiler will be ready to operate when the fault has been cleared.
Overheat safety
In case of boiler overheating, the overheat ther­mostat will turn the boiler off. The thermostat, lo­cated on the heat exchanger flow pipe, will need to be manually reset.
In case of power supply failure
The boiler no longer operates. As soon as power supply is restored, the boiler will be automatically restarted.
Frost protection
The ISOMAX has a built in frost protection device 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.
CHANGING GAS TYPE
Should it become necessary to change the gas type, a modification kit will be required. This modification must only be carried out by a suitably qualified engineer.
Conversion natural Gas (G20) to G30/G31 Part No.
86216.
19
Page 20
SETTINGS
Gas valve setting
All boilers are tested and factory set during manu­facture. Should it be necessary to reset a gas valve, for example, after replacement, proceed as fol­lows:
Shut down boiler.
Minimum setting
Remove one electrical connector from the
modulating gas valve coil, see diagram 23.
Connect a suitable pressure gauge.Set the OFF/Summer/Winter switch to the Sum-
mer position.
Adjust the domestic hot water temperature ad-
juster to maximum setting.
Remove the protective cover from the gas valve
adjuster.
Turn nut A, see diagram 23:
CLOCKWISE: To increase the pressure. ANTICLOCKWISE: To decrease the pressure.
Maximum setting
Reconnect the electrical connector removed
from the modulating gas valve coil.
Remove the protective cover from the gas valve
adjuster.
Turn nut B, see diagram 23:
CLOCKWISE: To increase the pressure. ANTICLOCKWISE: To decrease the pressure. After adjustment, refit the cover to the gas valve adjuster.
Diagram 23
MODULATING COIL
Electrical connection
Reg 020
a
Bypass
The
ISOMAX
has a built-in bypass. This must be ad­justed according to the requirements of the system, refer to the flow rate pressure curve (diagram 4). The boiler is supplied with the built-in bypass open a half a turn. It is adjusted by turning the bypass screw (a), see diagram 24. Turn the screw clock­wise to close the bypass.When using thermostatic radiator valves (TRVs) 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, see diagram 8. Any bypass must be fitted before system controls.
Diagram 24
Reg 054
20
Page 21
ROUTINE CLEANING AND INSPECTION
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 conditions and usage, but in gen­eral once a year should be enough.
It is the law that any servicing is carried out by a qualified registered person.
Service Check and Preparation.
Operate boiler and check for any faults that need to be put right.
Isolate boiler from the gas and electrical supplies.
On completion check all gas carrying parts for
soundness with leak detection fluid.
Remove boiler casing as follows:
Upper front panel
Remove the two front panel retaining brackets from the top of the boiler.
Remove panel by lifting up and forward.
Sealed chamber cover
Unclip the toggle clip holding the sealed cham­ber cover, see diagram. 1.
Lift cover up and off boiler.
Diagram 1
Car 033
Front control panel
Lift control panel up and lower forwards to gain access to lower part of boiler.
Side panels
Unscrew and remove the four screws securing lower grille onto boiler. Unhook grille from rear of boiler and remove.
Remove three screws from front of each side panel.
Unclip the toggle clips securing top of each panel.
Lift each panel up and then forward to remove.
Combustion chamber cover
Unscrew the three screws securing combustion chamber cover to combustion chamber, see dia- gram 2.
Remove combustion chamber cover from boiler .
Undo, but do not remove, two burner support screws
at rear of burner chamber.
Burner
Undo main gas supply nut from burner.
Pull off the ignition and flame sense leads from the
gas valve remove burner from boiler by lifting up and pulling forwards from keyhole slots. Note: The washer between main burner and main burner gas supply must be kept for use on reassembly.
Remove ignition and flame sense electrodes from burner.
Unscrew and remove injector bar retaining screws and separate injector bar from burner.
Examine and clean injectors as necessary. Note: DO NOT use a wire or sharp instrument on the holes. Clean burner by washing in soapy water. Dry thor­oughly before re-fitting.
Diagram 2
Heat exchanger
Disconnect power supply leads and earth lead from fan.
Unscrew and remove, two fan retaining screws at front edge of fan mounting plate.
Remove fan with mounting plate attached by pulling forwards out of boiler.
Remove air pressure switch sensing tube from sensing probe on flue hood.
Unscrew and remove screws securing flue hood to rear panel.
Withdraw flue hood from boiler.
Examine heat exchanger for any blockages or
build up of deposits.
Clean heat exchanger with soft brush or vacuum cleaner. Do not use any tool likely to damage
painted finish of heat exchanger.
Reassembly of parts removed for servicing
All parts are replaced in reverse order to removal.
Ech 052
21
Page 22
ROUTINE CLEANING AND INSPECTION
Flue system
Check externally to make sure that flue is not blocked
Inspect flue system to make sure that all fittings are secure.
Operation of fan
Switch on electrical supply and turn on gas.
Light burner by opening a hot water tap.
Without sealed chamber cover in place, burner
should be automatically prevented from lighting by air flow detection system.
Refit sealed chamber cover.
Check that fan operates when burner lights and
stops when it goes out.
Diagram 3
A
u
v
m
Cold water inlet filter
Drain down hot water circuit of boiler only, as fol lows:
Close isolating valve/throttle (m) on cold water isolating cock, see diagram 3. Note: This valve is closed when screwed fully clock­wise.
Open one or more hot water taps to drain boiler circuit.
Undo connecting nut from cold water inlet con­nection.
Clean and inspect filter, replace if necessary.
With both filter and restrictor in place, recon-
nect connecting pipe to inlet connection and tighten.
Fully open isolating valve/throttle on cold wa­ter inlet and check for leaks.
C
r
q
Pla 213
REPLACEMENT OF PARTS
For replacement of the following components it will be necessary to remove boiler casing panels as de­scribed in Routine Cleaning and Inspection’.
WARNING: Before commencing the replacement of any component, isolate appliance from electri­cal supply and turn off gas at service cock.
To replace domestic hot water thermistor
Locate domestic hot water thermistor on hot wa­ter flow pipe on right hand side of boiler adjacent to gas valve.
Unclip thermistor from pipe.
Disconnect leads from thermistor.
Fit replacement thermistor.
Fit leads to replacement thermistor, the polarity
is not important.
To replace central heating thermistor
Locate central heating thermistor on heating flow pipe on centre of boiler.
Unclip thermistor from pipe.
Disconnect leads from thermistor.
Fit replacement thermistor.
Fit leads to replacement thermistor, the polarity
is not important.
To replace storage vessel thermistor
For this operation the boiler must be removed from the wall.
Drain down heating and hot water circuit of the boiler only, as follows:
Close isolating valves (q) and (v) on central heat- ing isolating cocks (A) and (C), see diagram 3.
Note: These valves are closed when slots are at right angles to direction of flow.
Drain boiler by opening drain valves (r) and (u), see diagram 3.
Note: It is not necessary to drain down entire heat-
ing system to carry out this work.
Close isolating valve/throttle (m) on cold water isolating cock, see diagram 3. Note: This valve is closed when screwed fully clock­wise.
Open one or more hot water taps to drain boiler circuit.
Disconnect flue system.
Disconnect boiler pipes onto fixing jig.
Disconnect mains cable and any external con-
trols cables.
Remove boiler from wall.
From rear of boiler, disconnect domestic pipes
from storage vessel.
Disconnect electrical connections from vessel.
Unclip vessel from boiler frame and remove from
boiler.
Slide off plastic strap and separate two halves of vessel insulation.
Locate thermistor at top of insulation.
Replace thermistor in same position as old ther-
mistor.
Refit vessel in reverse order to removal.
Refit boiler onto fixing jig, tighten all connections
ensuring that all sealing washers are fitted before tightening.
Reconnect flue making sure that all joints are properly connected.
22
Page 23
REPLACEMENT OF PARTS
Open isolating valves on flow and return connec­tions, refill, vent and pressurise boiler.
Check for leaks.
Reconnect all electrical connections and restore
electrical supply.
Open gas cock, operate boiler and re-check all joints for soundness.
To replace fan
Remove fan as described in Routine Cleaning and Inspection’.
Fit replacement fan in reverse order to removal.
Reconnect electrical leads.
To replace air pressure switch
Locate air pressure switch situated inside sealed chamber on top right hand side.
Remove air pressure switch tube from sensing probe on flue hood.
Disconnect air pressure switch electrical connec­tions.
Undo screws on top of boiler securing air pres­sure switch to boiler and remove switch.
Pull sensing tube off switch.
Fit replacement switch to boiler in reverse order
to removal, noting that pressure sensing tube fits to left hand connection on switch.
let pipe to flow sensor and carefully remove from sensor.
Pull out slotted metal clip securing flow sensor to pump mounting and carefully remove sensor from boiler.
Fit replacement sensor to boiler in reverse order to removal.
To replace printed circuit board (PCB)
Gain access to rear of control panel.
Unclip and remove external controls/mains con-
nection access cover.
Unclip side clips and hinge up control panel cover to gain access to PCB, see diagram 5.
Carefully pull off electrical connections to PCB.
Unclip and lift out PCB.
Fit replacement PCB in reverse order to removal.
Note: 1) Make sure that PCB connections are fully pushed onto replacement PCB.
2) Set the heating temperature option to the
same value as the old PCB, refer to 'Installation and
User' instructions.
To replace domestic water flow sensor
Drain down hot water circuit of boiler only as de­scribed previously.
Undo connecting nut from cold water inlet con­nection.
Locate flow sensor on cold water inlet pipe to boiler inside controls area, see diagram 4.
Carefuly pull off electrical connector from flow sensor.
Pull out slotted metal clip securing cold water in-
Diagram 4
Ins 104
Diagram 5
Acc 010/Acc011
23
Page 24
REPLACEMENT OF PARTS
To replace pump
Drain down heating circuit of the boiler only, as described previously. Note: It is not necessary to drain down entire heat­ing system to carry out this work.
Undo two fixing screws and remove pump retain­ing bracket from front of pump.
Undo clips securing pump outlet hose connec­tion to pump.
Slide hose along pipe to clear pump outlet.
Disconnect pump electrical connection from
PCB.
Transfer automatic air vent to replacement pump using new washers supplied.
Re-connect electrical connection to PCB.
Fit replacement pump in reverse order to re-
moval.
Open isolating valves on flow and return connec­tions, refill, vent and pressurise boiler.
Check for leaks.
To replace domestic hot water heat exchanger
Drain down heating and hot water circuits of boiler only as described previously. Note: It is not necessary to drain down entire heat­ing system to carry out this work.
Unscrew and remove cold water inlet pipe from fixing jig to water flow sensor.
Supporting domestic heat exchanger, unscrew and remove two screws securing it onto pump mounting and 3-way valve/bypass housing.
Remove heat exchanger from boiler.
Fit replacement heat exchanger in reverse order
to removal using new seals, supplied. Note: Heat exchanger mounting screws are offset to ensure correct fitting of replacement.
pipe from 3-way valve/bypass housing to storage vessel.
Undo pipe from 3-way valve/bypass housing to fixing jig.
From underneath boiler, undo two screws secur­ing 3-way valve/bypass housing and lift out of boiler.
Fit replacement 3-way valve/bypass housing in reverse order to removal.
To replace system pressure sensor
Drain down heating circuit of boiler only as de­scribed previously. Note: It is not necessary to drain down entire heat­ing system to carry out this work.
Locate system pressure sensor at front left hand side of boiler, see diagram 8.
Remove electrical connections from sensor.
Pull off slotted metal clip and remove sensor from
boiler.
Fit replacement sensor in reverse order to re­moval.
To replace gas valve module
Locate gas valve module attached to side of gas valve.
Diagram 6
Pho483
To replace 3-way valve head
Locate 3- way valve in centre of lower controls area.
Remove electrical plug from valve head.
Pull out slotted metal clip from valve body and
remove valve head from body.
Fit replacement valve head in reverse order to removal.
Note :
1) When refiting clip, ensure that letters OK are as shown in diagram 6.
2)It is not necessary to drain boiler to carry out this
work.
To replace 3-way valve/bypass housing
Drain down heating and hot water circuit of boiler only as described previously. Note: It is not necessary to drain down entire heat­ing system to carry out this work.
Remove 3-way valve head as described previ­ously.
Remove domestic hot water heat exchanger as described previously.
Undo pipe connection from 3-way valve/bypass housing to primary heat exchanger, see diagram 7.
Pull out slotted metal clips and remove bypass pipe.
Pull out slotted metal clip and remove domestic
Diagram 7
Diagram 8
Pho484
Pho485
24
Page 25
REPLACEMENT OF PARTS
Diagram 9
Remove screw securing cover onto gas valve module, see diagram 9.
Remove cover and disconnect multi-plug from module.
Disconnect ignition and flame sense leads from module.
Withdraw module from gas valve.
Fit replacement module, ensuring it is of the cor-
rect type for the boiler , in reverse or der to removal.
Reconnect ignition and flame sense leads, the connections are uniquely sized to ensure correct replacement.
Reconnect multi-plug onto replacement module.
Refit cover ensuring all sealing grommets are cor-
rectly located in module body.
To replace gas valve
Ensure that gas supply to boiler is turned off at gas cock.
Remove gas valve module as described previ­ously.
Disconnect electrical connections to gas valve modulating coil, see diagram 9.
Undo main gas supply nut from main burner. Note: The washer must be kept for use on reassembly.
Undo main gas union nut between gas valve sup­ply pipe and gas inlet valve. Note: The washer must be kept for use on reassembly.
Disconnect plastic sensing pipe from gas valve to base of sealed chamber.
Unscrew and remove screws securing gas valve bracket to boiler frame.
Withdraw gas valve assembly.
Using old gas valve as a guide, transfer gas pipes
from old gas valve to replacement gas valve.
Fit replacement gas valve into boiler.
Reconnect gas pipes in reverse order to removal.
Refit electrical connections in reverse order to re-
moval, the polarity of the wires to the modulating coil is not important.
To replace modulating coil
Ensure that gas supply to boiler is turned off at gas cock.
Disconnect electrical connections to gas valve modulating coil, see diagram 9.
Undo two screws securing modulating coil to gas valve and remove coil.
Mec 140
Fit replacement coil in reverse order to removal.
Refit electrical connections in reverse order to re-
moval, the polarity of the wires to the modulating coil is not important.
To replace central heating safety valve
If safety valve seating is damaged, it will be neces­sary to replace safety valve as a complete unit, repair is not possible.
Drain down heating circuit of boiler only as de­scribed previously.
Disconnect safety valve discharge pipe from safety valve.
Remove wire clip securing safety valve to fixing jig and remove safety valve, see diagram 10.
Fit replacement safety valve in reverse order to removal.
Note: Apply a small quantity of silicon grease to the safety valve 'O' ring prior to fitting.
Open isolating valves on flow and return connec­tions, refill, vent and pressurise boiler.
Check for leaks.
To replace storage vessel safety valve
If safety valve seating is damaged, it will be neces­sary to replace safety valve as a complete unit, repair is not possible.
Drain down hot water circuit of boiler only as de­scribed previously.
Disconnect safety valve discharge pipe from safety valve.
Remove wire clip securing safety valve to fixing jig and remove safety valve, see diagram 10.
Fit replacement safety valve in reverse order to removal. Note: Apply a small quantity of silicon grease to the safety valve 'O' ring prior to fitting.
Diagram 10
Open isolating valve on cold water inlet connec­tion.
Check for leaks. To replace heat exchanger
Drain down heating circuit of boiler only as de­scribed previously. Note: It is not necessary to drain down entire heat­ing system to carry out this work.
Remove combustion chamber cover, as de­scribed in Routine Cleaning and Inspection'.
Disconnect electrical connector from high limit thermostat.
214 Pla
25
Page 26
REPLACEMENT OF PARTS
Remove slotted metal clips from heat exchanger con­nection pipes.
Undo nut securing pipe from heat exchanger to 3­way valve/bypass housing.
Swing pipe away from 3-way valve/bypass housing and pull down to disengage from heat exchanger pipe.
Pull down pipe from pump to heat exchanger to dis­engage from heat exchanger pipe.
Slide heat exchanger forwards and remove from boiler, see diagram 11.
Fit replacement heat exchanger in reverse order to removal.
Reconnect electrical connector to high limit thermo­stat.
Open isolating valves on flow and return connections, refill, vent and pressurise boiler .
Check for leaks.
Diagram 11
To replace central heating expansion vessel
Replacement of the expansion vessel is not possi­ble with the boiler on the wall. Remove boiler from wall as described in 'To replace
storage vessel thermistor'.
Undo pipe coupling on expansion vessel.
Supporting expansion vessel, unscrew and re-
move screw securing expansion vessel to boiler.
Lift vessel out of boiler.
Fit replacement vessel to boiler in reverse order
to removal, ensuring that sealing washer is fitted to pipe connection before tightening.
Ensure that expansion vessel charge pressure is
0.5 bar (7.5 psi) using a pressure gauge. If neces­sary, increase pressure using a car or cycle tyre pump connected to the Schrader valve.
Refit boiler onto fixing jig, tighten all connections ensuring that all sealing washers are fitted before tightening.
Reconnect flue making sure that all joints are properly connected.
Open isolating valves on flow and return connec­tions, refill, vent and pressurise boiler.
Check for leaks.
Reconnect all electrical connections and restore
electrical supply.
Open gas cock, operate boiler and re-check all joints for soundness.
Ech 040
To replace combustion chamber insulation
Remove combustion chamber cover as de­scribed in Routine Cleaning and Inspection’.
Remove heat exchanger as described previously.
Remove fan and flue hood as described in Rou-
tine Cleaning and Inspection’.
Front panel:
Lift front insulation panel free from retaining lugs on combustion chamber cover.
Rear panel:
Pull rear insulation panel free from retaining lug at rear of combustion chamber by tilting forward.
Fit replacement insulation panels in reverse or­der to removal
Refit combustion chamber cover.
Side panels:
Pull out side panels.
To replace burner
Remove burner as described in 'Routine Clean­ing and Inspection'.
Assemble replacement burner , supplied in parts, as follows:
Fit burner injectors to burner injector bar and tighten. Note: Make sur e that injector size, marked on each injector , is the same as that given in T echnical Data for the type of gas being used.
Fit injector bar into burner , secure with retaining rods.
Fit replacement burner into boiler in reverse or-
der to removal.
To replace burner injectors
Remove burner as described in 'Routine Clean- ing and Inspection'.
Pull out injector bar retaining rods and separate injector bar from burner.
Unscrew and remove injectors from injector bar.
Fit replacement injectors to injector bar and
tighten. Note: Make sure that injector size, marked on each injector , is the same as that given in T echnical Data for the type of gas being used.
Reassemble burner and fit into boiler in reverse order to removal.
To replace ignition electrode
Remove burner as described in Routine Clean­ing and Inspection’.
Undo and remove screw securing electrode onto burner.
Fit replacement electrode onto burner in reverse order to removal.
Refit burner into boiler in reverse order to removal.
To replace high limit thermostat
Locate high limit thermostat on heating flow pipe on left hand side of boiler.
Disconnect electrical connection from thermostat
Unclip thermostat from heating flow pipe.
Fit replacement thermostat in reverse order to re-
moval.
Refit connection to thermostat.
26
To replace flame sense electrode
Remove burner as described in Routine Clean­ing and Inspection’.
Undo and remove screw securing electrode onto burner.
Fit replacement electrode onto burner in reverse order to removal.
Refit burner into boiler in reverse order to removal.
Page 27
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
23
19 - Heating expansion vessel 20 - Heating ther mistor 21 - Over heat safety thermostat 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)
12
19
25
21
22
16
18
15
11
7
20
17
14
13
10 28
27
6
9
5
8
3
4
2
26
24
1
Diagram 12
AB C DE
D1
D1
D2
D1
D3
D1
Shy 163cUK
27
Page 28
TECHNICAL DATA
Heating
Heating output ajustable from 10,1 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 Maximum hot water temperature 60 °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. Maximum supply pressure 8 bar Minimum operating pressure 0,7 bar
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
1
Open 1/4 turn
2
3
Open 1/2 turn
Open 1 turn
4
Open 2 turns
5
Bypass fully shut
1
Open 1/4 turn
2
60
50
40
1
2
3
4
5
30
20
10
heating supply and return lines
Available pressure (kPa) between
0
(10 kPa = 1 m WG)
3 4 5
Open 1/2 turn
120010008006004002000
Flow rate through heating system (I/h)
Open 1 turn
Open 2 turns
Pom 010 a
28
Page 29
SCHEMATIC WIRING DIAGRAM
B6.1 B6.3 B6.4 B6.2
B2.4
H6.1 H6.2
h8.1 h8.2 h4.1
Opt.
L N
M/A
Ps
h4.3 h3.1
Ex
h3.3 h1.1
P
h1.2 h2.4 h2.2
h2.3 h2.5
h2.1
h5.2 h5.3
h5.1 B2.8
B2.7
ACF
Flam
K4
CH
V
89
Ph11N10DA
1
2
3
COM
V
SAN
B8.1 B8.2 B3.3 B1.2
B2.9
B2.8
B2.11
B1.13
B1.15
B1.7
B1.8
B1.10
B3.1 B3.2
B3.3 B3.4
B2.6 B2.5 B1.5 B1.6
B1.4 B1.3
b5.1 b5.2 b5.4
b5.5
HL
Db
+
CTN 3
V1
P
J1
CTN 2
CTN 1
Cp
Pr
1
TA
2 3
Ra
4 5
B4.1
B4.2
FA FL
INTERFACE
M/A - on/ off Ps - domestic water pump P-heating pump ACF - ignition card and flame control
DA - ignition demand - safety engaged Flam - ionisation contact
V3V - three-way valve
CH - heating COM - common
SAN - hot water INTERFACE - User interface Db - output detector Cp - water pressure sensor V1 - gas mechanism modulating valve J1 - connector for room temp. thermostat TA - room temperature thermostat
B4.3
B4.4
B3.5
CD
B3.6
B7.3
SE
B7.2
+
B7.1
B2.4
B2.1
B2.2
GND S Ve
Vitesse Extracteur (option)
Ra - room temp. thermostat anticipation resistor FA - ignition electrodes FL - ionisation electrode CTN1 - hot water thermistor CTN2 - heating thermistor CTN3 - accumulator thermistor K4 - overheating safety Pr - air pressure switch Ex - fan accessories Opt - option card CD - remote control SE - external sensor HL - clock
Diagram 14
sch292
29
Page 30
FAULT FINDING
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.
The heating system pressure is at least 1 bar.
There is a permanent mains supply to the boiler .
The fuse on the PCB is intact.
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.
Table 1
Voltage Measured value Measuring point
230 Volt 230 V AC Between terminals H8.1 and H8.2
24 Volt maximum 33V DC Between terminals B2.4 and B2.7
minimum 20V DC
Should there be any doubt about the voltage sup­ply to any of the components, it is possible to carry out a simple electrical test to ensure all is opera­tional in that area.
To carry out the electrical test, gain access to the main Printed Circuit Board (PCB), as described pre­viously, and measure the voltages according to table 1.
15 Volt 15V + 0.5V Between terminals B2.4 and B2.2
Display 5V + 0.5V Between terminals B2.4 and B4.2
ISOF AST
The the top of the user display will illuminate and the LCD display will indicate the precise area where the fault has occured.
has an on-board fault diagnostic system. Should a fault occur on the boiler, the warning LED at
09 FF
Sec 052
A fault code is displayed on the left hand side of the LCD display, whilst at the same time, the letters appear with a telephone symbol.
FF
30
Page 31
FAULT FINDING
List of fault codes
Code Fault Additional display
00 No fault
02 Air flow fault
04 Ignition fault -flame detection
05 Overheating
06 Central heating thermistor/wiring fault
07 Domestic hot water thermistor/wiring fault
08 Storage vessel thermistor/wiring fault
09 System pressure sensor fault
information
10 Fan fault
11 Pump blockage
12 User interface fault
13 Main PCB fault
14 CTN2 > 97°C - pump will run
15 Gas mechanism fault
20 Communication fault
31
Page 32
FAULT FINDING
Thermistor values
The following table applies to the central heating, domestic hot water and storage vessel thermistors:
Temperature (°C) Resistance (Ω)
0......................................32565
5......................................25345
10.....................................19875
15.....................................15700
20.....................................12500
25.....................................10000
30......................................8060
35......................................6535
40......................................5330
45......................................4370
50......................................3605
55......................................2989
60......................................2490
65......................................2085
70......................................1755
75......................................1480
80......................................1260
85......................................1070
90.......................................920
95.......................................785
100......................................680
System pressure sensor
The resistance of the sensor at various pressures is as follows :
0 bar ...................... between 280 Ω and 320
1 bar ...................... between 195 Ω and 220
3 bar ...................... between 93 Ω and 143
SPARE PARTS
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.
1 ..........Domestic hot water thermistor ..........57213
2 ..........Central heating thermistor .................57215
3 ..........Storage vessel thermistor ................... 57250
4 ..........Fan ........................................................57238
5 ..........Air pressure switch ............................... 57237
6 ..........Domestic water flow sensor ............... 57202
7 ..........Printed circuit board ........................... 57248
8 ..........Pump ....................................................57207
9 ..........3-way valve head ............................... 57206
10 ........System pressure sensor .......................57205
11 ........Gas valve module .............................. 57079
12 ........Central heating safety valve .............57228
13 ........Storage vessel safety valve ............... 57229
14 ........High limit ther mostat ...........................57212
15 ........Ignition electrode................................ 57194
16 ........Flame sense electrode ....................... 57195
32
116277 B 07/00
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