High Efficiency Condensing Boiler Instructions for use Installation and servicing Xeon 18 HE G.C. 41-920-38 Xeon 30 HE G.C.
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 Guarantee. This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts.
The instructions consist of three parts, User, Installation and Servicing Instructions. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use) Regulations, be handed to the user on completion of the installation. Important Information ..............................................................4 Manual Handling .....................................................................
WARNINGS Gas Leak or Fault Turn off the gas emergency control valve immediately. Eliminate all sources of ignition, i.e. smoking, blowlamps, hot air guns etc. Do not operate electrical lights or switches either on or off. Open all doors and windows, ventilate the area. Sheet Metal Parts This boiler contains metal parts (components) and care should be taken when handling and cleaning, with particular regard to edges.
Insulation Pads / Ceramic Fibre General Note 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. Once the controls are set the boiler operates automatically. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory.
Condensate Drain If 2 persons performing lift, ensure co-ordinated movements during lift. The condensate drain, see section 7.3, must not be modified or blocked. Avoid upper body/top heavy bending - do not lean forward/sideways. Pluming from flue terminal Recommend wear suitable cut resistant gloves with good grip to protect against sharp edges and ensure good grip. Like all condensing boilers this appliance will produce a plume of condensation from the flue terminal in cool weather.
Spare Parts As a safety feature the boiler will stop working if the condensate drain becomes blocked. During freezing conditions this may be due to the forming of ice in the condense drain external to the house. Release an ice blockage by the use of warm cloths on the pipe. The boiler should then restart. Contact your installation/servicing company if the fault persists.
3 5 4 1. Digital Display 2. Control Light 3. Mains Reset Switch 4. Central Heating Water Temperature Control Knob 5.
Operation of the Boiler Sealed Water Systems CAUTION: A sealed water system must be filled and pressurised by a competent person. Only light the boiler when you are sure that the system and boiler have been filled and pressurised. The pressure should read at least 0.7 bar, anything less than this figure could indicate a leak and you MUST contact your installer or Saunier Duval’s own Customer Care Line using the telephone number on page two of this booklet. Do not operate the boiler without water.
1 TECHNICAL INFORMATION 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. 1.1 Important Notice The boiler is supplied in one carton, which includes a fittings and documentation pack. 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.
12566 600 MAX. 87 MIN. 334 48 113.5 176 53 76 INSIDE WALL FIXING FACE 33 CONDENSATE DRAIN 600 133 GAS 30 48 73 CONDENSATE DRAIN 13 GAS 54 375 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) (Propane G31, 37mbar) at the boiler.
1.4 Technical Data TABLE 2 All dimensions are given in millimetres (except as noted). 18 HE BURNER %CO2 Case Off BURNER %CO2 Case On See diagram 1.1 and Tables 1 and 2. The data label is positioned on the inner door, refer to diagram 1.2. 9.1 + 0.2 - 0.5 9.3 + 0.3 - 0.5 MIN. MAX. APPROXIMATE GAS RATE (after 10 mins. from cold) The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is: All HE boilers: Class ‘A’.
2 BOILER LOCATION AND VENTILATION 2.4 Room Ventilation 2.1 Boiler Location The boiler is room sealed, so when it is installed in a room or space, a permanent air vent is not required. This boiler is not suitable for outdoor installation. 2.5 Compartment Ventilation Due to the high efficiency and hence low casing temperature of this boiler, cupboard or compartment ventilation is not necessary.
3 FLUE LOCATION AND VENTILATION 3.3 Flue Options There are various flue systems to choose from, as follows: 3.1 Flue Position and Length Horizontal telescopic flue pack - Pt. No. A2045000 The maximum permissible horizontal flue length is 10 metres plus the flue terminal, this can be achieved by use of the accessories, however should additional 90° or 2 x 45° elbows be used then the length MUST be reduced by 1 metre. Standard flue pack - Pt. No. A2044900 Black terminal - Pt. No. A2045100 The diagrams 3.
12746 12744 NOTE. If necessary, it is permitted to increase this dimension up to 600mm max. NOTE. If necessary, it is permitted to increase this dimension up to 600mm max. 208 min. to 413 max. 75 min. to 540 max. WALL THICKNESS WALL THICKNESS 87min. FLUE 112 C L C L 176 OUTSIDE WALL FACE 176 OUTSIDE WALL FACE BOILER MOUNTING WALL Top rear flue - telescopic Diagram 3.1 12747 12745 87min. “A” Max flue length 717mm 20mm min.
12570 3.4 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 3.5. Dimensions shown are measured from edge of terminal. The terminal must be exposed to the external air, allowing free passage of air across it at all times. Being a condensing boiler some pluming may occur from the flue outlet. This should be taken into consideration when selecting the position for the terminal.
3.5 Terminal Guard 4 WATER SYSTEM A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage. 4.1 Draining Tap A draining tap must be provided at the lowest point of the system, which will allow the entire system and hot water system to be drained. If a terminal guard is required, it must be positioned to provide minimum of 50mm clearance from any part of the terminal and be central over the terminal.
12572 4.6 Water Treatment In the case of an existing installation, it is ESSENTIAL that prior to installing the new boiler the system is thoroughly flushed. For optimum performance after installation of a new system, the boiler and its associated central heating system should also be flushed. Flushing should be carried out in accordance with BS7593: 1992 using a cleanser such as Sentinel X300 or X400, or Fernox Superfloc.
12574 4.9 Domestic Hot Water Cylinder The boiler must be supplied from an unrestricted water supply taken from a feed and expansion cistern situated at a maximum height of 27 metres (90ft) above the boiler. SINGLE FEED INDIRECT CYLINDERS ARE NOT SUITABLE The domestic hot water cylinder must be of the double feed fully indirect coil type. The cold feed must be 15mm minimum size. 4.10 Domestic Hot Water System unvented The vent must rise continuously and be unrestricted.
Where a storage system will not have a vent to atmosphere the installation must comply with the building regulations and local Water Company bylaws, see also the current issue of BS5546 and BS6700. Guidance on vessel sizing is also given in the current issue of BS5449 and BS7074 Part 1, for IE refer to the current edition of I.S.813 “Domestic Gas Installations”.
4.17 Filling a Sealed Water System 5 INSTALLATION PREPARATION Provision for filling the system at low level must be made, see diagram 4.4. There must be no permanent connection to the mains water supply, even through a non-return valve. 5.1 Appliance Pack IMPORTANT: With regards to the Health and Safety Manual Handling requirements, two persons shall be required to lift the appliance, refer to manual handling on page 5.
BOILER FIXING For extended side flues the flue hole centre should be determined by extending the dashed inclined line on the template to the side wall. This dashed line is drawn at 44mm/metre (2.5°) rise from the boiler. Where this line reaches the side wall, a horizontal line should be marked. The vertical centre line of the flue should then be marked at 176mm from the back wall, see diagram 5.2. 6.
12579 GAS SERVICE COCK SHOWN IN OPEN POSITION UNION CONNECTOR SPIGOT GAS SERVICE COCK LINER GAS SERVICE COCK CAP GAS SUPPLY PIPE IN PLASTIC OVERFLOW PIPE CONDENSATE DRAIN CONNECTION Diagram 7.1 GAS, WATER AND CONDENSATE CONNECTIONS 7.1 Gas Connection Before connection check the supply of local gas. The gas supply can be connected from below, see diagram 7.1. or through the wall at the rear of the boiler. Refer also to section 1.2 and 1.3.
12579 22mm compression is the recommended fixing for servicing. (not supplied) FLOW RETURN Diagram 7.
Diagram 7.
FLUE PREPARATION TELESCOPIC AND STANDARD 8.2 Extension pipes Telescopic Top Rear flue - with the flue elbow temporarily fitted, measure the distance from the outside wall to the butt joint, see diagram 8.3. If the measurement ‘Y’ exceeds 525mm , then the appropriate length of extension pipe is required, if the dimension is less than 320mm DO NOT cut the flue, it can project to a maximum of 600mm, if this is not desirable then a Standard flue MUST be used and cut to length. 8.
WALL THICKNESS OUTER RUBBER COLLAR Diagram 8.3 112 COLLAR Top rear flue - standard FLUE Diagram 8.4 COLLAR FLUE DUCT Top side flue - standard 27 Diagram 8.
8.2 (cont’d) Flue and Air Ducts Push the flue assembly into the wall, externally or internally, initially until the end of the assembly protrudes a short way from the inside face of the wall. This will enable the internal trim ring (if required) to be positioned and allow the flue duct to be drawn back into the flue elbow after the boiler has been mounted. Telescopic: The Telescopic Flue system MUST NOT be cut. Adjust the flue to your required length “Y”, mark the securing hole position in the air duct.
Diagram 8.9 29 for qualified gas installers Installation and servicing instructions strictly reserved 13mm 12756 12755 L AIR DUCT L TERMINAL CATCH FLUE DUCT L + 11mm Diagram 8.
ELECTRICAL CONNECTIONS To gain access to the connection box remove the two retaining screws indicated in Diagram 9.1 and carefully lower and pull forward the box to reveal the terminal strip inside. WARNING: This boiler must be earthed. This appliance must be wired in accordance with these instructions. Any fault arising from incorrect wiring cannot be put right under the terms of the Saunier Duval guarantee. Remove the test cable from the terminal strip and discard.
9.2 Electrical connections - testing 9.3 Pump Connection Carry out preliminary electrical system checks as below: Ensure that a separate pump supply cable is fed to the boiler, see diagram 9.2. 1. Test insulation resistance to earth of mains cable. Remove connection box, see diagram 9.1. Route the pump supply cable through the strain relief cable gland, connect to the connection box as shown in diagram 9.2. Refer to diagram 12.2 for wiring colour code. 2.
12589 Diagram 9.
COMMISSIONING position. See diagram 11.7. The fan speed should now reduce to minimum and ‘12’ should be shown flashing on the digital display. Check the CO2 value. If necessary refer to diagram 10.3 and using a 2mm allen key carefully adjust the offset screw until a CO2 reading of 10.5% ± 0.2% is achieved. Turning the offset screw clockwise increases the CO2 reading. LPG CONVERSION - 30 HE only NOTE: Steps 10.1 to 10.3 will need to be completed before the appliance can be converted.
Isolate the boiler from the mains electrical supply. FLOW THERMISTOR OVERHEAT THERMOSTAT / RESET SWITCH 12591 10.3 Preparation for Lighting FLOW PIPE Test for gas soundness and purge air from the gas supply. Turn on the gas service cock, slot in line with the length of the valve, see diagram 7.1. VENT POINT RETURN THERMISTOR RETURN PIPE OFFSET ADJUSTMENT 12590 INNER CASING PANEL CASING PANEL 12592 Diagram 10.
10.4 Initial Lighting 10.5 Testing - Gas (Natural Gas only) The lighting procedure of the boiler is fully automated. Burner CO2 (G20) Check that all external controls are calling for heat. If an integral programmer is fitted check that it is correctly programmed and if necessary overridden to call for heat. Burner CO2 Propane (G31) Case Off 9.1+0.2-0.5 Case On 9.3+0.3-0.5 10.5+0.3-0.7 10.7+0.3-0.
10.9 Frost Protection Drain the entire system rapidly whilst hot, using the drain tap at the lowest part of the system. Fill and vent the system as described previously in section 10.2 The boiler has a built in frost protection programme as long as the electricity and gas are left switched on. Lock or remove the handles from controls valve ‘A’ and bypass valve ‘B’ to prevent unauthorised adjustment. This device operates the burner and system pump when the temperature inside the boiler falls to 3°C. 10.
Advise the user of the precautions necessary to prevent damage to the system, boiler and the building, in the event of the heating system being out of use during frost or freezing conditions. All routine servicing requirements can be achieved by the removal of the front panel, inner panel and chassis front only. Remove the two screws on the underside of the front panel and lift off. Undo the two screws on the front of inner panel and lift off, see diagram 10.1. To remove chassis front, refer to diagram 11.
12595 SPARK GAP 3.5 to 4.5 11.3 Burner HEAT EXCHANGER Refer to diagrams, 11.2,11.3,11.4 and 11.5. Isolate the gas supply at the gas service cock. SPARK ELECTRODE Disconnect the gas supply at the gas service cock. NOTE: DO NOT DISCONNECT AT THE GAS VALVE. Remove the two gas pipe bracket securing screws from underside of inner case, see diagram 11.2. SECURING SCREW 2 OFF EARTH LEAD Drop down the control panel into the service position. Remove the four screws from the chassis front, see diagram 11.3.
11.6 Combustion Check 11.4. Combustion Chamber and Heat Exchanger. Once the appliance has been reassembled (apart from the front and inner casing panels) connect a CO2 combustion analyser to the test point on the flue elbow or vertical flue adapter, see diagram 11.6. Refer to diagram 13.3. Remove loose debris from combustion chamber using a soft brush and vacuum cleaner.
This will allow the digital display to indicate the ‘flashing’ fan speed on the appliance fascia. TABLE 4 18 HE In the fully clockwise position the display should be indicating the maximum fan speed of the appliance, 41±1 for 18 HE and 57±1 for 30 HE). Check the CO2 value, corresponds to the value in table 4. BURNER %CO2 Case Off BURNER %CO2 Case On 9.1 + 0.2 - 0.5 9.3 + 0.3 - 0.5 MIN. MAX. APPROXIMATE GAS RATE (after 10 mins.
12600 COMBUSTION CHAMBER GAS VALVE GAS PIPE BRACKET AND SEAL FLUE ELBOW VERTICAL FLUE ADAPTER 12720 Diagram 11.5 COMBUSTION ANALYSER TEST POINT Diagram 11.
USER INTERFACE 12594 CONTROLS FASCIA FRONT CASING PANEL 12603 12593 RETAINING LATCHES SEAL INNER CASING PANEL Diagram 11.8 MIN. MAX. 11.7 Inner Casing Panel Seal Check. SERVICE POTENTIOMETER POTENTIOMETERS Refer to diagram 11.8. Diagram 11.7 Check the condition of the seal, replace as required. To replace remove the old seal, thoroughly clean the casing surfaces. Fit the new seal, it is supplied to the correct length.
NOTE: 12597 FAULT FINDING RETAINING STRAP Before trying to operate the boiler make sure that : • All gas supply cocks are open and that the gas supply has been purged of air. • There is a permanent mains supply to the boiler. • There is a heating demand from the external controls. WARNING: RETAINING SLOT Always isolate the boiler from the electrical supply before carrying out any electrical replacement work. CONTROL PANEL Diagram 12.1 Always check for gas soundness after any service work.
12604 Diagram 12.
Diagram 12.
12606 Diagram 12.
REPLACEMENT PARTS 13.3 Igniter Unit 13.1 Important Notes: For access, refer to section 13.1. Remove ignition lead and electrical connections, see diagram 11.4. 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 Saunier Duval. Remove igniter unit by removing two securing screws. 13.
13.9 Rear Insulation Remove the gas supply pipe from the gas valve. For access, refer to section 13.1. When refitting the gas valve take care as it can be fitted more than one way. Refer to section 11.3 for removal of the fan, gas valve and burner assembly. After assembly test for gas soundness and purge in accordance with the current issue of BS6891 or in IE, the current edition of I.S.813 “Domestic Gas Installations”.
13.10 Viewing Window 12610 FIBRE WASHER For access, refer to section 13.1. Refer to diagram 13.4. CIRCLIP Remove circlip. Remove steel washer. Remove glass. GLASS STEEL WASHER Replace in reverse order. 13.11 Heat Exchanger Refer to Manual Handling section on page 6. Diagram 13.4 12611 Remove fibre washer. FLOW AND RETURN PIPE NUTS For access, refer to section 13.1. Refer to section 11.3 for removal of the fan, gas valve and burner assembly. Drain the boiler.
HEATING FLOW THERMISTOR For access, refer to section 13.1. Refer to diagram 13.7. OVERHEAT THERMOSTAT 12591 13.13 Heating Flow Thermistor FLOW PIPE Remove the electrical connections from the thermistor. Remove the retaining clip from the flow pipe. Remove the thermistor from the retaining clip. NOTE: that the polarity of the wiring to thermistors is unimportant. 13.14 Heating Return Thermistor For access, refer to section 13.1. Refer to diagram 13.7.
Lift off the siphon adapter. 13.19 Mains Reset Switch Remove the drain connection downstream of the condense trap. Refer to section 13.18 for access. Remove switch from housing, see diagram 13.9. Remove the two condense trap securing screws. Lift up and carefully remove the condense trap taking care not to spill any water which may be left in the unit. As the unit is lifted remove the flexible pipe on the outlet. Remove electrical leads. 13.20 Mains Reset Slider Refer to section 13.18 for access.
13.22 Main PCB 12594 SECURING SCREWS For access, refer to section 13.1 Hinge down the control box, see diagram 13.11. Remove TORX screws and unhook the rear panel. Remove the electrical connections to the PCB. Prise back the two PCB retaining clips and withdraw the PCB. When refitting the rear panel ensure the leads are not trapped. USER INTERFACE 13.23 Control Box 12597 For access refer to section 13.22. Diagram 13.10 Remove relevant plugs and connectors, refer to wiring diagram 12.2.
SPARE PARTS When ordering spare parts, contact 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 and serial number, to be found on the data label, see diagram 1.2. Part No.
11 and 12 12616 5 4 6 8 3 2 1 7 13 9 and 10 Diagram 14.
for qualified gas installers Installation and servicing instructions strictly reserved
manual part number 0020005496 -02/05 Saunier Duval, Nottingham Road Belper,Derbyshire DE56 1JT Tel. 00 44 (0)1773 525914 Fax. 00 44 (0)1773 828070 www.saunier-duval.co.
