INSTRUCTIONS FOR USE, INSTALLATION AND SERVICING by Saunier Duval. Manual Handling Guidance During...

INSTRUCTIONS FOR USE, INSTALLATION AND SERVICINGFOR ISOFAST CONDENS F 35 E

3

4000135500-2 04/04

INSTRUCTIONS FOR USE

Lighting : make sure that :• the boiler is connected

to the electrical supply,• the gas service tap is open,• Switch ON (I).

Switch off the boiler : Switchto OFF (0) : the electricalsupply is off. Stop the gassupply if the boiler is to beout of use for a long time.

In case of fault, thered warning light will flashand a code appearson the boiler display .

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

Other codes: press the key of theroom thermostat and read the indicationsgiven by the display.

Lighting/switch off the boiler

Fault indication

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

button light is ON3 - Sanitary function enabled when the

button light is ON4 - Heating function enabled when the

button light is ON5 - Hot water temperature adjuster.6 - Heating temperature adjuster.7 - Graphic display.8 - Green running light.9 - Red, flashing fault light.

10 - Yellow running lamp for the burner.

1

➡

423

5 67

8 9 10

Operation without room thermostat

• Press the key (the key will light-up)• Press the and/or buttons to

activate the heating and/or hot waterfunctions

• Use buttons and to determine theheating and hot water temperatures.

• To revert to the operating mode with roomthermostat, again press the key (thelight will turn OFF;

5 69

7

t

21

OK

2

Important notice : The settings performedon the boiler control panel are nottransmitted to the room thermostat.Perform the temperature settings fromthe wireless room thermostat suppliedtogether with the boiler, strictly adheringto the instructions given in this manual,pages 10 through 17.

Contents

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

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

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

Important information

The instructions consist ofthree parts, User,Installation and ServicingInstructions, whichincludes the GuaranteeRegistration Card. Theinstructions are an integralpart of the appliance andmust, to comply with thecurrent issue of the GasSafety (Installation and Use)Regulations, be handedto the user on completionof the installation.

GeneralThis combination boiler isable to provide room heatingas part of a central heatingsystem, and domestic hotwater direct from the coldwater supply without theneed for secondary storage.The central heating watertemperature and domestichot water temperature canboth be adjusted on theboiler.Once the controls are setthe boiler operatesautomatically.A frost protection program isalso included.

Please read theseinstructions and follow themcarefully for the safe andeconomical use of yourboiler.

Gas CategoryThis boiler is for use only onNatural gas (G20) orpropane (G31).

Gas Safety (Installationand Use) RegulationsIn your own interests andthat of safety, it is the Lawthat ALL gas appliances areinstalled by a competentperson in accordance withthe current issue of theabove regulations.

Gas Testing andCertificationThe boiler is tested andcertificated for safety andperformance.It is, therefore, importantthat no alteration is made tothe boiler unless approved,in writing, by Saunier Duval.Any alteration not approvedby Saunier Duval, couldinvalidate the certification,boiler warranty and may alsoinfringe the current issue ofthe statutory requirements.

CE MarkThis boiler meets therequirements of StatutoryInstrument, No. 3083 TheBoiler (Efficiency) Regulations,and therefore is deemed tomeet the requirements ofDirective 92/42/EEC on theefficiency requirements fornew hot water boilers firedwith liquid or gaseous fuels.Type test for purposes ofRegulation 5 certified by :Notified body 0086.Product/production certifiedby : Notified body 0086.

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Important information

The CE mark on thisappliance showscompliance with :1. Directive 90/396/EEC onthe approximation of thelaws of the Member Statesrelating to appliancesburning gaseous fuels.

2. Directive 73/23/EEC onthe harmonisation of theLaws of the Member Statesrelating to electricalequipment designed for usewithin certain voltage limits.

3. Directive 89/336/EEC onthe approximation of theLaws of the Member Statesrelating to electromagneticcompatibility.

Control of SubstancesHazardous to HealthUnder Section 6 of TheHealth and Safety at WorkAct 1974, we are requiredto provide information onsubstances hazardous tohealth.The adhesives and sealantsused in this appliance arecured and give no knownhazard in this state.Insulation PadsThese can cause irritation toskin, eyes and therespiratory tract.If you have a history of skincomplaint you may besusceptible to irritation. Highdust levels are usual only ifthe material is broken.Normal handling should not

cause discomfort, but follownormal good hygiene andwash your hands beforeeating, drinking or going tothe lavatory.If you do suffer irritation tothe eyes or severe irritationto the skin seek medicalattention.

Spare PartsREMEMBER, Whenreplacing a part on thisappliance, use only spareparts that you can beassured conform to thesafety and performancespecification that we require.Do not use reconditioned orcopy parts that have notbeen clearly authorisedby Saunier Duval.

Manual HandlingGuidanceDuring the applianceinstallation and thereplacement of theheat exchanger it will benecessary to employ cautionand assistance whilst liftingas the appliance orcomponent exceeds therecommended weight for aone man lift.In certain situations it maybe required to use amechanical handling aid.Take care to avoid triphazards, slippery or wetsurfaces.

Gas Leak or FaultIf a gas leak or fault exists or

is suspected, turn the boilermains electrical supply offand turn off the gas supplyat the meter. Consult yourlocal gas company or yourlocal installation/ servicingcompany.

Electrical Supply FailureThe boiler must be earthed.The boiler will not workwithout an electrical supply.Normal operation of theboiler should resume whenthe electrical supply isrestored.Reset any external controls,to resume normal operationof the central heating.If the boiler does not resumenormal operation turn themains reset switch off andon. If the boiler does notresume normal operationafter this the overheat statmay have operated. Theoverheat stat would onlyoperate under abnormalconditions and, under thesecircumstances; it would beadvisable to consult yourinstallation / servicingcompany.

Boilers Installed in aCompartment or CupboardIf the boiler is fitted into acompartment or cupboard,it does not require anyventilation openings. Do notuse the compartmentor cupboard for storage.

Pluming from flue terminalLike all condensing boilersthis appliance will produce aplume of condensation fromthe flue terminal in coolweather. This is due to thehigh efficiency and hencelow flue gas temperature ofthe boiler. It is normal andnot a fault indication.

Replacement PartsIf replacement parts arerequired contactSaunier Duval service usingthe telephone number onthe back cover of thisbooklet.Please quote the name of theappliance this infomation willbe on the front of theappliance.

Protection Against FreezingThe room thermostatautomatically ensures aminimum installationtemperature of 6°C.This protection is ensuredby the room thermostat aslong as it is active. Thismeans that the buttonof the boiler must not be litand that the batteries of theroom thermostat must be ingood condition.

If you are out of home for afew days, use the holidaysmode of your roomthermostat, and set the Startand End dates, as well asthe desired temperature.

If the mains electricity andgas are to be turned off forany long periods duringsevere weather, it isrecommended that thewhole system, including theboiler, should be drained toavoid the risk of freezing.

Contact yourinstallation/servicingcompany as draining, refillingand pressurising MUST becarried out by a competentperson.

As a safety feature the boilerwill stop working if thecondensate drain becomesblocked. During freezingconditions this may bedue to the forming of ice inthe condense drain externalto the house. Release an iceblockage by the use of

warm cloths on the pipe.The boiler should thenrestart. Contact yourinstallation/servicingcompany if the faultpersists.

Draining and FillingThis boiler works in apressurised system, whichmust only be drained,refilled and pressurised by acompetent person.

Pressure Relief SafetyValveA pressure relief safety valveand discharge pipe is fittedto the boiler. This valve mustnot be touched. Shouldthere be any discharge fromthe pipe, isolate the boilerelectrical supply andcall your installer orSaunier Duval service usingthe telephone number onthe back cover of thisbooklet.

Access to the user menu :

+OK

OK

HOLIDAYS START DATE

END DATE

CANCEL

MENU +

To ensure the continuedefficient and safe operationof the appliance it isrecommended that it ischecked and serviced asnecessary at regularintervals. The frequency ofservicing will depend uponthe particular installationconditions and usage, but ingeneral once a year shouldbe enough. Refer to Section«Routine Cleaning andInspection».

If this appliance is installedin a rented property there isa duty of care imposed onthe owner of the property by

the current issue of the GasSafety (Installation and Use)Regulations, section 35.Servicing/maintenanceshould be carried out by acompetent person inaccordance with the rules inforce in the countries ofdestination.

To obtain service,please call your installer orSaunier Duval service usingthe telephone number onthe back cover of this booklet.

Please be advised that the‘Benchmark’ logbook

should be completed by theinstallation engineer oncompletion ofcommissioning andservicing.All CORGI RegisteredInstallers carry a CORGI IDcard, and have a registrationnumber. Both should berecorded in your boilerLogbook. You can checkyour installer is CORGIregistered by calling CORGIdirect on: 01256 372300.

CleaningThe boiler casing can becleaned with a damp clothfollowed by a dry cloth topolish.Do not use abrasive orsolvent cleaners.

Boiler casingCAUTION. Do not removeor adjust the casing in anyway, as incorrect fitting mayresult in faulty operation. If indoubt, consult yourinstallation/service company.

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Servicing,all you need to know

Many thanks for choisingSaunier Duval marketleaders in boilermanufacture,

Your appliance isguaranteed for a period of24 months from the dateof installation or 30months from the date ofmanufacture whichever isthe shorter and coversmanufacturing defects only.

We, Saunier Duval,undertake to repair orreplace parts free of chargewhich are recognised by usto be of faulty manufacture -if necessary after return toour factory for examination -on condition that :a) The appliance wasinstalled by a qualifled gasinstaller in accordance withinstallation instructions, andall the relevant codes ofpractice, standards andlegislation in force.b) The appliance has beenused for normal domesticpurposes and in accordancewith the manufacturer'soperating and maintenance

instructions.c) The appliance has notbeen serviced, maintained,repaired dismantled ortampered with during theguarantee period, by anyoneother than an engineerapproved by Saunier Duval.d) The appliance is still inthe possession of theoriginal user, and proof ofpurchase in the form of areceipt or invoice is shownto the service engineer onrequest.The repair or replacement ofparts during the guaranteeperiod does not have theeffect of extending theperiod.

This guarantee does notcover :a) Any defects or damageresulting from incorrect orpoor installation, inadequateservicing, or maladjustmentof the gas or water used.b) Any defects in the systemto which the appliance isconnected.c) Any deterioration ormaladjustment followingchanges in the nature orpressure of the gas or thewater used, or a change inthe characteristics of theelectrical supply voltage.

Notification of any faultshould be made to theappliance installer.No repairs should beundertaken upon the

Welcome users

appliance, intending it to becovered by the productguarantee without priorauthorisation fromSaunier Duval.

IMPORTANT : Theappliance serial numbermust be quoted on allcorrespondence/contactmade with Saunier Duval.

This guarantee is inaddition to your statutoryand other legal rights, whichwill not be excluded ordiminished by the returnof the guarantee registrationcard.

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8 9

SYSTEM PRESSURETOO LOWFILL IN AT 1,5 BAR

Ambienttemperature display

Time period for the COMFORT temperature

Hot watermode indicatorHeating mode

indicator

Time display Time period for theECO temperature

Low batteryindicator

1 - Display.

2 - Fault indicator.

3 - Return to previous menu

4 - Confirm OK.

5 - Access to the menus.

6 - Menu scrolling

7 - Changing the mode

8 - Wall bracket

9 - Mains power plug

1

23 4

5

6

78

9

Fault description

Heating demandindicator

Indicators of thecurrent temperature levelsfor “COMFORTor ECO”(Day/Night).

(Attention: this value mayvary when you hold the

thermostat in your hand).

Your Isofast boiler isfactory set to operate withina customary installation.

Nevertheless, as manyinstallations mayincorporate specificfeatures, feel free to contactyour installer who will beable – by adapting theparameters of the boiler(maximum temperatureand/or maximum power ofthe heating system) - towarrant you the bestoperating performance ofyour installation.

These settings being made,you still have the possibilityof selecting the ambienttemperature to suit yourown requirements not onlywhen you are at home, butalso during nightime orwhen you are out

All these settings areachieved from the roomthermostat suppliedtogether with your boiler: ifyou accurately determinethe temperatures that bestsuit to your needs, you willmake significant savings interms of gas consumption.

Controlas a source of savings

Essential adjustments tothe wireless roomthermostat :A – Setting the timeB – Setting the date

The thermostat’sweekly programmefunctions enable you :C – To activate ordeactivate the heatingfunction.

D – To have a standardweekly programme byactivating the programmepre-set at the factory.

E – To bypass the currentprogramme, temporarily,to increase or lower thetemperature at any timeduring the day.

F – To set up a customprogramme for each day ofthe week, with 2temperature levels, forexample:• COMFORT for the periodsyou are present and.• ECO at night or when youare away.

G – To have the sametemperature 24 hours a dayby deactivating theprogramme.

H – To leave on holiday,determining the desiredtemperature according to thedate you leave and whenyou return.

I – To select the temperatureof your domestic hot waterfrom 38°C to 60°C.However, keeping thetemperature below 50°C,reduces gas consumptionand provides goodprotection against scalds.

J – To prevent undesiredalterations to your settingsby locking the thermostat’sbuttons.

K – To be informed of anyoperating faults in theboiler and be instructed inthe procedure to follow.

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

C

C

Progress of the operations:

Activating the initial programme

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

D

PROG

PROG

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

PROGRAMME OFF PROGRAMME ON

or

• Press , the room thermostat shows this display:

• Pressing reversesON and OFF mode every time

1 - Activating the weekly programme

2 -Accessing the initial programme

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

ECO temperature 16°C COMFORT temperature 19°C

11 PM >> 7 AM >> 11 PM

ECO ECOCOMFORT COMFORT ECO COMFORT

Monday to Friday Weekends

OKPROGRAMME INITIAL PROGRAMMEMONDAY

OK

OK

+

SET COMFORT T¡SET ECO T¡PROGRAMME...

• Press to select the "Programme" menu :

MENU +

Temporarily bypassing the weekly programmeE

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

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

OKSET ROOM T¡22¡C

OK

SET ROOM T¡

Confirm by pressing 20¡C

OKSET TIME 17:23 + OK

+ OKOKSET DATE TUE 14/JUA/ 03

CProgress of the operations : Please note that pressing button at any time takes you back to the previous step

Settings for the time and the dateand

A B

SET COMFORT T¡SET ECO T¡PROGRAMMESET HOT WATER T¡ON/OFF HEATINGHOLIDAYSSET TIMESET DATE

• Press to call up the next menu:

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

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

MENU

1 - Accessing the user menu

2 - Setting the time

3 - Setting the date

Activating/deactivating the heating functionC

PROGRAMMESET HOT WATER T¡ON/OFF HEATING...

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

MENU

1 - Activate the heating

OK OKON/OFF HEATING ONOFF

OK OKON/OFF HEATING ON OFF

2 - Deactivate the heating

+OK


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PROG

OK

MODIFYCOPY TO

MONDAYTUESDAY

MONDAYTUESDAY

OK OK OK

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

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

19.5

MODIFYTIME-SLOTS :T¡ CHOICE : PROG

19.5 16.5

Press to switch fromCOMFORT to ECO temperature This symbol indicates the

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

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

E.g. :In the case of the illustration opposite, each press of the buttonadds a square from 11 PM onwards, corresponding to an extra 30 minutes heating at 19.5°C.

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

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

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

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

/

MODIFYTIME-SLOTS :T¡ CHOICE : PROG

/ MODIFYTIME-SLOTS :T¡ CHOICE : PROG

/

23:00 6:00


OK OKSET COMFORT T¡

SET COMFORT T¡SET ECO T¡PROGRAMME...

19.0¡C 19.5¡C18.5¡C

20.0¡C

OKPROGRAMME MODIFYCOPY TO

MONDAYTUESDAYWEDNESDAYTHURSDAYFRIDAYSATURDAYSUNDAYINITIAL PROGRAMME

OK OK

/...

/...

(to set the desired temperature during the day)

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

OK OKSET ECO T¡ 16.0¡C 16.5¡C16.0¡C

17.0¡C

/...

/...

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

PROG

PROG

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

PROGRAMME OFF PROGRAMME ON

or

C

• Press to call up the next menu:

• Press , the room thermostat shows this display:

• Pressing reverses ON and OFF mode every time.

Progress of the operations :

MENU

Setting the custom weekly programme

1 - Activating the weekly programme

2 - Access to the user menu

3 - Setting the Comfort temperature

4 - Setting the Eco temperature

5 - Programme


F

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SET ECO T¡PROGRAMMESET HOT WATER T¡...

OK OKSET HOT WATER T¡ 50¡C 51¡C49¡C

52¡C

/....

/....

(to set the hot water tothe desired temperature)

C

• Press to call up the next menu :


MENU

Setting the hot water temperature


2 - Setting the hot water temperature


+

I

Locking/unlocking the thermostat’s buttonsJ

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

• Follow the same procedure to unlock the buttons.

Press for 3 seconds

C OK

OK OKSET ROOM T¡

SET ROOM T¡...

19.0¡C 19.5¡C18.5¡C

20.0¡C

/...

/...

(to set the constanttemperature desired)

PROG

C


• Pressing activates or deactivates the programme mode each time :

• Retain the PROGRAMME OFF position. After 5 seconds, the display returns to its normal position and automatically validates this selection.


MENU

Setting the heating temperatures outside Programme mode

1 - Deactivating the weekly programme


3 - Setting the ambient temperature


PROGRAMME ON PROGRAMME OFFPROG PROG

G


SET HOT WATER T¡ON/OFF HEATINGHOLIDAYS...

HOLIDAYS


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

MENU

Holiday programme


2 - Activating the Holiday programme

+

H

+OK

OK

START DATE

END DATE

SET ROOM T¡

CANCEL

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Glossaryfor the user menu


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

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

• Press the button on the thermostat:

• The thermostat shows the procedure to follow:

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

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

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

Fault indicators

Fault level 1

Fault level 2

21

23

SYSTEM PRESSURETOO LOWFILL IN AT 1.5 BAR

FLOW RATE FAULTCALL AFTERSALESTEL 00 00 00 00 00

OK

K Setting the ambient temperature when the programme hasnot been activated (Programme inactive).

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

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

Allocating operating periods for Confort and Ecotemperature for each day of the week. In the morning, forexample, you are recommended to start heatingapproximately 1 hour before you get up.

Displaying the external temperature when an externalsensor is installed.

Setting the hot water temperature.

Starting / stopping heatingOn = Heating + hot waterOff = Hot water onlyOutdoor T° = displayed when an external sensor is

connected. When “Driven by ext. T°” isselected, the boiler automatically cuts off theheating when the temperature is higher than18°C (factory setting).

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

Setting the ambient temperature for while you are away.

Setting the time.

Setting the date.

Set room T°

Set comfort T°

Set eco T°

Programme

Outdoor T°

Set hot water T°

ON/OFF heating

Set radiator T°orFloor heating T°

Holidays

Set time

Set date

INSTALLERS

1918

Dimensions

The boiler is delivered inone package :the boiler itself, the wirelessthermostat, the fixingbracket, the template andpipe connections .

The different packagesrelating to the flue systemwill be ordered dependingon the actual configurationof the installation

418

890

510

232

Isofast F 35 E

Net weight (kg) 52

Gross weight (kg) 60

The “as delivered” package consists of :- 1 wireless thermostat- 1 fixing bracket- 3 x 1.5 V alkaline battery cells type LR6- 1 access cover to the battery cells

ATTENTION: DO NOT FORGET TO RECOVERTHE ROOM THERMOSTAT placed in apolystyrene case in the bottom of the package.

General Information

IMPORTANT NOTICEThe boiler and pipes aresupplied in one pack, theflue is supplied seperately.This boiler is factory set foruse only on G20 naturalgas.

Where no British Standardsexists, materials andequipment should be fit fortheir purpose and of suitablequality and workmanship.Refer to Manual HandlingOperations, 1992regulations.

The installation of this boilermust be carried out by acompetent person inaccordance the rules inforce in the countries ofdestination.

Manufacturer’s instructionsmust not be taken asoverriding statutoryrequirements.

Sheet Metal PartsWARNING: When installingthe appliance, care shouldbe taken to avoid anypossibility of personal injurywhen handling sheet metalparts.

Statutory RequirementsThe installation of the boilerMUST be carried out by acompetent person inaccordance with the relevant

requirements of the currentissue of : Manufacturer’sinstructions, supplied.

The Gas Safety (Installationand Use) Regulations, TheBuilding Regulations, TheBuilding Standards(Scotland) Regulations(applicable in Scotland),local Water CompanyBylaws, The Health andSafety at Work Act, Controlof Substances Hazardousto Health, The Electricity atWork Regulations and anyapplicable local regulations.Detailed recommendationsare contained in the currentissue of the following BritishStandards and Codes ofPractice, BS4814, BS5440Part 1 and 2, BS5449,BS5546, BS6700, BS6798,BS6891 and BS7074 Part 1and 2, BS7478, BS7593,BS7671.

We also suggest that youhave to hand a copy of theBritish Gas publication,“Guidance Notes for theInstallation of DomesticCondensing Boilers”.

Manufacturer’s notes mustnot be taken as overridingstatutory obligations.

CertificationThis boiler certificated to thecurrent issue of EN 483 for

performance and safety.It is important that noalteration is made to theboiler, without permission, inwriting, from Saunier Duval.

Any alteration that is notapproved by Saunier Duval.,could invalidate the warrantyand could also infringe thecurrent issue of theStatutory Requirements.

Electrical SupplyAll system components shallbe of an approved type andall wiring to current I.E.E.wiring regulations.External wiring must becorrectly earthed, polarisedand in accordance with therelevant standards.

In GB this is BS 6891.In IE this is the currentedition of I.S.813 "DomesticGas Installations".The boiler must beconnected to a permanent230V ac, 50Hz supply.Connection of the wholeelectrical system of theboiler, including any heatingcontrols, to the electricalsupply must be through onecommon isolator and mustbe fused 3 Amp maximum.

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

INSTALLERS

2120

Natural Gas (G 20) F 35 E

Ø burner injector (mm) 5,65

inlet pressure (mbar) 20

Sanitary flow rate at maximum input (m3/h) 3,62

Heating flow rate at maximum input (m3/h) 3,02

Flow rate at minimum input (m3/h) 0,85

Electricity F 35 E

Electrical supply (V) 230

Electrical rating (A) 0,9

Maximum absorbed power (W) 206

IP classification IPX4D

Class 1

Technical DataIsofast

Heating F 35 E

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

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

Heating input min. (Q) (kW)/(BTU/H) 8 / 27,296

Heating input max. (Q) (kW)/(BTU/H) 28,6 / 97,583

SEDBUK efficiency (%) ?

Heating output at 50°C/30°C adjustable (kW) from 8,6 to 30,6

Maximum heating temperature (°C) 80

Minimum heating temperature (°C) 22

Expansion vessel charge pressure (bar) 0,5

Maximum system capacity at 75°C (l) 215

Safety valve, maximum service pressure (PMS) (bar) 3,0

Hot water F 35 E

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

to… (kW)/(BTU/H) 7,6 / 25,931

Maximum hot water temperature (°C) 60

Threshold flow rate (l/min.) 1

Specific flow rate (D) (for 30°C temp rise) (l/min.) 16,3

Storage capacity (l) 4

Expansion valve setting (bar) 10

Minimum operating pressure (bar) 0,7

Maximum operating pressure (PMW) (bar) 10

Combustion F 35 E

Product outlet diameter (mm) 60

Fresh air inlet diameter (mm) 100

Fresh air flow rate (1013 mbar - 0°C) (m3/h) 43

Product outlet flow rate (g/s) 15,3

Product outlet temperature (°C) 68

Values of product outlet CO (ppm o mg/kWh) 100 or 176

CO2 (%) 9,2

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

Gas SupplyThe gas installation must bein accordance with therelevant standards.In GB this is BS6891.In IE this is the currentedition of I.S.813 "DomesticGas Installations".

The supply from thegoverned meter must be ofadequate size to provide asteady inlet workingpressure of 20mbar (8in wg)at the boiler.

On completion, test the gasinstallation for soundnessusing the pressure dropmethod and suitable leakdetection fluid, purge inaccordance with the abovestandard.

Technical Data All dimensions are given inmillimetres (except asnoted).

The data label is positionedon the inner door.

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

The value is used in the UKGovernment's StandardAssessment Procedure(SAP) for energy rating ofdwellings. The test datafrom which it has beencalculated has been certifiedby B.S.I.

F 35 E

Gas category II2H3P

INSTALLERS

2322

By-pass fully shut

Open 1/2 turn

By-pass fully shut

Open 1/4 turn

Open 1/2 turn

Open 2 turns

1

2

NB : Factory seeting : Speed II

IIIII

I

Spe

ed II

I

BypassThe Isofast boiler has abuilt-in bypass. This mustbe adjusted according to the requirements of thesystem, refer to the flowrate pressure curve.The boiler is supplied withthe built-in bypass open a half a turn. It isadjusted by turning thebypass screw (a).Turn the screw clockwise to close the bypass. When using thermostaticradiator valves (TRV’s) on all of the radiators, it isessential that a separate,adjustable bypass of 15 mmminimum diameter is fittedbetween the flow and return

of the heating circuit.Anybypass must be fitted beforesystem controls.

a

By-pass fully shut

Open 1/4 turn

Open 1/2 turn

70

60

50

40

30

20

10

500 14001000

2

3

9

7

8

6

1

4

5

Curve output/pressure

Ava

ilabl

e pr

essu

re (k

Pa)

betw

een

heat

ing

supp

ly a

nd r

etur

n lin

es

Flow rate through heating system (l/h)

Technical Data

Spe

ed II

Spe

ed I

3

4

5

6

7

8

9

INSTALLERS

2524

1

3

22

A B C D E

2

8 9

7

10

14131211

19

24

15

16 17 18

20 21 23

25 26 27

28

29 30 31 32

6

3

45

Isofast F 35 E

Schematic layout of boiler

1 - Flue outlet

2 - Main heat exchanger

3 - Burner

4 - Ignition and controle electrode

5 - Fan

6 - Gas control valve

7 - DHW storage vessel

8 - Condensate drain

9 - Overheat safety thermostat.

10 - Temperature sensor for DHW storage vessel

11 - Expansion vessel

12 - Heating return thermistor

13 - Heating outlet thermistor

14 - Ignition module

15 - Pump

16 - Water pressure sensor

17 - Domestic plate to plate heat exchanger

18 - Three way valve

19 - Heating element

20 - Drain cock

21 - Water flow sensor

22 - Discharge safety valve3 bars

23 - DHW temperature sensor

24 - Discharge safety valve10 bar

25 - Isolating valve

26 - Filter on cold water inlet

27 - Filling system

28 - Filter on heating circuit





A - Heating return

B - Cold water inlet

C - Heating flow

D - Domestic hot water outlet

E - Gas

a - Flue outlet

b - Overheat safety thermostat.

c - Combustion chamber

d - Expansion vessel

e - Air/Gas mixture inlet

f - Ignition and control electrode

g - Fan

h - Gas control valve

i - Ignition module

j - Condensate drain

k - Heating flow thermistor

l - Heating return thermistor

m - Water flow sensor

n - Water pressure sensor

o - Pump

p - Filter on cold waterinlet

q - Domestic plate to plate heat exchanger

r - Discharge safety valve 10 bar

s - Discharge safety valve 3 bar

t - Filling system

u - Drain cock

v - Room thermostat plug

w - Control panel

Boiler components

Isofast F 35 E

a

bc d

fe

j

kl

m nq

r

t u

v

w

g h

i

sop

INSTALLERS

2726

installed in a timber framebuilding it should be fitted inaccordance with theInstitute of Gas Engineersdocument IGE/UP/7/1998.If in doubt seek advice fromthe local gas undertaking orSaunier Duval.

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

• Due to the high efficiencyand hence low casingtemperature of this boiler,cupboard or compartmentventilation is not necessary.

Boiler location

• This boiler is not suitablefor outdoor installation.

• This boiler may beinstalled in any room,although particular attentionis drawn to the installation ofa boiler in a room containinga bath or shower wherereference must be made tothe relevant requirements. In GB this is the currentI.E.E. WIRINGREGULATIONS andBUILDING REGULATIONS.In IE reference should bemade to the current editionof I.S.813 "Domestic GasInstallations" and the currentETCI rules.

• The boiler should bepositioned so that at leastthe minimum operationaland servicing clearances areprovided, see diagramopposite.Additional clearances maybe beneficial around theboiler for installation andservicing.For flue installations whereexternal access is notpracticable, considerationshould be given for thespace required to insert theflue internally, which maynecessitate clearance largerthan those specified indiagram.

• If the boiler is to be

Leave existing air vents.A template is supplied withthe fixing bracket.Position setting of theassembly shall beperformed in compliancewith the indications shownon the template.Use two or three screws forthe fixing bracket.

The mechanicalcharacteristics of the screwsshall – at least – meet therequirements specified onthe sketches below. Also,they shall be suited to thecharacteristics of the carrierwall.

16 kg mini

33 k

g m

ini

16 kg mini

33 k

g m

ini

If the boiler is notimmediately installed,protect the different

couplings so that no plasteror paint could jeopardize thetightness of subsequent

connections.

232

GAS

70 102 70

2

115

20 mini

160

118

750

66

160

Ø 105

890

510

INSTALLERS

2928

Flue location and Ventilation

Flue Position and LengthThe standard horizontal flueis fitted onto the top of theboiler using the flue elbow.See diagrams to determinewhether a standard flue canbe used.

An elevated flue system canbe installed with the additionof a vertical flue adapter,extension kits and elbow,see section flue options.

When extension pipes areused the flue system mustbe designed to have acontinuous fall to the boilerof at least 3% to allowcondensate to run back intothe boiler and out via thedrain.

Internal Flue InstallationThe flue can be installedfrom inside the building,when access to the outsidewall face is not practicale.

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

Minimum siting dimensions for fanned flues terminalsporitionsHorizontal flues A - directly below an opening, air brick,

opening windows . . . . . . . . . . . . . . . . . . . . . . . . .300B - above an opening, air brick, opening windows . . . .300C - horizontally to an opening, air brick,

opening windows . . . . . . . . . . . . . . . . . . . . . . . . .300D - below gutter, drain/soil pipe . . . . . . . . . . . . . . . . . . .25E - below eaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25F - below a balcony or car port . . . . . . . . . . . . . . . . . .25G - from vertical drain pipes and soil pipes . . . . . . . . . .25H - from internal/external corners . . . . . . . . . . . . . . . . .25H*- to a boundary alongside the terminal . . . . . . . . . . .300I - above adjacent ground or balcony level . . . . . . . . .300J - from surface or a boundary facing the terminal . . .600K - facing terminals . . . . . . . . . . . . . . . . . . . . . . . . .1200L - from opening (door/window) in car port

into dwelling . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200M - vertical from a terminal . . . . . . . . . . . . . . . . . . . .1500N - horizontally from a terminal . . . . . . . . . . . . . . . . . .300

Vertical flues P - from another terminal . . . . . . . . . . . . . . . . . . . . . .600Q - above roof level . . . . . . . . . . . . . . . . . . . . . . . . . . .300R - from adjacent opening window . . . . . . . . . . . . . .1000S - from adjacent wall to flue . . . . . . . . . . . . . . . . . . . .300

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

Warning notice :Use only flue accessoriesdeveloped forSaunier Duval condensingboilers.

INSTALLERS

3130

Flue location and Ventilation

• Terminal PositionThe minimum acceptablesiting dimensions for theterminal from obstructions,other terminals andventilation openings areshown in page 29. ForIreland the minimumdistances for flue terminalpositioning must be thosedetailed in I.S.813 "DomesticGas Installations".

The terminal must beexposed to the external air,allowing free passage of airacross it at all times.

Being a condensing boilersome pluming may occurfrom the flue outlet. This

should be taken intoconsideration whenselecting the position for theterminal.

It may be necessary toincrease dimensions H & J ifthere is a risk that the boilerproducts could stain anyadjoining surface.

Carports or similarextensions of a roof only, ora roof and one wall, requirespecial consideration withrespect to any openings,doors, vents or windowsunder the roof. Care isrequired to protect the roof ifmade of plastic sheeting. Ifthe carport comprises of a

roof and two or more walls,seek advice from the localgas supply company beforeinstalling the boiler.

• Terminal GuardA terminal guard is requiredif persons could come intocontact with the terminal orthe terminal could besubject to damage.If a terminal guard isrequired, it must bepositioned to provideminimum of 50mmclearance from any part ofthe terminal and be centralover the terminal.

3%

The flue system pipes mustfeature a slope of 3%towards the boiler in orderto recover any condensates.

Attention : The flue systemterminal supplied by SaunierDuval already integrates thisslope. Therefore, it shall be

applied to any flue systemextensions.

L

64

Gasket

The maximum head lossis reached with an elbowand flue system length (L)of 10 m.

Horizontal flues (installation type C13)

INSTALLERS

3332

Heating system

GeneralThe boiler is for use onlywith sealed central heatingsystems. The safety valve is anintegral part of the boilerand it cannot be adjusted.The digital readout on thecontrols fascia indicates thesystem pressure when thereis no central heatingdemand.The circulation pump isintegral with the boiler.

Expansion vesselThe boiler has an integralexpansion vessel with acapacity of 10 litres, with acharge pressure of 0.5 bar.Note : The expansion vesselvolume depends on the totalwater system volume andthe initial system designpressure. Guidance onvessel sizing is also given inthe current issue of BS5449and BS7074 Part 1, for IErefer to the current edition ofI.S.813 "Domestic GasInstallations".

Flow rateIf it is necessary to alter theflow rate, the system can befitted with a lockable balancingvalve in the main flow orreturn pipes shown as valve"A" in diagram.The flow rate through theboiler must not be allowedto fall below 14 l/min.

BypassThe boiler is fitted with anadjustable automaticbypass. Ensure that underno circumstances does theflow rate drop below14l/min.

The installation of the boilermust comply with therequirements of the currentissue of BS6798, in Ireland,refer also to the currentedition of I.S.813 "DomesticGas Installations".

In GB it is necessary tocomply with the WaterSupply (Water Fittings)Regulations 1999 (forScotland, the WaterByelaws 2000, Scotland).

To comply with the Waterregulations your attention isdrawn to : The WaterRegulations guide publishedby the Water RegulationsAdvisory Service (WRAS)gives full details of therequirements.

Heating system

In IE the requirements givenin the current edition ofI.S.813 "Domestic GasInstallations" and the currentBuilding Regulations mustbe followed.

Water tratmentIn the case of an existinginstallation, it is ESSENTIALthat prior to installing thenew boiler the system isthoroughly flushed. Foroptimum performance afterinstallation of a new system,the boiler and its associatedcentral heating systemshould also be flushed.Flushing should be carried

out in accordance withBS7593: 1992 using acleanser such as SentinelX300 or X400, FernoxSuperfloc or Salamandercorrosion guard cleaner. For long-term corrosionprotection, after flushing, aninhibitor suitable for stainlesssteel heat exchangersshould be used, refer to thecurrent issue of BS 5449and BS 7593 on the use ofinhibitors in central heatingsystems. Examples areSentinel X100 Fernox orSalamander corrosion guardinhibitor.

Draining TapA draining tap must beprovided at the lowestpoints of the system, whichwill allow the entire systemto be drained.A drain tap for the applianceis provided as an integralpart of the hydroblock, seediagram page 24.General - All domestic hotwater circuits, connections,fittings must be inaccordance with therelevant standards andwater supply regulations.

Domestic Hot WaterSystem

For GB: Guidance G17 toG24 and recommendationR17 to R24 of the WaterRegulations Guide.For IE: The current edition ofI.S.813 "Domestic GasInstallations".

Water PressureThe maximum workingpressure of the domestichot water circuit is 10 bar. Ifthe cold water supplypressure exceeds this, then

a pressure-reducing valvemust be fitted in the supplyto the boiler.

'Hard' Water AreasThe temperatures within theheat exchanger are limitedby the boiler control systemto minimise scale formationwithin the hot water pipework.However, in areas where thewater is 'hard' (i.e. morethan 200mg/litre), it isrecommended that the hot

water setting is reduced andthat a scale reducer is fitted. Refer to the manufacturer'sinstructions or consult thelocal water company foradditional advice.

Domestic Water Flow RateThe water flow rate isrestricted to a maximum 16l/min by a restrictor fitted onthe cold water inlet.

INSTALLERS

3534

2

Boilerinstallation

Prior to performing anyoperation, it is essential thatthe piping systems beflushed with a suitableproduct in order to eliminateany impurities such asfillings, weld spatters, oilsand greases.

Such foreign materials couldbe driven into the boiler, andcould impair its operation.NB: Solvents may causedamages to the pipingsystem.Remove the wooden beamplaced behind the boiler.

Appliance Connection IMPORTANT: With regardsto the Manual HandlingOperations, 1992

Regulations, the following liftoperation exceeds therecommended weight for aone man lift, refer to ManualHandling section, on page 4.The appliance will contain asmall amount of water,place a water containerbeneath the boilerconnections beforeremoving the protectivecaps.

1 - Lifting the boiler intoposition, lean the top of theboiler slightly to the wall andposition just above thehanging bracket.

2 - Lower the boiler slowlyand engage onto thehanging bracket.

Connect isolating valvesusing washers and domesticflow restrictor supplied withthe boiler.

3 - Do not forget to connectthe blue extension on thefilling tap, as shown on thepicture below.

1 ➡

➡

3

AB

C

DE

GAS

70

70

115

250223

WALL

102

u

t

v

w

x

Pipinginstallation

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

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

Water restrictor16 l/min.

Pressure connection

Gas ConnectionBefore connection checksupply of local gas.Refer also to page 18.Do not subject the gasservice cock to heat.Fit the sealing washer intothe union nut and makegood the connection to thegas service cock on thewall.

Make sure the on / off leveris accessible.The whole of the gasinstallation, including themeter, should be inspected,tested for soundness andpurged in accordance withthe current issue of BS6891and in IE the current editionof I.S.813 "Domestic GasInstallations".

A - C : Central heatingØ 22 mm

B - D : Domestic hot water Ø 15 mm

E : Gas supply Ø 15 mm

INSTALLERS

3736

Water ConnectionsFlush out the domestic hotwater and the heatingsystems before connectingto the boiler.Make the connections to thedomestic hot water andheating systems by fittingthe sealing washers into thesecuring nuts and makegood the connection to theisolating valves.Do not subject the isolationvalves to heat.Make sure the drain point isaccessible.

• The heating returncoupling is equipped with afilter, accessible afterremoving the end nut.

•The proof-test pressure canbe read on a pressure gaugescrewed instead of theheating return coupling endnut (A).

u

A

t

Filter on heatingreturn (A)

A pressure gauge can bescrewed instead of theheating return coupling

Pipinginstallation

Safety Discharge ValveThe pipes from the safetydischarge valves S1 and S2must not discharge abovean entrance, window or anytype of public access area.Take the short safetydischarge tube, union nutand seal, supplied loose inthe boiler fittings pack andfit as shown in diagrambelow. This must be extended,using not less than 15mm

o.d. pipe, to discharge, in avisible position, outside thebuilding, facing downwards,preferably over a drain. The pipe must have acontinuous fall and berouted to a position so thatany discharge of water,possibly boiling, or steamcannot create any danger topersons, damage toproperty or externalelectrical components andwiring.

To ease future servicing it isadvisable to use acompression type fittingsupplied with the boiler toextend the safety dischargevalve tube.

s2

s1

39

WARNING : This appliancemust be earthed.

This appliance must bewired in accordance withthese instructions. Any faultarising from incorrect wiringcannot be put right underthe terms of theSaunier Duval guarantee.All system componentsmust be of an approvedtype.

Electrical components havebeen tested to meet theequivalent requirements ofthe BEAB.Do not interrupt the mainssupply with a time switch orprogrammer.Connection of the wholeelectrical system and anyheating system controls tothe electrical supply must bethrough a common isolator.

Isolation should preferablybe by a double poleswitched fused spur boxhaving a minimum contactseparation of 3mm on eachpole. The fused spur boxshould be readily accessibleand preferably adjacent tothe boiler. It should be identified as to its use.

Mains CableImportant: If a replacementsupply cable is required itmust be purchased fromSaunier Duval.

• The 630 mA fuse of thePCB must be connected tothe neutral.

Electricalconnection

INSTALLERS

38

Connect the A elbowØ 22 mm to a dischargesystem leading to thesewer, in compliance withthe instructions below:

- Use a rigid PVC tube or aflexible silicon pipe resistantto condensate.

- The pipe must have acontinuous fall.

- Do not use copper pipes

Important notice : The float of the condensaterecovery system alsoensures fume tightness.Therefore, it is useless toadd water in thecondensate box.

Condensatedischargeelbow.

Condensate box withaccess plugs for cleaningpurposes.

Ø 22 mm

A

NO YES

Pipinginstallation

➡Cold waterinlet

Heatingreturn

➡

Heating flow

INSTALLERS

4140

Commissioning on boiler

Please ensure the"Benchmark" logbook iscompleted and left with theuser .

Filling the system 1 to 8

The commissioning and firstfiring of the boiler must onlybe done by a qualified registered person.

Make sure that the boiler isconnected to the electricalsupply and the gas servicecock is open.

Switch ON (I). Open the isolatingtaps (t), (u), (v) and (w)

on boiler : slot in line withthe lenght of the valve21

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

Fill the system until the pressure indicated on the display is

between 1 and 2 bar.Close filling device.

43

v

t

w

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

Leave the cap on the pump auto air vent open.65

➡

Open various hot water taps to bleed system.

Make sure the display indicates a system pressure of between

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

87

1,5 bar

u

INSTALLERS

Commissioning on boiler

4342

Press the key tooperate the boiler withoutroom thermostat.

• Adjust heating temperatureto maximum.

• Allow the temperature torise to the maximum value,with all radiator valves open.The temperature rise willcause release of the gasescontained in the water of thecentral heating system.

• Gases driven towards theboiler will be automaticallyreleased through theautomatic air vent.

• The gases trapped at thehighest point of the systemmust be released by bleedingthe radiators. Check theburner gas rate required, tenminutes from lighting. Referto Data Label on electricalcontrols box. Should therebe any doubt about the gasrate it should be checked at

the meter. On reachingmaximum temperature, theboiler should be turned offand the system drained asrapidly as possible whilst stillhot.

• Refill system to a pressureof between 1 and 2 bar andvent as before.

• Restart boiler and operateuntil a maximum temperatureis reached. Shut down boilerand vent heating system. If necessary, top up heatingsystem and make sure thata pressure of at least 1 baris indicated when system isCOLD.Flush the domestic hot watersystem by opening the hotwater taps for severalminutes.

Instruct the User• Instruct and demonstratethe lighting procedure andadvise the user on the safe

and efficient operation of theboiler.

• Instruct on and demonstratethe operation of heatingsystem control.

• Advise the user on the useand maintenance of anyscale reducer and pass onany relevant instructionaldocuments.

• Advise that to ensure thecontinued efficient and safeoperation of the boiler it isrecommended that it ischecked and serviced atregular intervals. Thefrequency of servicing willdepend upon the installationconditions and usage, but ingeneral, once a year shouldbe enough.

• Draw attention, ifapplicable, to the currentissue of the Gas Safety(Installation and Use)Regulations, Section 35,

which imposes a duty ofcare on all persons who letout any property containinga gas appliance in the UK.

• The user shall not interferewith or adjust sealedcomponents.

• It is the Law that anyservicing is carried out by acompetent person.

• Advise the user that, likeall condensing boilers thisappliance will produce aplume of condensation fromthe flue terminal in coolweather. This is due to thehigh efficiency and hencelow flue gas temperature ofthe boiler.

• Advise the user of theprecautions necessary toprevent damage to thesystem, boiler and thebuilding, in the event of theheating system being out of

use during frost or freezingconditions.

• Advise the user that thepermanent mains electricalsupply SHOULD NOT beswitched off, as the built infrost protection andpump/valve saver programwould not be operable.

• Reminder, leave theseinstructions and the‘Benchmark’ logbook withthe user.

• For IE, it is necessary tocomplete a "Declaration ofConformity" to indicatecompliance to I.S.813. Anexample of this is given inthe current edition ofI.S.813.

INSTALLERS

4544

Settings

The description belowspecifies the operations tobe performed to makeadjustments to aninstallation fitted withradiators or fora direct floor system.For other types of

installation (for examplewith a floor-heatingsystem) , follow theinstructions in theappropriate accessoriesmanual.

OK

OK

C

INSTALLER MENU

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

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


CHOOSE LANGAGEINSTALLATION TYPERADIO SATELLITEHEATING REGULATIONBOILER CONFIG.

INSTALLER MENUAFTERSALES MENUFAULT HISTORYBOILER DATA

SELECT THE LANGUAGE

ACCESS CODE96

OKENGLISH

1 RADIATOR ZONE OKINSTALLATION TYPE

+

OK +

OK +

MENU

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

1 - Accessing the installer menu

2 - Select the language

3 - Installation configuration

• Select installer menu :


Your installation consists of a single radiator zone or direct floor system 1/3

Access to the boiler’stechnical data(reserved for use by theinstallers and After-Salesservice personnel).This enables adjustmentsto be made and anymalfunctions to beanalysed :

Commissioning on room thermostat

The wireless room thermostat(R.O.) has been speciallydeveloped for the Isofast.• It is powered by 3 LR61.5V alkaline batteries.

• The boilers variousfunctions are parameteredfrom the room thermostat.

Installing the roomthermostat• Fasten the bracket for theroom thermostat on aninternal wall approximately1.50 m from the floor, in anarea sheltered from directsunlight and any source ofinterference, such astelevision, lamps, draughts,etc.• Insert the batteries in thethermostat.

When commissioning forthe first time, At initialcommissioning stage, theboiler automatically shifts tomanual mode (the controlpanel keys are lit, andthe key is blinking),thus meaning that thewireless room thermostathas not yet beenacknowledged by the boiler.To do this :• Open the control panel• Locate connector (A) onthe left-hand side and insertit in the thermostat for a fewseconds as shown in the photo opposite.

When the red indicator lightstops flashing, this showsthat the boiler hasrecognised the thermostat.

A

LCD display

Confirm OK

Access to the menusWeekly

programme

ScrollUp/Down

Return

Mains power pointor power cable

Fault indicator (red)

Wallbracket A

INSTALLERS

4746

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

6.3 Selecting the maximum radiator temperature

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

6.4 Selecting the minimum radiator temperature

6.5 Selecting the pump’s operation

MAX 50¡CMAX 65¡CMAX 73¡C

OK OK

MIN 22¡C

MIN 50¡CMIN 38¡CMIN 28¡C

OK OK

WITH THERMOSTATWITH BURNER

PERMANENT

PERMANENT

OK OK

MAX RADIATOR T¡

MIN RADIATOR T¡

PUMP MODE

WITH THERMOSTAT

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

6.2 Adapting the length of the vent

CHIMNEY SET

6.6 Choice of preheat

OKPREHEAT AUTOON

OFF

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

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

In OFF mode, the function is inhibited.


Settings

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

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

OK RADIO SATELLITE IN OUTDOOR SENSOR� OFFREPEATER�� OFFTHERMOSTAT 2�� OFFMODEM�� OFF

SET RADIATOR T¡

MANUAL

MANUAL

AUTO

AUTO

6.1 Limiting the maximum heating power

OK OK

OK

OK

HEATING CONTROL

OKBOILER CONFIG.

MAX OUTPUT

MAX OUTPUTCHIMNEY SETMAX RADIATOR T¡MIN RADIATOR T¡PUMP MODE

HEATING SETPOINT

OK15kW16kW

14kW

/...

/...

+

4 - Radio accessories

5 - Heating control

6 - Boiler configuration

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

a/ Press for 5 seconds

b/

MENU

SET RADIATOR T¡

OK TO VALIDATE50¡C


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

MENU

INSTALLERS

4948

OKEXT. SENSOR� ON HEATING REGULATIONBOILER CONFIG.CHOOSE LANGUAGE

+C

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

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

MANUAL

AUTO

AUTO

OKHEATING SETPOINTT¡ HEATING OFF

T¡ HEATING OFFHEATING SETPOINT

Note : we recommend selecting 17 or 18°C.

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

OK OK

CORRECT T¡ ZONE1

SLOPE ZONE 2

SLOPE ZONE 1

CORRECT T¡ ZONE2

0,70,80,60,2 ......

OK OK1,61,51,40,2

4,0

4,0......

... ...OK OK

... ...OK OK

... ...OK OK

Temperaturesetting curves.

30

-30 -20 -10 100

40

50

60

70

80

90

100

Hea

ting

tem

pera

ture

out

let (

°C)

Outsidetemperature (°C)

b/ T° heating off

a/ Heating setpoint

2.2 Heating setpoint

0,2

0,5

0,7

1,0

1,2

1,5

1,7

2,0

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

MANUAL

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

49

Accessories settings 2/3

Settings

Accessories settings

OK

OK

C

INSTALLER MENU

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


RADIO ACCESSORIESHEATING REGULATIONBOILER CONFIG.


ACCESS CODE96

OK

OK

RADIO ACCESSORIES EXT. SENSOR�� OFFREPEATER�� OFFTHERMOSTAT 2� OFFMODEM�� OFF

EXT. SENSOR� OFF

EXT. SENSOR�� ONREPEATER�� OFFTHERMOSTAT 2� OFFMODEM�� OFF

CONNECT

++

MENU

1 - Access to the Radio accessories menu

• Select the installer menu:

• Select the Radio accessories menu:


2.1 External sensor recognition

OK

2 - External sensor

The external sensor is now operating

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

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

1/3

Selecting the language on the thermostat’s display.

Selecting the type of heating installation.

The ON position of this menu assigns the TA1clock function to the radiator zone. In such case,the ambient temperature at floor level is selectedfrom the TA1 user’s menu.

Activating the various radio accessories on theinstallation.

Selecting Automatic or Manual control mode.In Automatic mode, the radiator temperatureadapts automatically to the heating requirements ofthe room in which the thermostat is located, opera-ting between the maximum and minimum tempera-ture values set.

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

INSTALLERS

5150

Glossary for theinstallater menu

Select the language

Installation config.

Clock zone 2

Radio accessories

Heating regulation

Boiler config.

Settings

Accessories settings

OKREPEATER OFF

REPEATER�� ONTHERMOSTAT 2� OFFMODEM�� OFFEXT. SENSOR�� OFF

CONNECT

The repeater is now operating

OK

OK

3 - Repeater

OKTHERMOSTAT2 OFF

THERMOSTAT 2� ONMODEM�� OFFEXT. SENSOR�� OFFREPEATER�� OFF

CONNECT

The room thermostat 2 is now operating

C

4 - Room thermostat 2

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

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

3/3

INSTALLERS

5352

OK

OK

INSTALLER MENU


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

CHOOSE LANGUAGEINSTALLATION TYPERADIO SATELLITEHEATING REGULATIONBOILER CONFIG.


ACCESS CODE96

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

OK

OK OKBOILER CONFIG.

MAX OUTPUT

MAX OUTPUTCHIMNEY SETMAX. RADIATOR T¡

OK5 kW6 kW

/...

MENU

+

+

MENU

1 - Access to the installer menu

2 - Access to boiler configuration

• Select the Installer menu:

• Set MAX OUTPUT on the minimal value:

2/ Minimum HEATING inputsetting, through the CO2 :a - Connect a CO2 analyserto sample point B of theadapter or flue elbow.

b - Adjust the boiler at itsminimum heating powerusing the room thermostatmenus described in thebelow.

c - Perform a heatingdemand and record the

CO2 value after stabilization(2 minutes or so).

d - Adjust the screw D toobtain the G31 CO2 valuestated in the table, takingthe following principle intoaccount :To increase the CO2 value,turn the screw clockwiseTo decrease the CO2value, turn the screwanti-clockwise

Note : After re-installation ofthe sealed front face, theCO2 value changes, andmust correspond to thatgiven in the table.

3/ After setting andreassembly, restore themaximum heating power toits initial value (20 kW) andstick the gas data tag closeto the nameplate.

Gas conversion

Your Isofast boiler isfactory-set to operate withG20 gas.For operation with G31 gas,some adjustments must bemade on the gas valve afterremoval of the sealed frontcover in order to obtain theCO2 values given in theadjacent table.

1/ Maximum hot waterinput setting, through theCO2.a - Connect a CO2 analyserto sample point B of theadapter or flue elbow.

b - Fully open a hot watertap.

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

d - Adjust the screw C toobtain the G31 CO2 valuestated in the table, takingthe following principle intoaccount:To increase the CO2 value,turn the screw anti-clockwiseTo decrease the CO2 value,turn the screw clockwise

Note : After re-installation ofthe sealed front face, theCO2 value changes, andmust correspond to thatgiven in the table.

Isofast F 35 E G20 G31

Heating output max. hot water kW 34,2 34,2

Heating output max. heating kW 6,4 6,4

C02 case off % 9±0,2 10,3±0,2

C02 case on % 9,2±0,3 10,5±0,3

B

CD

Push the gas pipe upwardsfurther into gas valveconnection and then rotateanti-clockwise (lookingdown) until the gas pipe endis over the large hole inboiler chassis. Withdraw thegas pipe from gas valveconnection and remove.Note : When replacingensure that the sealinggrommet, situated belowthe gas valve is correctlyre-seated.Disconnect the gas valveelectrical plug at the gasvalve.Disconnect the electricalleads from the fan.Remove the five combustionchamber front retainingnuts, see diag. 5.Gently remove the fan, gasvalve and burner assemblyfrom the combustionchamber, see diag. 5.Clean the burner with a softbrush taking great care notto damage the frontinsulation. DO NOT use

wire or sharp instruments toclean the holes of theburner.Inspect the burner for anysigns of damage.Inspect the sealing ringsand replace if necessary.

Removal of the burner is notnecessary during a normalservice.NOTE : IF THE BURNERHAS TO BE REMOVED ITWILL REQUIRE A NEWGASKET WHEN REFITTED.

INSTALLERS

5554

Servicing

Important NotesTo ensure the continuedefficient and safe operationof the boiler it isrecommended that it ischecked and serviced atregular intervals. Thefrequency of servicing willdepend upon the particularinstallation and usage, but ingeneral once a year shouldbe enough.It is the Law that anyservicing is carried out by acompetent person.When replacing a part onthis appliance, use onlyspare parts that you can beassured conform to thesafety and performancespecification that we require.Do not use reconditioned orcopy parts that have notbeen clearly authorised bySaunier Duval.

GeneralMeasurement of theproducts of combustion canbe achieved by connectionof a probe to thecombustion analyser testpoint, see diagram 1.

IMPORTANT NOTE :Products of combustion willbe discharged when the capis removed. It is important toreplace the cap immediately.Before commencing with aservice or replacement ofparts, the boiler should be

isolated from the electricalsupply and the gas supplyshould be turned off at thegas isolation valve, seepage 35.All routine servicingrequirements can beachieved by the removal ofthe front panel and innerpanel only. To remove simplyundo the two screws on theunderside of the front paneland lift off. Undo the twoscrews on the front of innerpanel and lift off, see diag. 2.Unless stated otherwise anypart removed duringservicing should be replacedin the reverse order toremoval.Servicing should alwaysinclude the removal of anydebris from the condensatepipe and siphon.After completing anyservicing of gas carryingcomponents, ALWAYS testfor gas soundness and carryout a functional test of thecontrols.

Spark ElectrodeDisconnect the electrodelead and two securingscrews. Withdraw the sparkelectrode carefully from thecombustion chamber, seediagram 3.Inspect the tips for damage.Clean away any debris andcheck the spark gap is 3.5to 4.5 mm.

Check the electrode gasketfor signs of damage andreplace if necessary.

BurnerDrop down the control panelinto the service position.Disconnect the gas supplyat the gas service cock.Remove the two gas piperetaining clips, one locatedbelow gas valve and theother one located on theunderside of the boilerchassis.Pull sealing grommet downgas pipe diagram. 4.

Diagram 1

Combustionanalyser test point

Diagram 2

Torx screws

Diagram 3

Diagram 4 Diagram 5

Sealinggrommet

Gas piperetaining clip

Electrode

Gasket

Spark Gap 3.5 to 4.5

Heat exchanger

Combustionchamber

Burner

Sealing ring

Gas valve

Fan

SecuringNut (5)

Draining of Boiler HeatingCircuitDrain down the HeatingCircuit of the boiler only, byclosing the heating flow andreturn isolating taps (t, uand w), on the boilerconnections, see diag. 10.Attach a length of hose tothe drain point and open thedrain valve (r), see diag. 9.After servicing or replacingparts, close the drain valveand remove the hose. Openthe heating flow and returnisolating valves and refill,vent and pressurise theheating circuit.Check for leaks.

Draining of Boiler HotWater CircuitDrain the Domestic HotWater circuit by closing thecold-water isolation tap (v)on the boiler connection.Open one or more hot watertaps to drain the hot watercircuit.After servicing or replacingparts open the cold-waterisolation valve and slowlyopen a hot water tap to

remove air. Close the hotwater tap and check for anyleaks.

Inner Casing Panel SealCheck.Check the condition of theseal, replace as required.To replace remove the oldseal, thoroughly clean thecasing sufaces. Fit the newseal, it is supplied to thecorrect length.

➡

Cold waterinlet

Heatingreturn

➡

Heating flow

v

t

u

INSTALLERS

Servicing

5756

Combustion Chamber andHeat ExchangerRemove loose debris fromcombustion chamber usinga soft brush and vacuumcleaner. Carefully flush byspraying water removing anyremaining debris through thecondensate trap (Ensure thewater is kept away fromelectrical components).

Condensate DrainThe condense drain doesnot normally need removingduring servicing.To flush the condense draincarefully pour water into theheat exchanger and checkthat water flows freely todrain.

Combustion Check.If a gas carrying componenthas been replaced, thecombustion of the applianceshould be checked. Oncethe appliance has beenre-assembled (apart fromthe front and inner casingpanels) connect a CO2combustion analyser to thetest point on the flue adapter,and follow indications givenon page 52-53.

Domestic Cold Water InletFilterIf the water flow ratethrough the appliance hasreduced it may benecessary to clean or

replace the water inlet filter.Turn off the electrical supplyto the boiler.Drain the domestic hotwater circuit.Slide out the securing clip,and remove the filter toclean or renew if necessary,see diag. 6.Replace the filter into itshousing and replace thesecuring clip. Open the cold waterisolating valve and test theDomestic Hot Water circuitfor soundness.Check for leaks.

“Mouss” FilterTurn off the electrical supplyto the boiler.Drain the heating circuit ofthe boiler.Remove the filter retainingclip under the pump seediag. 7, and filter clean orrenew if necessary. Refit thefilter.Open the heating flow andreturn isolating valves andrefill, vent and pressurise theheating circuit.Check for leaks.

Central Heating ReturnFilterTurn off the electrical supplyto the boiler.Drain the heating circuit ofthe boiler.Unscrew the filter placed onheating return, see diag. 8,and clean filter or renew ifnecessary. Refit the filter.Open the heating flow andreturn isolating taps andrefill, vent and pressurise theheating circuit.Check for leaks.

t

u

➡

Cold Water Inlet Filter

Diagramm 6

Diagramm 7

Diagramm 8

Heating Return Filter

Diagramm 10

r

Diagramm 9

w

INSTALLERS

5958


• Select Aftersales menu


BOILER CODEMIN. FAN SPEEDMAX. FAN SPEEDSTART FAN SPEEDBURNER OVERRIDEFAULT RESETAFTERSALES TEL

TEST RADIO SIGNAL

AFTERSALES MENUFAULT HISTORYBOILER DATA

ACCESS CODEXX

OK

OK +

OK +OK +

OK +

OK +

MENU

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

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

MENU

Accessing the Aftersales menu

Communication test

BOILER CODE

MIN. FAN SPEED

MAX. FAN SPEED

OK +START FAN SPEED

BURNER OVERRIDE

FAULT RESET

AFTERSALES TEL

OK OK+

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

MENU

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

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

1 2 3 4

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

This factory-set value corresponds to the minimum input.

This factory-set value corresponds to the maximum input.

Fan start-up speed selection

Allows analysing boiler operation at its minimum or maximum power.

Erases the fault log.

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

The use of the menusdescribed here after isexclusively reserved forthe after-sales personnel.

Servicing


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

Every validation throughthe OK key will causedisplay of thecorresponding valueduring boiler operation.


BOILER DATAINSTALLER MENUAFTERSALES MENUFAULT HISTORY

WATER PRESSURERADIATOR SETPOINTFLOW T¡RETURN T¡DHW T¡TANK T¡FAN SPEEDDHW FLOWBURNER PHASEPOWER

MENU

Access to the data menu

1 - "Fault history" menu

2 - "Boiler data" menu

OK

FAULT HISTORYBOILER DATAINSTALLER MENU

OK FAULT HISTORYTUE 04/02/03 10��--/--/--

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

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

The display shows thefault N° and its date ofoccurrence.

OK+

The after-sales menus,accessible from the roomthermostat, allowinvestigating possible malfunctions andmodifying certainfactory set values.

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

MENU

INSTALLERS

Fault finding

6160

NOTEBefore trying to operate theboiler make sure that :• All gas supply cocks areopen and that the gassupply has been purged ofair.• There is a permanentmains supply to the boiler.• There is a heating demandfrom the external control.

WARNING. Always isolate the boilerfrom the electrical supplybefore carrying out anyelectrical replacement work.

Always check for gassoundness after any servicework.

Electrical TestingShould there be any doubtabout the voltage supply toany of the components, it ispossible to carry out asimple electrical test.

Important. On completionof the Service/Fault Findingtasks which have requiredthe breaking and remakingof the electrical connectionsthe earth continuity, polarity,

short circuit and resistanceto earth checks must berepeated using a suitablemultimeter.To carry out the electricaltest, gain access, as follows :Hinge down the control boxand remove Torx screwsand unhook the rear panel,refer diagram 2 page 54.Refer to the Wiring diagramand fault finding chartsdiagrams.

2

12

3

1

11

13

15

16

17

4

5

8

9

10

6

7

14

Wiring diagram

1 - Overheat thermostat2 - Fan3 - Gas valve4 - Heating return

thermistor5 - Heating flow thermistor6 - Water pressure sensor7 - Pump8 - Water flow sensor

9 - User interface10 - Room thermostat11 - Ignition and controle

electrode12 - Ignition module13 - DHW temperature

sensor14 - Three way valve15 - Fuse 630 mA

16 - Chassis earth17 - Main reset switch

Wiring diagram

INSTALLERS

Fault finding

6362

FOLLOWING PAGE

INSTALLERS

6564

Replacement ofparts

GeneralReplacement of parts mustbe carried out by acompetent person.Before replacing any partsthe boiler should be isolatedfrom the mains electricsupply and the gas shouldbe turned off at the servicecock on the boiler.Unless stated otherwiseparts are replaced in thereverse order to removal.After replacing any partsalways test for gassoundness and if necessarycarry out functional test ofthe controls.For replacement of parts thefront casing and the innercasing panel of the boilerwill need to be removed. Toremove undo the twoscrews on the underside ofthe front casing and lift off.Undo the two screws on thefront of the inner front paneland lift off. The side panels can behinged sideways to aidreplacement of parts.To hinge a side panel undoand remove the threescrews securing each sidepanel to the boiler, two atthe front and one at the top.

Spark ElectrodeFor access, refer to section“General”.Remove the spark pluglead, earth lead and two

securing screws. Withdrawthe spark electrode carefullyfrom the combustionchamber, see diagram3page 55.

Igniter UnitFor access, refer to section“General”.Remove ignition lead andelectrical connections thenremove igniter unit byremoving two securingscrews, see diagram 1.

Ignition LeadFor access, refer to section“General”.Pull the spark plug styleconnector off the sparkelectrode and the spadeconnector connected to theigniter unit, see diagram 1.

Gas ValveFor access, refer to section“General”.Remove the electrical plugfrom the gas valve, seediagram 2.Refer to pages 54 and 55for removal of the fan, gasvalve and burner assembly.Before removing the gasvalve note its position on thefan.Remove the three securingscrews, which fix the gasvalve and plastic swirl plateto the venturi on the fan,see diagram 3.Remove the gas valve.

Diagram 1

Securing screws (2)

Spadeconnector

Igniterunit

When re-fitting the gas valvetake care as it can be fittedmore than one way.After re-fitting check thecombustion CO2 and adjustif necessary, see page52-53.After assembly test for gassoundness and purge inaccordance with the currentissue of BS6891or in IE, thecurrent edition of I.S.813"Domestic Gas Installations".

FanFor access, refer to section“General”.Refer to pages 54 and 55for removal of the fan, gasvalve and burner assembly.Remove the gas valve.Remove the venturi platesecured with three screws,see diagram 3.Remove the two screwssecuring the fan to the gasmanifold, see diagram 4,check the gasket andreplace if necessary.

BurnerFor access, refer to section“General”.Refer to pages 54 and 55for removal of the fan, gasvalve and burner assembly.Remove the four screwsthat secure the burner, seediagram 5.NOTE : THE BURNER WILLREQUIRE A NEW GASKETWHEN REFITTED.

Front InsulationFor access, refer to section“General”.Refer to pages 56 and 57for removal of the fan, gasvalve and burner assembly.Remove burner as previoussection.Remove spark electrode..NOTE: THE BURNER WILLREQUIRE A NEW GASKETWHEN REFITTED.

Rear InsulationFor access, refer to section“General”.Refer to pages 54 and 55for removal of the fan, gasvalve and burner assembly.Remove securing screw andwasher in the centre of theinsulation and withdrawinsulation, see diagram 6.

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

Diagram 2

Electricalplug

Gas valve

Pressuretest point

Diagram 3

Securingscrews (3)

Venturiplate

Diagram 4

Diagram 5

Gasmanifold

Securingscrews (2)

Burner

Securingscrews (4)

Insulation

Diagram 6

Washer

rear insulation

Securing screw

Circlip

Steel washer

Glass

Fibre washer

Diagram 7

INSTALLERS

Replacement ofparts

6766

Expansion VesselFor access, refer to section“General”.Refer to page 57 and drainthe boiler heating circuit.Undo the coupling at thebase of the vessel, seediagram 8.While holding the vesselremove the securing bolt onthe top panel of the boiler.Remove upper supportbracket.Lift the vessel up, drawbottom out to the left, lowerand remove.Fit the replacement unit.Fit a new gasket betweenthe expansion vessel andcoupling. Refill, vent and pressurisethe boiler.Check for leaks.

Heat ExchangerFor access, refer to section“General”.Refer to pages 54 and 55for removal of the fan, gasvalve and burner assembly.Drain the boiler heatingcircuit, and the hot watercircuit see page 57.Remove the clip securingthe clear condense pipe toheat exchanger.Pull to remove the clearcondense pipe out of thebottom of the heatexchanger.Undo the two nuts of theflow and return pipes from

the heat exchanger.Move the pipes away fromthe heat exchanger.Loosen the three heatexchanger securing screwsand clamps (two at the topand one at the bottom) toremove the heat exchanger,see diagram 9.CAUTION: There will bewater in the heat exchanger.Remove condense pipeconnector from bottom ofheat exchanger.Carefully ease heatexchanger out.

Flue HoodFor access, refer to section“General”.Remove heat exchanger asper previous section.Remove the two securingscrews and pull the fluehood down and away fromthe flue hood bracket andflue elbow, see diagram 10.

Diverter Valve MotorFor access, refer to section“General”.Refer to diagram 11.Remove the electrical plug.Unscrew the retaining nut.Remove the diverter valvemotor.

Pump (head only)For access, refer to section“General”.Drain the boiler heatingcircuit.

Diagram 8

Expansionvessel

Diagram 9

Securing screwsand clamps

Flow and returnpipe nuts

Diagram 10Securingscrews (2)

Fluehood

Flue hoodbracket

Refer to diagram 12.Remove the four cap headscrews.Carefully remove the pumphead together with cable.Do not strain cable.Support the pump head,unscrew cable cover at theside of pump head and takeoff.Disconnect wiring frompump head.Reconnect wiring to newpump head and fit cover.Fit the new pump head with'O' ring.Refill, vent and pressurisethe boiler.Check for leaks.

Safety Discharge ValveFor access, refer to section“General”.Drain the boiler heatingcircuit.Refer to diagram 13.Undo the safety dischargevalve union and removefrom the pipework.Remove the securing clipand withdraw the safetydischarge valve.Fit new 'O' ring.Refill, vent and pressurisethe boiler.Check for leaks.

Domestic Hot WaterThermistorFor access, refer to section“General”.Drain the boiler domestic

hot water circuit.Refer to diagram 14.Disconnect the domestichot water thermistorelectrical connectionsRemove retaining clip.Withdraw domestic hotwater thermistor from itshousing.Note : When reconnectingelectrical connections,polarity is not important.Fit new 'O' ring.Carry out a functional test ofthe controls.

Heating Flow ThermistorFor access, refer to section“General”.Refer to diagram 15.Remove the electricalconnections from thethermistor.Remove the retaining clipfrom the flow pipe.Note: When reconnectingthe polarity of the wiring tothermistors is unimportant.

Diagram 11 Diagram 12

cap headscrew (4)

Cablecover

Pumphead

Diagram 13

Diagram 14

Electricalplug

Diverter valvemotor

Safetydischargevalve

Domestichot waterthermistor

INSTALLERS

6968

Heating Return ThermistorFor access, refer to section“General”.Refer to diagram 15.Remove the electricalconnections from thethermistor.Remove the retaining clipfrom the flow pipe.Note: When reconnectingthe polarity of the wiring tothermistors is unimportant.

Overheat ThermostatFor access, refer to section“General”.Refer to diagram 15.Remove the electricalconnections from theoverheat thermostat.Remove the retaining clipfrom the flow pipe.Remove the overheatthermostat from theretaining clip.NOTE. When fitting newthermostat, please ensurethat it is located correctlyonto the flat area of the pipeand the retaining clip issecure.

Automatic Air VentFor access, refer to section“General”.Drain the boiler heatingcircuit.Refer to diagram 16.Remove the retaining clipand remove the automaticair vent.Fit the new automatic air

vent and 'O' ring ensuringthe vent cap is left loose. Refill, vent and pressurisethe boiler.Check for leaks.

Flow SensorFor access, refer to section“General”.Drain down the hot watercircuit.• Undo the union nut on thecold water inlet isolatingvalve.• Pull out slotted metal clipsecuring filling system tapinto housing, swing the tapforwards.• Pull out the two slottedmetal clips retaining thedomestic water inlet filterhousing.• Remove domestic waterinlet filter housing.• Remove electricalconnections from water flowsensor.• Pull off slotted metal clipand remove water flowsensor.

Replacement ofparts

Diagram 15

Diagram 16

Automticair vent

Retainingclip

Diagram 17

Low Water PressureSensorFor access, refer to section“General”.Drain the boiler heatingcircuit.Refer to diagram 18.Disconnect the electricallead by pushing up retainingtab to withdraw the leadplug.Remove the retaining clip toremove the low waterpressure sensor.Fit new 'O' ring.Fit the new low waterpressure sensor. Refill ventand pressurise the boiler.Check for leaks.

Bypass ValveFor access, refer to section“General”.Drain the boiler heatingcircuit.Refer to diagram 19.Remove the retaining clip toremove the bypass valve.Fit new 'O' rings.Replace the bypass valve,refill, vent and pressurise theboiler.Adjust the bypass asdescribed pages 22-23.Check for leaks.

Filling Loop TubeFor access, refer to section“General”.Drain the boiler hot watercircuit.Refer to diagram 20.

Remove the retaining clipsto remove the filling looptube.Fit new 'O' rings.After replacing the fillingloop tube open the cold-water isolation valve andslowly open a hot water tapto remove air. Close the hotwater tap and check for anyleaks.

Filling Loop ValveFor access, refer to section“General”.Drain the boiler hot watercircuit.Refer to diagram 20.Remove the clip securingthe filling loop valve to thedomestic water filterhousing. Disengage bypulling forward.Remove the clip securingthe filling loop to the fillingloop valve.Remove the filling loop valvefrom the filling loop.Fit new 'O' rings.After replacing the filling

loop valve open the coldwater isolation valve andslowly open a hot water tapto remove air. Close the hotwater tap and check for anyleaks.

Diagram 18

Retainingclip

Flowsensor

➜➜

➜

➜

Water flowsensor

Diagram 19

Bypassvalve

Diagram 20

Retainingclip

Filling looptube

Filling loopvalve

Retainingclip

Returnthermistor

Overheatthermostat

Flowthermistor

Reducedpressure zonevalve

INSTALLERS

Replacement ofparts

7170

Reduced Pressure ZoneValveFor access, refer to section“General”.Refer to diagram 20.Drain the boiler hot watercircuit.Remove the filling loopRemove the retaining clip toremove the reducedpressure zone valve.Fit new 'O' rings.Replace the reducedpressure zone valve, refill,vent and pressurise theboiler.Check for leaks.

Domestic Cold Water InletFilterFor access, refer to section“General”.Refer to page 56.Fit new 'O' rings.

Central Heating FilterRefer to section page 56.Fit new 'O' rings.

Heating Circuit Drain PointRefer to page 57 to drainthe boiler heating circuit.Refer to diagram 21.Remove the retaining clip toremove the drain point.Fit new 'O' rings.Replace the drain point,refill, vent and pressurise theboiler.Check for leaks.

Inner Casing Panel Seal For access, refer to section“General”.Remove the inner casingpanel.To replace remove the oldseal, thoroughly clean thecasing surfaces. Fit the newseal, it is supplied to thecorrect length.Refit the inner casing panel.NOTE: Ensure the seal isfitted correctly giving anairtight joint.

Condense DrainFor access, refer to section“General”.Refer to diagram 22.Remove the clips securingthe flexible tubes to thesiphon adapter by twistingthe clips slightly todisengage the clip jaws fromeach other.Remove black flexible tubesfrom siphon adapter.Lift off the siphon adapter.Remove the drainconnection downstream ofthe condense trap.Remove the two condensetrap securing screws. Liftup and carefully remove thecondense trap taking carenot to spill any water whichmay be left in the unit. Asthe unit is lifted remove theflexible pipe on the outlet.Remove the cap at the baseof the condense trap.Remove any solids found.

Remove the float to clean it.Flush water through the trapto remove any remainingsolids.Check for any debris in theoutlet pipe of thecondensate drain and cleanas necessary.Reassemble and refit thecondense trap.When refitting the capensure that a watertight seal

Diagram 21

Diagram 22

Siphonadapter

Float

Condenstrap

Screw

Seal

is achieved, but do not useexcessive force.Remove the siphon adaptorfrom the flexible tubes,using a suitable container,flush the heat exchangeruntil the water appears clearin the container.

Plate-to-Plate HeatExchangerFor access, refer to section“General”.Drain the boiler heating andhot water circuits.Remove the water flowsensor, refer to previoussection.Unclip the central heatingthermistor.Unscrew the heating flowpipe union nut, swing pipeforwards.Remove the system waterpressure sensor.Supporting domestic hotwater plate to plate heatexchanger, unscrew andremove two screws securingit onto pump mounting and3-way valve/bypasshousing.Remove plate to plate heatexchanger from boiler.Fit replacement plate toplate heat exchanger inreverse order to removalusing new seals, supplied.Note: Plate to plate heatexchanger mounting screwsare offset to ensure correctfitting.

Domestic safety valve (10bar BLUE), refer todiagram 24.For access, refer to section“General”.Drain down the hot watercircuit only.Undo discharge pipe unionnut.Pull out slotted metal clipfrom valve body and removevalve.

Micro accumulator vesselthermistor, refer todiagram 25.For access, refer to section“General”.For this operation the boilermust be removed from thewall.IMPORTANT: With regardsto the manual handlingoperations, 1992regulations, the followingoperation exceeds therecommended weight forone man lift.

Cap

Diagram 23

➜

➜

Diagram 24

➜

➜

Diagram 25

Microaccumulatorvessel

Thermistor

Heatingelement

Electricalcable

73

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

Short parts list

No. Description Part No. G.C. No.1 Central heating thermistor S5739800 •••••••2 Fan S152000 •••••••3 Domestic water flow sensor S5720200 •••••••4 Printed circuit board - Main S1040000 •••••••5 Pump head S1024000 •••••••6 System water pressure sensor S5720500 •••••••7 Gas control valve S1043900 •••••••8 Overheat thermostat S1040100 •••••••9 Three way valve S1025500 •••••••10 Pressure relief valve S1006700 •••••••11 Heat exchanger S1041100 •••••••12 Burner S1042200 •••••••13 Micro accumulation vessel S1025000 •••••••14 Micro accumulation vessel thermistor S1027300 •••••••

Spareparts

INSTALLERS

Replacement ofparts

72

Note : It is not necessary todrain down entire heatingsystem to carry out thiswork.Disconnect the flue system.Disconnect the boilerconnections pipes .Disconnect the pressurerelief valve discharge pipes.Disconnect the mains cableand any external controlscables.Lift up to remove the boilerfrom the wall.Locate micro accumulatorvessel thermistor, on side ofthe micro accumulationvessel.Disconnect the inlineelectrical connection plug tothe micro accumulatorvessel thermistor.Pull out to remove thethermistor.

Micro accumulator vessel,refer to diagram 25.For access, refer to section“General”.For this operation the boilermust be removed from thewall, see previous section.

From the rear of the boiler,disconnect the inlineelectrical connection plug tothe micro accumulatorvessel thermistor.Remove the heating elementelectrical cable.Unscrew the retaining nuts

pipes.• Remove the vessel fromthe boiler.

Micro accumulator vesselheating element, refer todiagram 25.For access, refer to section“General”.For this operation the boilermust be removed from thewall, see previous section.Disconnect the electricalconnection plug to themicro accumulator vesselheating element at thecontrol board PCBconnection.• Release the microaccumulator vessel heatingelement cable from thesecuring clips, note therouting of the cable forreassembly.• Pull out micro accumulatorvessel heating element.

Printed circuit board(PCB), refer to diagram 26For access, refer to section“General”.Gain access to rear ofcontrol panel.Undo and remove the twofront retaining screws.Hinge up the control panelcover and ease forwardsfrom the rear retaining lugsto gain access to PCB. Donot strain the cablesattached to the PCB. Notethe routing of the cables.• Carefully pull off electricalconnections to PCB.Unclip and lift out PCB.Fit replacement PCB inreverse order to removal. Becareful not trap any of thecables.Make sure that PCBconnections are fully pushedonto replacement PCB.

Diagram 26

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

Retaining clips

07/0

4 -

4000

1355

00-2

Isof

ast

UK

PLEASE DO NOT FORGET

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We carry most spare parts on our vans - over 98% offaults are fixed first time round.

Saunier Duval Service N° 01773 525914

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INSTRUCTIONS FOR USE, INSTALLATION AND SERVICING by Saunier Duval. Manual Handling Guidance During...

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Transcript of INSTRUCTIONS FOR USE, INSTALLATION AND SERVICING by Saunier Duval. Manual Handling Guidance During...