Saunier duval XEON 120FF User Manual

2000225135A.03.03

Instructions for Use

Installation and Servicing

To be left with the user

120ff

11865

Fanned Flue Boiler

GC No. 41-920-36

Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

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

to offer our customers' a Comprehensive First Year Guarantee.

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

and return as soon as possible.

If your guarantee registration return literature is missing you can obtain a copy by telephoning

Heatcall our Customer Service Company 00 44(0)1773 828100.

RECORD YOUR SAUNIER DUVAL APPLIANCE DIRECT BY CALLING

0044 (0)208 247 9857

Customer service :

Saunier Duval GB Great Britain :

Tel. [phone]

Fax. [phone]

Hepworth Heating Ltd.,

Nottingham Road, Belper, Derbyshire. DE56 1JT

Saunier Duval IE IRELAND:

Tel. 00 353 (0)14191919

Fax. 00 353 (0)14584806

Hevac

,

Muirfield Drive

Naas Road

Dublin 12

Technical Advice Line:

Tel. [phone]

General and Sales enquiries:

2000225135A

Tel. [phone]

Fax. [phone]

2

Contents

CONTENTS DESCRIPTION SECTION PAGE No.

Important Information 4

INSTRUCTIONS

FOR USE

INSTALLATION

INSTRUCTIONS

Draining 5
Appliance Introduction 5
Appliance Safety Devices 6
Maintenance and Servicing 6
Instructions for Use 7

General Data 1 9
Flue Terminal 2 12
Water Systems 3 13
Flue and Appliance Preparation 4 16
Boiler Installation 5 20
Flue Fixing 6 22
Electrical Connectors 7 23
Commissioning 8 24
Instructions to the User 9 28

SERVICING

INSTRUCTIONS

Servicing 10 28
Fault Finding 11 31
Replacement of Parts 12 35
Spare Parts 13 38

3 2000225135A

Important Information

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 competent person in
accordance with the above regulations.

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. The
requirements are: 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. Manufacture's instructions supplied.
Manufacture's instructions must not be taken as overriding
statutory requirements.

Mandatory WARNING for EEC countries

This appliance is designed, approved and inspected to meet
the requirements of the Intended market. The data label
indicates where the product was manufactured and the

country for which it is intended.

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.

Control of 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

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.
The insulation is composed of non-combustible material.

Thermostats

These contain very small amounts of xylene in the sealed phial
and capillary. If broken, under normal circumstances the fluid
does not cause a problem, but in case of skin contact, wash with
cold water. If swallowed drink plenty of water and seek medical
attention.

Cut-off Device

These contain activated charcoal and a very small amount of
chlorodifluormethane in the sealed phial and capillary. If
broken, under normal circumstances the fluid does not cause
a problem. If there is irritation to the eyes or skin then seek
medical attention.

Electrical Supply

WARNING: This boiler must be earthed.

All system components shall be of an approved type and shall
be connected in accordance with the current issue of BS7671
and any applicable local regulations.

All external wiring between the appliance and the electrical
supply and earthing requirements shall comply with the current
IEE Regulations.

Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A, maximum. This method of connection must be by a fused
double pole isolating switch, with a minimum contact separation
of 3mm on both poles. The switch should be readily accessible
and preferably adjacent to the appliance. It should supply the
appliance only and be easily identifiable as so doing.

Alternatively, an unswitched shuttered socket outlet and 3A
fused 3 pin plug, both to the current issue of BS1363 may be
used provided that they are not used in a room containing a bath
or shower.

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

2000225135A

Gas leak or fault

WARNING: 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.

Manual Handling Guidance

During the appliance installation it will be necessary to employ
caution and assistance whilst lifting as the appliance exceeds
the recommended weight for a one man lift.

In certain situations it may be required to use a mechanical
handling aid.

Take care to avoid trip hazards, slippery or wet surfaces.

4

Important Information

Heating System Controls

The heating system must be controlled as described in the
relevant part of the current issue of :

Building Regulations, approved document L1, and the
references:

1) GIL 59, 2000: Central heating system specification (CheSS)
and

2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.

3) The domestic heating and hot water guide to the building
regulations 2001.

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

Draining

Draining

System

A draining tap must be provided at the lowest points of the
system which will allow the entire system, boiler and hot water
cylinder to be drained.

Draining taps should be to the current issue of BS2879.

Boiler

A draining point is fitted at the bottom right hand side of the heat
exchanger.

Cover controls to avoid water damage.

If required remove the combustion chamber front cover to
improve access.

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.

Protection Against Freezing.

If the boiler is to be out of use for any long period of time during
severe weather conditions we recommend that the whole of the
system, including the boiler, be drained off to avoid the risk of
freezing up. Make sure that, if fitted, the immersion heater in the
cylinder is switched off.

Appliance Introduction

The Xeon ff series are fanned flue boilers designed to provide
central heating and indirect domestic hot water.

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

The boiler is for use only on G20 gas.

The boiler can be used on an open vented or sealed water
system.

When used on an open vented system domestic hot water can
only be provided by pumped circulation to the indirect cylinder.

5 2000225135A

Appliance Safety Devices

The Gas Safety (Installation and Use)
Regulations

In your interest and that of gas safety it is the law that ALL gas
appliances are installed by a competent person in accordance
with the above regulations.

Electrical Supply Failure

Failure of the electrical supply will cause the burner to go out.
Should this occur, operation of the appliance will normally
resume after the electrical supply is restored.

If the boiler does not relight after an electrical supply failure the
overheat safety cutoff device may need resetting, remove the
controls cover and press the reset button, refer to diagram 1.

Overheat Safety Cut-off

If the overheat safety cutoff device operates on any other
occasion than an electrical supply failure, press the reset button
as in “Electrical Supply Failure”. If the overheat operates again,
turn the appliance off and contact your installation/servicing
company.

Maintenance and Servicing

Cleaning

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

Clean the casing occasionally by wiping it over with a damp
cloth or dry polishing duster.

Do not use an abrasive cleaner.

Maintenance and Servicing

To ensure the continued efficient and safe operation of the
boiler 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 in the UK there
is a duty or care imposed on the owner of the property by the
current issue of The Gas Safety (Installation and Use)
Regulations, Section 35.

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

To obtain service, please call your installer or Heatcall (Saunier
Duval’s own Service Organisation) using the telephone number
given on the controls tray.

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.

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.

If a part is required contact Heatcall (Saunier Duval’s own
service organisation) using the telephone number on the inside
front cover of this booklet.

Please quote the name of the appliance, this infomation will be
on the front cover of this booklet and also on the data label inside
the appliance.

If in doubt seek advice from the local gas company or Heatcall
(Saunier Duval’s own service organisation) using the telephone
number on the inside front cover of this booklet.

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.

2000225135A

6

Instructions for Use

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

Important Notice

This boiler is for use only on natural gas (G20).

Warning: The user shall not interfere with or adjust sealed
parts.

Boiler Clearances

If fixtures are positioned close to the boiler space must be left
as shown in diagram 2. At least a minimum clearance of 500mm
must be left in front of the boiler to allow for servicing.

Boilers Installed in a Compartment or
Cupboard

If the boiler is installed in a compartment or cupboard do not
obstruct any ventilation openings.

Do not use the compartment or cupboard for storage.

10264

CONTROLS COVER

VIEWING WINDOW

4140

DATA &
SERIAL
NUMBER
LABEL

Boiler Electrical Supply

WARNING. This boiler must be earthed.

The boiler must only be connected to a 230V~50Hz supply
protected by a 3A fuse.

All wiring must be in accordance with the current issue of
BS7671.

Wiring to the boiler must be PVC insulated type to the current
issue of BS6500 Table 16, not less than 0.75mm2 (24/0.20mm).

The colours of three core flexible cable are:

Brown - live, Blue - neutral,

Green/yellow - earth.

As the markings on your plug may not correspond with these
colours continue as follows:

The cable coloured blue must be connected to the terminal
marked “N” or black.

The cable coloured brown must be connected to the terminal
marked “L” or red.

The cable coloured green/yellow must be connected to the
terminal marked “E”, or green or the earth symbol .

To Light the Boiler

WARNING. Sealed Systems

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

Only light the boiler when you are sure that the system has been
filled and pressurised.

The pressure gauge should show at least 0.7bar, anything less
than this figure could indicate a leak and you MUST contact your
installation/servicing company.

If there is any doubt about the boiler being full of water consult
your installation/servicing company.

ALL SYSTEMS.

Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat.

SETTING POINT

RESET
BUTTON

CONTROL
THERMOSTAT
KNOB

GAS SERVICE
COCK (Shown
Off)

Diagram 1

7 2000225135A

Instructions for Use

To Turn the Boiler On

Remove the controls cover, by withdrawing it forward and off,
see diagram 1.

Turn the control thermostat knob clockwise to any position
between MIN and MAX. The maximum temperature setting is
about 82oC (180oF), see diagram 1.

The boiler lighting operation is now automatic as follows.

The fan operates, followed by an ignition spark until the pilot is
lit. When the pilot is alight the ignition system switches off and
the main burner lights. The flames can be seen through the
viewing window, see diagram 1.

The main burner will remain alight until switched off by the
control thermostat or any remote control.

If the boiler is switched OFF, by hand, wait at least 30 seconds
before switching on again.

When the boiler switches off, both the pilot and main burner go
out.

The automatic lighting sequence will operate again when heat
is required.

Refit the controls cover.

It should be noted that this is a fan flue appliance and fan
operation may be heard.

To Turn the Boiler Off

For short periods, turn the control thermostat knob anti-clockwise
to “O” Off. To relight, turn the control thermostat knob to any
position between “MIN” and “MAX”.

For longer periods, turn the control thermostat knob fully anti­clockwise to “O” Off and switch off the electrical supply to the
boiler.

To relight follow the lighting sequence given above.

6mm

Additional clearances may be
required for installation

160mm

6mm

500mm

65mm

6mm

6mm

6mm

FRONT
VIEW

11854

Diagram 2

2000225135A

8

B

AO

1 General Data

C

PUMPED

FLOW

PUMPED

RETURN

F

G

H

11860

E

J

MODEL

D

SIDE ELEVATION FRONT ELEVATION

ABCDEFGHJ KLMO

120ff

67 300 63 127 114 450 168 132.5 835 772 63 132 43

WATER CONNECTIONS
28mm COPPER PIPE

GAS CONNECTIONS

1

RC

/2 (1/2 in. BSPT)

Important Notice

This boiler is for use only on G20 gas.

This boiler can be used on an open vented or sealed water
system.

When used on an open vented system domestic hot water can
only be provided by pumped circulation to the indirect cylinder.

Wherever possible, all materials, appliances and components
used shall comply with the requirements of applicable British
Standards.

Where no British Standard exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.

Sheet Metal Parts

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

1.1 Statutory Requirements

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.

In GB the installation of the boiler must be carried out by a
competent person as described in the following regulations:

The manufacturer’s instructions supplied.

The Gas Safety (Installation and Use) Regulations.

The appropriate Buildings Regulations either The Building
Regulations, The Building Regulations (Scotland),The Building
Regulations (Northern Ireland).

The Water Fittings Regulations or Water byelaws in Scotland.

The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).

The Current I.E.E. Wiring Regulations.

P

C

L

K

L

M

P

78.5

Diagram 1.1

Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent person
and installed in accordance with the current edition of I.S.813
"Domestic Gas Installations", the current Building Regulations
and reference should be made to the current ETCI rules for
Electrical Installation.

In GB the following Codes of Practice apply:

BS4814, BS6798, BS5440 Part 1 and 2, BS5546 Part 1,
BS5449, BS6891, BS6700, BS7074 Part 1 and 2, BS7593,
BS7671.

In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593.

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

Note: For further information, see the current issue of the
Building Regulations, approved document L1 ( in the UK) and
the references:

1) GIL 59, 2000: Central heating system specification (CheSS)
and

2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRECSU.

An optional programmer for fitting on the boiler is availble, kit no.

458065.

1.2 Data

See Table 1

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

The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
Xeon 120ff = 78.1.

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.

9 2000225135A

1 General Data

DATA TABLE 1.

TOTAL DRY
WEIGHT
(Including
Terminal)

*

LIFT WEIGHT

WATER
CONTENT

GAS
CONNECTION

ELECTRICITY
RATING

WATER

Internal fuse F1 & F2 (F1A)

2x28mm copper pipes from

CONNECTION

ELECTRICITY
SUPPLY

DATA LABEL

Bottom right hand side of case

1.3 Range Rating

This boiler is range rated and may be adjusted to suit individual
system requirements.

Diagram 1.2 gives the ratings and settings.

*Note: Lift weight is with Flue Elbow, Controls Cover and Front
Cover removed.

71.0 kg
(157 lb)

63.3 kg

(140 lb)

3.8 litres

(0.84 gal)

1

Rc

/2 in.

97W

top of case

230V~50Hz, fused 3A

11855

Diagram 1.2

1.7 Water System

This boiler may be fitted to an open vented or sealed water
system.

1.8 Safety Valve

A safety valve need not be fitted to an open vented system.

11856

1.4 B.S.I. Certification

This boiler is certificated to the current issue of BS6332 Part 1,
invoking the current issue of BS5258 Part 1 for performance
and safety. It is, therefore, important that no alteration is made
to this boiler without permission, in writing, from Hepworth
Heating Ltd.

Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the B.S.I. Certification of the boiler, warranty
and could also infringe the current issue of the Statutory
Requirements.

1.5 Gas Supply

The gas installation shall be in accordance with the relevant
standards.

In GB this is BS6891.

In IE this is the current edition of I.S.813 "Domestic Gas
Installations".

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

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

1.6 Contents of Packaging

The boiler is delivered in one pack, refer to Section 4.1 for
contents.

Refer to Section 4.2 to check that the flue terminal assembly
supplied is suitable.

2000225135A

10

1 General Data

1.9 Location

This boiler is not suitable for outdoor installation.

This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.

In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.

In IE reference should be made to the current edition of I.S.813
"Domestic Gas Installations" and the current ETCI rules.

Any electrical switch or boiler control utilising mains electricity
should be placed so that it cannot be touched by a person using
the bath or shower. The electrical provisions of the Building
Standards (Scotland) apply to such installations in Scotland.

The boiler must be mounted on a flat wall which is sufficiently
robust to take its total weight.

The boiler may be fitted to a wall made of combustible material.

1.10 Boiler Clearances

Refer to diagram 1.3.

The boiler must be positioned so that at least the minimum
operational and servicing clearances are provided.

Additional clearances may be required for installation.

If fixtures are positioned next to the boiler they should be made
removable for access to pipework.

Sufficient clearance must be left in front of the boiler for
servicing.

6mm

Additional clearances may be
required for installation

160mm

6mm

500mm

65mm

6mm

PLAN
VIEW

6mm

6mm

FRONT
VIEW

11854

1.11 Room Ventilation

The boiler is room sealed and does not require the room or
space containing it to have permanent airvents.

1.12 Boilers in a Compartment

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

A compartment used to enclose the boiler must be designed
and constructed specifically for this purpose. An existing
cupboard or compartment modified for the purpose may be
used. Details of essential requirements for cupboard or
compartment design are given in the current issue of BS6798.

The doorway 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 high and low level ventilation must be provided. The
minimum ventilation areas are given in Table 3.

1.13 Timber Frame Building

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.

1.14 Heating System Controls

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

MINIMUM CLEARANCES FROM WALLS
CEILING, FLOOR, CUPBOARD, WORKTOPS,
AND INFLAMMABLE MATERIALS

Diagram 1.3

TABLE 3. COMPARTMENT AIR VENTS

VENTILATION
REQUIREMENTS

HIGH LEVEL
VENT AREA

2

cm

VENTILATION
FROM
ROOM

396 61.5 396 61.5

OR SPACE

VENTILATION
FROM
OUTSIDE

198 30.5 198 30.5

Note: For further information, see the current issue of the
Building Regulations, approved document L1 (in the UK) and
the references:

1) GIL 59, 2000: Central heating system specification (CheSS)
and

2) GPG 302, 2001: Controls for domestic central heating
system and hot water. BRESCU.

2

in

LOW LEVEL
VENT AREA

2

cm

in

2

11862

11 2000225135A

2 Flue Terminal

2.1 Terminal Position

The minimum acceptable siting dimensions for the terminal
from obstructions, other terminals and ventilation openings are
shown in diagram 2.1. For Ireland the minimum distances for
flue terminal positioning must be those detailed in I.S.813
"Domestic Gas Installations".

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

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

If the terminal is fitted within 600mm below plastic guttering or
painted soffit 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.

A

A

F

G

Under Car Port etc.

C

B,C

G

A

E

G

H,I

B,C

K

M

F

F

G

J

K

L

L

K

G

D

F

K

0103M

2.2 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.

A suitable guard, reference Type K3, can be obtained from:

Tower Flue Components Ltd
Morley Road
Tonbridge
Kent
TN9 1RA

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 75

C BELOW EAVES 200

D BELOW A BALCONY OR CAR PORT 200

E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 25

F FROM INTERNAL/EXTERNAL CORNERS

OR TO A BOUNDARY ALONGSIDE
THE TERMINAL 25

G ABOVE ADJACENT GROUND OR BALCONY LEVEL 25

H FROM A 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

M FROM INTERNAL CORNERS 25

SPACING in mm

MINIMUM

2000225135A

4307

Diagram 2.1

12