Saunier duval SB 30E User Manual

Instructions for Use

Installation and Servicing

To be left with the user

SB30e

Fanned Flue System Boiler

221872B.07.01

7086

G.C. No. 41 920 31

This is a Cat I2H Appliance

The instructions consist of three parts, User, Installation and Servicing Instructions, which include the Guarantee Registration Card.

The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use)

Regulations, be handed to the user on completion of the installation.

Guarantee Registration

Thank you for installing a new Saunier Duval appliance in your home.

Saunier Duval appliances' are manufactured to the very highest standard so we are pleased

In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and

If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer

Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:

to offer our customers' a Comprehensive First Year Guarantee.

return as soon as possible.

Service number 01773 828100.

✔

❑

✔

❑

✔

❑

One Contact Local Service

All replacement parts
All labour charges
All call-out charges

REGISTER YOUR SAUNIER DUVAL APPLIANCE

FOR 1ST YEAR GUARANTEE PROTECTION

CALL 0208 247 9857

Customer Services:
Tel: [phone]
Fax: [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

General/Sales enquiries:

Tel: [phone] Fax: [phone]

Important Information

Testing and Certification

This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler,
without permission, in writing, from Hepworth Heating Ltd.

Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.

CE Mark

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.

Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:

1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning
gaseous fuels.

2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment
designed for use within certain voltage limits.

3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic
compatibility.

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 complaint you may be susceptible to irritation. High dust levels are usual only if the material is
broken.
Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or
going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.

SPARE PARTS

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

CONTENTS DESCRIPTION SECTION PAGE No.

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Introduction 3
Programmer Settings 4
Lighting the Boiler 5

General Data 1 7
Boiler Position 2 9
Flue and Ventilation 3 10
Water System 4 11
Domestic Hot Water 5 12
Installation Preparation and
Gas/Water Connections 6 13
Flue Preparation 7 13
Mounting the Boiler 8 16
Electrical Connections 9 20
Commissioning 10 22

SERVICING

INSTRUCTIONS

221872B

General Data 11 25
Servicing 12 25
Fault Finding 13 27
Replacement Parts 14 33
Spare Parts 15 43

2

Instructions for Use

Introduction

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

This boiler must have been installed by a competent person in
accordance with the current rules in force in the countries of
destination at the time of installation.

The boiler is fully automatic in operation, having only one user
control, the control thermostat.

The boiler being a fully pumped sealed system is able to provide
room heating as part of a central heating system and indirect
domestic hot water.

The boiler can be fitted with a programmer, which look like this:-

Programmer

DAY HR MIN

IMPORTANT NOTICE:
The User must always adhere to the warnings

given in these instructions and those on the
boiler. Under no circumstances must the
User interfere with any sealed component as
this could result in a potentially dangerous
situation arising.

This boiler is for use only on G20 gas.
Gas Leak or Fault

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

Electrical Supply

WARNING. The boiler must be earthed.
The boiler must be connected to a 230V~50Hz permanent

supply.
Connection of the whole electrical system of the boiler and any

heating system controls to the electrical supply, must be through
one common isolator.

Isolation should preferably be by a double pole switched fused
spur box. The fused spur box should be readily accessible and
preferably adjacent to the appliance. It should be identified as
to its use.

Alternatively a fused 3A 3 pin plug and shuttered unswitched
socket may be used.

The colours of three core flexible cable are, blue - neutral, brown

- live, green and yellow - earth.
As the markings on your plug may not correspond with these

colours continue as follows:­The wire coloured blue must be connected to the terminal

marked “N” or “Black”.
The wire coloured brown must be connected to the terminal

marked “L” or “Red”.
The wire coloured green and yellow must be connected to the

terminal marked “E” or “Green” or the earth symbol
PVC flexible cable having a conductor size of 0.75mm

0.20mm) must be used within the boiler casing to connect to the
boiler.

Electrical Supply Failure

The boiler will not work without an electrical supply.
Normal operation of the boiler should resume when the electrical

supply is restored.

7809

Note. The boiler safety cutoff may have operated, please refer
to the following section to reset.

Reset any external controls, to resume normal operation of the
central heating.

The digital programmer, has a lithium battery back up and will
not need resetting. Unless it is without power for a considerable
period.

Boiler Safety Cutoff Reset Button

The boiler is fitted with a safety cutoff device to protect the
appliance and the user in the event of a fault occuring.

Should the main burner go out during a demand the red lockout
light “F” will illuminate on the control fascia situated above the
Reset Button “G”, see diagram 2.

The red light will not illuminate if there is no system demand.

Allow the boiler and system to cool down waiting at least
a minimum of four minutes before pressing the Reset
button “G”.

The boiler will take a few seconds to reset after the button is
pressed.

If the problem persists, turn the boiler off and consult your
installation/ servicing company.

The Gas Safety (Installation & Use)
Regulations

In your interests and that of safety it is the law that ALL gas
appliances are installed by competent persons in accordance
with the current issue of the above regulations.

.

2

(24/

3

221872B

Instructions for Use

Setting Instructions for the 7 Day Digital
Programmer

This is a 24 hour programmer, that is 1pm is 13:00, and has two
sets of 8 “ON” and 8 “OFF” daily switching actions
(P1 and P2).

It is fitted with a lithium battery back up which protects the
programme in the event of an electrical failure. The battery
should have a life of several years.

3 SETTINGS SLIDE
SWITCH (AUTO)

DAYS OF THE WEEK
MON. TO SUN.

POINTER

SET 16
PROGRAMMES
BUTTON

DAY HR MIN

DAY OF THE WEEK
AND BLOCK SETTING
BUTTON

TIME HOURS
SETTING BUTTON

Setting the Programmer - Diagram 1

1. With both AUTO and RUN switches set, press R reset button,
the display will flash.

2. Press and hold HR and MIN until display stops flashing.

3. Set day of week or block setting by pressing button DAY.

4. Set time of day by pressing buttons HR and MIN.

5. When set if no buttons are pressed for 15 seconds, colon will
flash, this indicates the programmer is set.

With the programmer set, the factory preset programme shown
below will operate.

MON / SUN

ON - 6:30
OFF - 8:30
ON - 12:00
OFF - 12:00
ON - 16:30
OFF - 22:30

Setting Timed Programmes

With the programmer set to the correct time, see SETTING THE
PROGRAMMER paragraphs 1-4, and then continue as follows:

1. Set RUN switch to P1 or P2, the display will indicate
the 1st (ON) preset programme and the symbol

2. Set day of week to be programmed by pressing the
DAY button.

Note: The days can be selected individually or as
groups:

Mon-Fri., Sat/Sun., Mon-Sat., Mon-Sun.
An arrow or arrows will be displayed under the day

or days selected.

.

3 SETTINGS SLIDE
SWITCH (RUN)

DISPLAY

SOFT
OVERRIDE
BUTTON

TIME MINUTES
RESET
BUTTON

3. Set time of day by pressing the buttons HR and MIN.

4. Press button P to confirm programmes, the

5. Repeat procedures 2, 3 and 4 until desired

6. Set the RUN switch, your appliance will now operate at the

General Notes.

SETTING BUTTON

Diagram 1

display will indicate the 2nd (OFF) preset programme
and subsequently, 3rd to16th.

programmes are set.
Note. It is not a requirement to use the 8 on/off

programmes.

programmed times.

With the AUTO switch in the I position the central
heating will operated constantly ON.

With the AUTO switch in the O position the central
heating will not operate.

Soft Override button indicated by the
symbol
central heating programme for the next available.

ON time programmes are indicated by the symbol

, this function will override the current

7809

.

221872B

4

Instructions for Use

To Light the Boiler

1. Check the two isolating valves are open, the levers in line with
the valve body, see diagram 3.

2. Open the controls cover door and familiarize yourself with the
controls, see diagram 2.

3. Set “C”, programmer (if fitted) and any remote controls as
required.

4. CAUTION. A sealed pressurised system must be filled and
pressurised by a competent person.

Only operate the boiler when you are sure that the system has
been filled and pressurised. Check this by looking at the
pressure gauge “A”, it should read 0.7bar minimum when the
boiler is switched off. If you are in any doubt about the boiler
being filled with water contact your installation/servicing company
or the local gas company.

5. Check that the electrical supply to the boiler is ON at the
external isolator.

6. Set switch “B” to 1, situated on the control fascia, light “E” on
the fascia will illuminate.

7. If the red light “F” comes “ON”, the boiler WILL NOT WORK.
Depress the boiler safety cutoff reset button “G” if the red light
stays “ON”, you MUST contact your installation/servicing
company.

The boiler lighting operation is automatic if the external controls
or programmer, if fitted, are calling for heat.

The fan operates, followed by an ignition spark, the burner lights.
Light “D” on the fascia will illuminate.

When the boiler switches off, the burner will go out.
The automatic lighting sequence will operate again when heat

is required.

8. Adjust the control thermostat knob “J” to desired setting.
Close the controls cover door.

To Turn the Boiler Off

Set switch “B” to 0. To relight follow the lighting sequence given
above.

PRESSURE
GAUGE ‘A’

KEY TO NEON LIGHTS

RESET
BUTTON

CONTROLS
FASCIA

CONTROLS
COVER

‘F’

‘G’

‘D’

‘H’

‘E’

CONTROL
THERMOSTAT

KNOB

PROGRAMMER
IF FITTED

DAY HR MI N

‘J’

‘C’

MAINS
ELECTRIC

SWITCH

7791

‘B’

‘F’ BOILER LOCKOUT

‘H’

LOW WATER PRESSURE

‘D’
‘E’

BURNER IGNITED

POWER ‘ON’

5

Diagram 2

221872B

Instructions for Use

HEATING
FLOW

LEVER (OPEN)
HEATING
FLOW/ RETURN

SAFETY VALVE
DISCHARGE PIPE POSITION

GAS
SERVICE
COCK

SLOT (OPEN)
GAS SERVICE
COCK

HEATING
RETURN

Diagram 3

7790

Protection Against Freezing

The boiler has a 2 stage built in frost protection. Provided power
and gas are available and there is adequate pressure in the
system, if the water temperature within the appliance falls below

o

10

C approx. the pump only will come on. If the water temp
continues to fall to 6
rate until the water in the appliance is greater than 15oC approx.
This function protects the appliance only.

Other system pipework external to the boiler may require frost
protection.

If the boiler is to be out of use for any long periods during severe
weather, it is recommended that the whole system, including the
boiler, should be drained to avoid the risk of freezing. Make sure
that, if fitted, the immersion heater in the cylinder is switched off.

If in doubt, contact you installation/servicing company for advice.

o

C approx. the main burner will fire at min

Draining and Filling

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

Note: If the pressure gauge indicates a loss of system pressure,
that is, less than 0.7bar, YOU MUST CONTACT YOUR
INSTALLER.

Pressure Relief Safety Valve

CAUTION. A pressure relief safety valve and discharge pipe is
fitted to the boiler. This valve must not be touched. Should there
be any discharge from the pipe, turn the boiler off, isolate from
the electrical supply and contact your installation/servicing
company.

Maintenance and Servicing

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

If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.

Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.

To obtain service, please call your installer or Heatcall (Saunier
Duval’s own service organisation) using the telephone number
behind the controls cover door.

Please be advised that the ‘Benchmark’ logbook should be
completed by the installation engineer on completion of
commissioning and servicing.

All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boiler Logbook. You can check your installer is CORGI registered
by calling CORGI direct on :- 01256 372300.

Clearances

The boiler requires a clearance in front, below and at the sides
of the casing for safety, servicing and maintenance access, see
diagram 2.1.

Cleaning

WARNING. This appliance contains metal parts (components)
and care should be taken when handling and cleaning with
particular regard to edges.

The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, then a dry cloth to polish.

Do not use any form of abrasive or solvent cleaner as you may
damage the paint work

Boiler Casing

CAUTION. Do not remove or adjust the casing in any way, as
incorrect fitting may result in incorrect operation or failure to
operate at all. If in doubt seek advice from the local gas
company or your installation/servicing company.

Replacement Parts

If replacement parts are required apply to your local supplier or
British Gas.

Please quote the name of the appliance.

221872B

6

1 General Data

C

E

D

D

E

L

M

B

N

C

C

L

L

G

9mm

K

J

A

Optional flue kits are available
Horizontal top outlet and Vertical.

F

H

Diagram 1.1

A B C D E F G H J K L M N

7792

450 700 300 100 75 138 142 18 135 110 138 85 115 103

EXTD. EASYFIT

1.1 Installation

Materials and equipment should be fit for their purpose and of
suitable quality and workmanship.

1.2 Important Notice

This boiler is for use only on natural gas, G20.

1.3 Sheet Metal Parts

WARNING. When installing or servicing this boiler care should
be taken when handling the edges of sheet metal parts to avoid
any possibility of personal injury.

1.4 Requirements

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

Manufacturer’s instructions, supplied.
Manufacturer’s instructions must not be taken as overriding

statutory requirements.

1.5 Data Label

The data label is on the inner case front, see diagram 1.2.

1.6 Data

See table 1 and diagrams 1.1, 1.2. & 1.3.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is

79%.
The value is used in the UK Government’s Standard Assessment

Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.

TABLE 1

Lift Weight 30Kgs (66Ibs)
Total Weight 39.5Kgs (88Ibs)

Gas connection Ø 15mm compression
Heating and return Ø 22mm compression
Safety valve Preset 3bar (43.5lbf/in
Safety valve discharge Ø 15mm copper
Water content 1.17 litres (.26 gallons)

■ Expansion vessel capacity 6 litres (1.32 gallons)

Heating cold fill 0.7bar
pressure minimum (10.1lbf/in2)

■ Maximum Heating 60 litres

system water (13.2 gallons)
content using with a cold
fitted expansion fill pressure
vessel. of 0.7bar

Electrical supply 230V~50Hz
Electrical rating 150W fused 3A
Internal Fuse rating 1) Type T2A

Approximate gas 3.06m3/h
rate at max input (108.2ft

■ For larger systems use an additional expansion

vessel, see Section 4.

3

/h)

2

)

7

221872B

1 General Data

1.7 Gas Supply

The gas installation shall be in accordance with the rules in force
in the countries of destination.

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

1.8 Electrical Supply

WARNING. This boiler must be earthed.
All system components shall be of an approved type.
The electrical installation shall be in accordance with the current

rules in force in the countries of destination at the time of
installation.

Connection of the whole electrical system of the boiler and any
heating system controls to the electrical supply, must be through
one common isolator.

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

Alternatively, a fused 3A 3pin plug and unswitched socket may
be used, provided they are not used in a room containing a bath
or shower.

The mains supply cable and other cables connected to the
boiler must be the PVC flexible type of at least 0.75mm

2

(24/

0.20mm) .

1.9 Heating System Controls

The heating system should have installed: a timer and room
thermostat controlling the boiler.

Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.

Note: All systems must have at least one radiator not fitted with
a thermostatic valve.

Note: For further information, see The Building Regulations
1991 - Conservation of fuel and power, 1995 edition - Appendix
G, table 4b.

The appliance flue type is a C
flue where the fan is downstream of the heat exchanger. The C12 is
a horizontal flue termination, and the C32 is a vertical flue termination.

and C32. This refers to a concentric

12

Diagram 1.2

9258

THERMISTOR

OVERHEAT
CUT-OFF

LOW WATER
PRESSURE
SWITCH

FANNED FLUE

HEAT EXCHANGER

MAIN BURNER

GAS VALVE

BYPASS
VALVE

FLOW

HOUSING

GAS

PUMP

RETURN

AUTOMATIC
AIR VENT

SAFETY
VALVE

EXPANSION

VESSEL

SAFETY

VALVE

DISCHARGE

7793

Diagram 1.3

221872B

8

2 Boiler Position

2.1 Location

This boiler must be installed in accordance with the rules in
force in the countries of destination.

This boiler is not suitable for fitting outside.
Any electrical switch must be positioned so that it cannot be

touched by a person using the bath or shower.
The boiler must be mounted on a flat wall which is sufficiently

robust to take its weight, refer to Table 1, “Data”.
Note: It is important that the wall hanging bracket and the

service cock bracket are fitted to a flat and true wall area for
correct alignment with the boiler. Where this can not be
achieved it is acceptable to pack out the service cock bracket
to obtain the correct alignment with the wall hanging bracket.

If the location of the boiler or any part of the system is subject
to severe cold weather conditions, it is recommended that a
frost thermostat is fitted. Any part of the system that may be
vulnerable to freezing must be protected.

2.2 Boilers in a compartment

Where the installation of the boiler will be in an unusual position,
the current issue of BS6798 gives detailed guidance on these
requirements.

An existing cupboard or compartment modified for the purpose
may be used, providing minimum clearances are maintained.
Details of essential requirements for cupboard or compartment
design are given in the current issue of BS6798.

The door way opening should be of sufficient size to allow for
easy removal of the boiler.

Where the boiler is fitted in a cupboard or compartment,
permanent ventilation is not required.

Any existing compartment air vents must not be removed or
blocked off.

25 ABOVE THE TOP OF THE BOILER CASE
OR THE FLUE ELBOW IF FITTED

5

150

To achieve minimum "Installation" clearance of 5mm.

The side panels will have to be fitted prior

to boiler mounting.

DIMENSIONS IN MILLIMETRES

450

Diagram 2.1

7087

5

2.3 Clearances

The boiler should be positioned so that at least the minimum
operational and servicing clearances are provided, see diagram

2.1. Additional clearances may be required around the boiler
for installation.

2.4 Timber Frame Buildings

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

9

221872B

3 Flue and Ventilation

3.1 General

The flue must be installed in accordance with the rules in force
in the countries of destination.

3.2 Terminal Position

The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 3.1.

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

Car port or similar extensions of a roof only, or roof and one wall,
require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required to
protect the roof if made of plastic sheeting. If the car port
comprises of a roof and two or more walls seek advice from the
local gas undertaking before installing the boiler.

If the terminal is fitted within 600mm below plastic guttering, an
aluminium shield 1500mm long should be fitted immediately
beneath the guttering or eaves. If the terminal is fitted within
450mm below painted eaves or a painted gutter, an aluminium
shield 750mm long should be fitted immediately beneath the
guttering or eaves.

3.3 Flue Options

There are various flue systems to choose from, as follows:
Easyfit Top Outlet Flue Pack - Pt.No. 232057
Standard Rear Outlet Flue Pack - Pt.No. 230482
Extended Top Outlet Flue Pack - Pt. No. 230487
1 Metre Extension Kit - Pt. No. 230484
Optional Wall Liner Kit No. 900862
A Flue Bend Kit or Vertical Flue Kit can be supplied, see

Hepworth Heating "Flue Options Guide" for configurations
available.

o

Flue Bend Pack - Pt. No. 230485

45

o

90

Flue Bend Pack - Pt. No. 230486
In Line Flue Adapter Kit - Pt. No. 230488
Vertical Flue Kit No. 458115

3.4 Internal Access Flue

All flue assemblies are designed for internal installation, given
that there is sufficient clearances opposite to the flue for the
installation of the flue.

If there is insufficient clearance the flue can be installed from
outside.

For a wall thickness up to 300mm, provided that there is
sufficient space and the optional wall liner kit is used, the flue
can be installed from the inside.

For a wall thickness of over 300mm the external flue hole will
need to be made good from the outside, this also applies if you
use the flue kit without the optional wall liner kit, irrespective of
wall thickness.

3.5 Terminal Guard

A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.

If a terminal guard is required, it must be positioned to provide
a minimum of 50mm clearance from any part of the terminal and
be central over the terminal.

The guard should be similar to that shown in diagram 3.1 .

3.6 Room Ventilation

Ventilation must be provided in accordance with the rules in
force in the countries of destination. The boiler is room sealed,
so where the boiler is fitted in a room or space, a permanent air
vent is not required.

3.7 Cupboard/Compartment Ventilation

If the boiler is to be fitted in a cupboard or compartment. Refer
to Section 2.2.

L

G

D

F

K

mm

Diagram 3.1

C

K

L

K

MINIMUM
SPACING

A

B,C

K

F

F

G

J

A

F

G

UNDER CAR PORT etc.

B,C

G

A

E

G

H,I

MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS
POSITION

A DIRECTLY BELOW, ABOVE OR HORIZONTALLY

TO AN OPENING, AIR BRICK, OPENING
WINDOWS, AIR VENT OR ANY OTHER

VENTILATION OPENING. 300
B BELOW GUTTER, DRAIN/SOIL PIPE 25
C BELOW EAVES 25
D BELOW A BALCONY 25

OR CAR PORT 200
E FROM VERTICAL DRAIN PIPES AND

SOIL PIPES 25
F FROM INTERNAL OR EXTERNAL

CORNERS 25
G ABOVE ADJACENT GROUND OR

BALCONY LEVEL 300
H FROM SURFACE FACING THE

TERMINAL 600
I FACING TERMINALS 1200
J FROM OPENING (DOOR/WINDOW)

IN CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300

TERMINAL GUARD TYPE K3
SUPPLIED BY :

Tower Flue Components Ltd.
Morley Road
Tonbridge
Kent
TN9 1RA

2816

221872B

10

4 Water System

7917

4.1 General Notes

The boiler is intended for use in a sealed system only.

4.2 Safety Valve

The safety valve is an integral part of the boiler.
It cannot be adjusted but has a manual test device.

4.3 Pressure Gauge

A pressure gauge is incorporated into the boiler to indicate the
system pressure.

The gauge has a cold fill set pointer.

4.4 Pump

The circulation pump is integral with the boiler.
The remaining circulating pressure head available from the

boiler is shown in diagram 4.1, Saunier Duval pump.

4.5 Expansion Vessel

The boiler has an integral expansion vessel with a capacity of
6 Litres. If the system water content exceeds the maximum
quoted in Table 1, Data, an additional vessel should be connected
into the system as close as possible to the central heating return
connection of the boiler, see diagram 4.2.

The charge pressure shall not be less than the static head at the
point of connection, that is, the height of the top point of the
system above the expansion vessel.

Diagram 4.1

4.6 Flow Rate

A valve must be incorporated in the main flow or return of the
system, valve “A” shown in the flow diagram 4.2. This valve
must be lockable and positioned so that inadvertent closure or
unauthorised interference is not possible.

4.7 Bypass

The bypass is an integral part of the boiler.

4.8 Water Make Up

Provision should be made for replacing water lost from the
system using a make up bottle mounted in a position higher than
the top point of the system, connected through a non-return
valve to the return side of the heating circuit, see diagram 4.2.

Alternatively, provision for make up can be made using a filling
loop.

4.9 Filling Sealed Systems

Provision for filling the system at a low level must be made.
Three methods of filling are shown in diagram 4.3.

There must be no permanent connection to the mains water
supply, even through a non-return valve.

NOTE: It is important that fittings used for connection to potable
water comply with the water undertakers requirements.

11

221872B

ADDITIONAL

METHOD 1

METHOD 2

METHOD 3

SUPPLY STOP
VALVE

SUPPLY
PIPE

HOSE
UNIONS

SERVICING
VALVE

TEMPORARY
HOSE

HEATING
SYSTEM

HEATING
SYSTEM

TEMPORARY
HOSE

HOSE
UNIONS

SERVICING
VALVE

SUPPLY
PIPE

SUPPLY STOP
VALVE

DOUBLE CHECK
VALVE ASSEMBLY

HEATING
SYSTEM

SERVICING
VALVE

SUPPLY
STOP VALVE

SUPPLY
PIPE

HOSE
UNIONS

DOUBLE CHECK
VALVE ASSEMBLY

OVERFLOW

CISTERN

COMBINED
CHECK VALVE
AND VACUUM
BREAKER

PRESSURE
REDUCING
VALVE

EXPANSION
VESSEL
(if required)

HEATING
CIRCUIT

4 Water System

ALTERNATIVE METHODS OF FILLING

7794

BOILER

3132

FILLING
POINT

RETURN

’A’

4.10 Corrosion Inhibitor

If an inhibitor is to be used in the system, contact the inhibitor
manufacturer so that they can recommend their most suitable
product.

When fitting the boiler into an existing system, special care
should be taken to drain the entire system, including radiators,
then thoroughly cleaning out before fitting the boiler whether or
not adding an inhibitor.

4.10 Draining

A draining tap must be provided at the lowest points of the
system, which will allow the entire system to be drained. An
additional draining tap MUST be fitted close to the boiler.

The flow and return isolation valves are provided with drain
points for boiler heat exchanger drainage.

General

The domestic hot water service must be in accordance with the
current issue of BS5546, refer also to the current issue of
BS6700.

5.1 Domestic Hot Water Cylinder

SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE
AND SHOULD NOT BE USED.

The domestic hot water cylinder must be of the indirect coil type.
It must be suitable for a working at a gauge pressure of 0.35bar
above the safety valve setting.

FLOW
CONTROL
VALVE

DRAIN
POINT

Diagram 4.2

Diagram 4.3

5 Domestic Hot Water

5.2 Domestic Hot Water System - Unvented

Where a storage system will not have a vent to atmosphere the
installation must comply with Building Regulations and local
Water Company bye-laws, see also the current issue of BS6700.

If fitting into an existing system the local authority should be
informed.

221872B

12

6 Installation Preparation and Gas / Water Connections

The installation requires the following components :-

1. Plumbing jig Carton

2. Boiler Carton

3. Flue Pack

6.1. Plumbing Jig

Remove from the wall template, then follow the instructions
given on the template.

Note: Leaving the service cock bracket (lower jig) fixing screws
loose will make the fitting of the boiler service elbows on to the
service cocks easier. Once the service connections are made,
tighten service cock bracket (lower jig) fixing screws. It is
important that the wall hanging bracket and the service cock
bracket (lower jig) are fitted to a flat and true wall area for correct
alignment with the boiler. If this cannot be achieved it is
acceptable to pack out the service cock bracket (lower jig) to
obtain the correct alignment with the wall hanging bracket.

6.2 Gas Connection

Provision is made for the gas supply to be connected from
below the boiler, see diagrams 1.1 and 6.1 for position.

Refer also to “Gas Supply”, Section 1.7.
Make the gas supply connection to the gas service cock. While

making the connection, do not subject the gas service cock to
heat as you may damage the seals.

6.3 Water Connections

Provision is made for the flow and return pipes to be connected
from below or through an internal wall at the rear of the boiler,
see diagram 1.1 and 6.1 for position. Provision is also made for
the flow and return to be connected from above, passing down
either side of the boiler. Take care that any pipework connected
from above will clear the expansion vessel. Refer to the wall
template. If connecting from above a piping kit 457620 is
available and is recommended.

NOTE: Top rear flue outlet is not possible with a vertical
piping kit.

Refer also to Section 4.11.
If necessary, temporarily fit the boiler.
Flush out the system before connecting the boiler.
Make the connections to the flow and return by means of the

isolating valves, see diagram 6.1.
While making the connections. Do not subject any of the

isolating valves to heat as you may damage the seals.

SAFETY DISCHARGE PIPE
ROUTING POSITION

HEATING
FLOW

LEVERS (OPEN)
HEATING
FLOW/ RETURN

Make sure that the drain and operating screw heads on the
isolating valves are accessible.

GAS
SERVICE
COCK

HEATING
RETURN

SLOT (OPEN)
GAS SERVICE
COCK

Diagram 6.1

6.4 Safety Valve Discharge

WARNING. It must not discharge above an entrance or window
or any type of public access area.

A short discharge pipe is supplied loose with the boiler, which
when fitted to the safety valve, will end below the boiler the
position is next to the heating return, for position see diagram

6.1.
This must be extended, using not less than 15mm od metal

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

Note. To ease future servicing it is advisable to use a compression
type fitting to extend the discharge pipe.

7795

7 Flue Preparation

7.1 Flue Position and Length

Determine flue application, length and terminal position before
starting, refer to diagram 7.1.

Note: The Easyfit Top Outlet Flue Pack and the Extended Top
Outlet Flue Pack contains a flue duct extension piece complete
with "O" rings, this should be discarded.

If you are using a Flue Bend or a Vertical Flue Kit, please follow
the instructions supplied with the kit.

To make a neat finish to the flue outlet a flue collar kit, part No.
443286, with instructions, is available, see diagram 7.2.

Note: If required an optional wall liner kit, part no. 900862, is
available complete with instructions.

7.2 Flue Assembly

Extend the telescopic flue to the required length, making sure
that the minimum overlap is no less than 25mm, and that the flue
terminal projects 15mm minimum beyond wall face, see diagram

7.1.
Carefully drill though air duct pilot hole and secure with self

tapping screw provided in fittings pack, see diagram 7.1.
Seal the joint with the tape provided.
If the flue system requires the addition of flue extension kits,

drill, seal and secure them with the self tapping screw and tape
provided.

Note: Should any one of the flue sections require cutting to
obtain desired flue system length, cut at the end opposite the
expanded end.

If the boiler is not to be fitted for some time cover the hole in the
wall.

13

221872B

7 Flue Preparation

9359

m

W

TOP OUTLET FLUE PACK

EXTENDED
'X' plus 254mm (RH) = flue length
'X' plus 10mm (LH) = flue length

EASYFIT
'X' plus 282mm (RH) = flue length
'X' plus 38mm (LH) = flue length
(must include 50mm min.
side clearance)

54mm*

5mm*

FLUE LENGTH

MAX 840mm (extended)

MAX 570mm (easyfit)

15mm

239mm*

SCREW

TOP OUTLET/
SIDE FLUE

'X'

& T APE

TOP OUTLET/
REAR FLUE

EXTENDED 'Y' plus 69mm = flue length

*EXTENDED flue only

EASYFIT 'Y' plus 97mm = flue length

EASYFIT/EXTENDED TOP OUTLET FLUE PACK & 1 METRE EXTENSION KIT

3 x 1 metre extension kits may be joined together.

Note: Remove heat exchanger baffle over 2.5m.

15mm

VIEW 'B'

SCREW
& T APE

'Y'

SCREW
& T APE

'X'

SIDE FLUE

EXTENDED
'X' plus 254mm (RH) = flue length
'X' plus 10mm (LH) = flue length
EASYFIT: 'X' plus 282mm (RH) 'X' plus 38mm (LH) = flue length

REAR FLUE

EXTENDED 'Y' plus 69mm = flue length
EASYFIT 'Y' plus 97mm = flue length

REAR OUTLET FLUE PACK

FLUE LENGTH

REAR OUTLET FLUE PACK & 1 METRE EXTENSION KIT

2 x 1 metre extension kits may be joined together.

510mm MAX.

FLUE LENGTH

MAX 840mm (extended)

MAX 570mm (easyfit)

15mm

SCREW
& T APE

'Y'

SCREW
& T APE

VIEW 'B'

15mm

80mm

FOAM
SEAL

'Y'

SCREW
& T APE

'Y' plus 95mm = FLUE LENGTH

FLUE

PACKS

EASYFIT

REAR
SIDE R.H.
SIDE L.H.

TOP EXTD.

REAR
SIDE R.H.
SIDE L.H.

REAR STD.

REAR 75 170 510 415 -

MINIMUM

WALL

THICKNESS

MINIMUM

LENGTH

75
75
75

75
75
75

FLUE

144
334

90

144
334

90

MAXIMUM

FLUE

LENGTH

570
570
570

840
840
840

BOILER MOUNTING FACE

TO EXTERNAL WALL FACE

80mm

FOAM
SEAL

'Y' plus 95mm = FLUE LENGTH

MAXIMUM DISTANCE FROM

"Y"

500

-

-

770

-

-

BOILER CASING TO

EXTERNAL WALL FACE

"X"

316
560

586
830

SCREW

15m

& T APE

'Y'

SCRE
& T APE

NOTE :

IF IT IS NECESSARY TO CUT THE DUCTS
TO ACHIEVE THE "FLUE LENGTH" MAKE SURE
THAT THE OVERLAPS ARE AS FOLLOWS :­THE OVERLAP FOR AIR DUCT = 25mm

-

-

THE OVERLAP FOR FLUE DUCT = 50mm
THE MAXIMUM LENGTHS CAN BE INCREASED

BY AN ADDITIONAL 2 METRES WITH THE USE
OF THE 1 METRE EXTENSION KITS.
NOTE :THIS APPLIES TO STANDARD KITS ONLY.

9360

Diagram 7.1

221872B

14