HIGH EFFICIENCY CONDENSING COMBINATION BOILER Instructions for use Installation and servicing ISOTWIN CONDENS F 35 E
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.
Instructions for use 1 General points .........................................................................2 2 Documents .............................................................................2 3 Safety ......................................................................................2 3.1 3.2 Gas Leak or Fault ..............................................................................2 Safety regulations and recommendations ..........................................
1 General points 2 Documents ISOTWIN CONDENS F 35 E boiler is an appliance that uses condensing technology, which recovers heat present in waste gas. Thanks to this operating principle, the boiler consumes less energy and decreases NOx and CO2 emissions. • Please keep this manual as well as any documents enclosed with it safe for future reference. We accept no liability in case of damage due to the non-compliance of the instructions of the present manual.
Your appliance is guaranteed for a period of 24 months from the date of installation or 30 months from the date of manufacture whichever is the shorter and covers manufacturing defects only. • Never switch off the safety devices and do not try to handle these devices as this could lead to a malfunction.
6 Servicing • Any deterioration or maladjustment following changes in the nature or pressure of the gas or the water used, or a change in the characteristics of the electrical supply voltage. • Clean the case of the appliance with wet soapy cloth. • Do not use any abrasive cleaning product as they could damage the housing or plastic parts. Notification of any fault should be made to the appliance installer.
5 Instructions for Use
8 Appliance use 8.1 Control panel 1 5 2 6 3 4 7 Legend 1 Operating indicator 2 Display of the available pressure in the heating circuit 3 Operating mode selection 4 DHW temperature adjustment 8.2 5 6 7 Commissioning and lighting Display of the measured temperature in the heating circuit On/off switch Heating temperature adjustment • Push “MODE” to modify the operating mode of the boiler.
9 Turn the boiler off Temperature adjustment • Push the switch (6) until the “O” symbol appears. The appliance is no longer supplied with electric power. 8.3.1 Domestic hot water temperature adjustment The domestic hot water must be set at max 63°C. • Push + or – on the side to adjust the max temperature. The ECO symbol remains until 49°C. We advise you to turn off the appliance gas supply if you leave home for a long period. 8.3.
Frost protection 12 Maintenance/After Sales Service 11.1 Boiler frost protection Please note that an incorrect servicing can affect the safety of the appliance and can lead to injury. In case of frost risk, do as follows: • Make sure the boiler is supplied with electrical power and gas. To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals.
Installation and servicing 1 Comments on the instructions............................................... 11 2 Appliance description ............................................................ 11 2.1 2.2 2.3 Data label ......................................................................................... 11 Mandatory WARNING for EEC countries ......................................... 11 Block diagram ..................................................................................
9 Gas conversion .....................................................................34 9.1 9.2 9.3 Maximum rate ..................................................................................34 Minimum rate ...................................................................................35 Reactivation .....................................................................................35 10 Fault finding...........................................................................
1 Comments on the instructions Member States relating to appliances burning gaseous fuels. • Please give all of the instructions to the user. The user shall keep them for future reference. We accept no liability in case of damage due to the non-compliance of the instruction manual. - Directive 73/23/EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits. 2 Appliance description 2.
2.
26 27 28 29 30 31 32 33 34 35 36 37 38 A B C D D1 D2 E F 3 Appliance location Filter on cold water inlet Filling system Filter on heating circuit Heating isolating valve Domestic cold water isolating valve Heating isolating valve Gas isolating valve DHW pump Storage anode protection Non return valve Temperature / pressure relief valve Tapping (plug connection) for the recirculation loop Pressure reducing valve and check valve Heating return Cold water inlet Heating flow Domestic hot water outlet Discharge
4 Safety instructions and regulations Warning! This appliance 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. This appliance is tested and certificated for safety and performance. It is, therefore, important that no alteration is made to the appliance, without permission, in writing, from Saunier Duval.
Regulations In IE: I.S.813, BS5546, BS 5449, BS 7074, BS 7593. When installing and commissioning the appliance, the regulations below shall be observed in their current version: Where no British Standard exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship. The installation of this appliance must be carried out by a competent person in accordance the rules in force in the countries of destination.
5 Appliance installation chapter “Technical Data” at the end of this instruction manual. All the dimensions in this chapter are expressed in mm. 5.1 The piping route should be designed in such a way that it avoids any air locks and make purging of gas from the system easier. Bleeders should be placed at each high point of the system as well as on any radiators. Recommendations before mounting 5.1.
5.1.3 Tundish discharge clear visibility at one or these of these locations. Examples of acceptance discharge arrangements are: The internal safety valves, 24 and 36 have been tee’d together and the discharge pipe run so that it exits at the right hand bottom of the boiler (see chapter «Block diagram»).
5.2 5.1.4 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, Fernox Superfloc or Salamander corrosion guard cleaner.
• Remove front panel, unscrew and remove the two retaining screws from the bottom of the front panel. Remove front panel by lifting up and forward. n. mi kg 5 1 n. mi kg 15 • To remove the self adhesive wiring diagram label from the document envelope, fit the self adhesive wiring diagram label to the inside of the front panel, put front panel in a safe place to avoid damaging it.
5.5 Gas and water connection • Before undertaking any operation, carefully clean the pipes with an appropriate product in order to remove impurities such as filings, welds, different oils and greases that may be present. These foreign bodies may enter the boiler and disrupt the operation. • Do not use any solvents that could damage the heating circuit. • Take care when soldering pipes as the heat could damage the seals and cause leakage. Fit washers after joints have cooled.
angular bush to weld Ø 15 + nut 1/2" Legend Connection pack 1 : A Pressure test point 1 Hanging bracket 2 Heating return pipe: angular bush to weld Ø 22 + nut 3/4" 5 Gasket 3/4" (x3) 8 Cold water inlet + domestic hot water outlet with isolating valve 12 Heating flow with isolating valve 13 Gas service cock 14 Gasket 1/2" (x3) 15 Gas pipe: angular bush to weld Ø 15 + nut 1/2" 16 Cold water inlet pipe + domestic hot water pipe: 17 Heating flow pipe: angular bush to weld Ø 22 + nut 3/4" Connection pack 2 : 4
23 1 22 2 21 3 20 24 4 19 18 17 16 15 14 5 6 7 8 9 9 7 10 8 13 12 11 Legend 1 Domestic hot water safety valve 2 Drain cock 3 Filling loop extension knob 4 Gasket 5 Nut 6 Discharge valve for PRV (BLUE) on domestic hot water circuit 7 Nut (x2) 8 Gasket (x2) 9 Gasket (x2) 10 Union coupling 11 Nut 12 Biconical ring 13 14 15 16 17 18 19 20 21 22 23 24 22 Tundish Biconical ring Nut Nozzle Nut Inner tee Biconical ring coupling Biconical ring Discharge pipe for PRV (RED) on heating circuit Gas
Valve outlet size Minimum size of discharge to tundish D1 Minimum size of discharge pipe D2 from tundish G 1/2” 15 mm 22 mm 28 mm 35 mm G 3/4” 22 mm 28 mm 35 mm 42 mm G 1” 28 mm 35 mm 42 mm 54 mm 1 500 mm Maximum resistance allowed expressed as a length of straight pipe i.e. no elbows or bends 0.8 m 1.0 m 1.4 m up to 9 m 1.0 m 1.4 m 1.7 m up to 18 m up to 27 m D1 Resistance created by each elbow or bend 1.4 m 1.7 m 2.3 m D2 300 mm max.
5.6 Connection to the condensate trap 3 1 OK 2 OK Legend 1 Acces plugs for cleaning purposes 2 Condensate drain connection 3 Condensate trap • Connect the flexible pipe to a discharge system leading to the sewer in compliance with the instructions below: 5.7 Flue connection Different flue outlet configurations can be carried out. • Use the condensate drain flexible connection pipe supplied (2). • Consult your supplier for more information about the other possibilities and associated accessories.
Position of the flue terminal Horizontal flues directly below an opening, air brick, A opening windows above an opening, air brick, B opening windows horizontally to an opening, air brick, C opening windows D below gutter, drain/soil pipe E below eaves F below a balcony or car port from vertical drain pipes G and soil pipes from internal/external H corners Position to a boundary alongside the terminal above adjacent ground or I balcony level from surface or a boundary J facing the terminal K facing termin
5.7.2 Vertical concentric flue Ø 60/100 (C33 type installation) H*: This dimension comply with the building regulations, but it may need to be increased to avoid wall staining and nusance from pluming depending on site conditions. 5.7.1 Horizontal concentric flue Ø 60/100 (C13 type installation) L L 1 72 Maximum flue index: 150 Pa This value is reached with the length of the maximum duct (L) + 1 90° elbow.
LL11 The mains cable integrated in the boiler is specific: if you want to change it, order it exclusively from Saunier Duval service. L2 188 Maximum flue index: 150 Pa This value is reached with 2 elbows, the separator and the maximum duct length (L1+L2) of 40 m. 5.8 Installation and servicing instructions strictly reserved for qualified gas installers Every time an extra 90° elbow is used (or 2 off 45°), the length (L) should be reduced by 1 m.
5.
29 Installation and servicing instructions strictly reserved for qualified gas installers
6 Commissioning 7 Specific adjustments • Slide the switch until the “I” symbol appears. The operating indicator on the control panel turns on: the boiler is ready to operate. 7.1 Heating circuit adjustment This flow rate will be adjusted according to the system calculations. When it is delivered, the (1) integrated bypass screw is open by half a turn. • Open the isolating valves located on the pipes: they will be placed in the direction of the flow.
Available pressure (kPa) between heating flow and return Output/pressure curve 70 60 1 50 2 3 40 4 30 8 20 7 9 10 6 5 500 1000 1400 Heating circuit flow rate (l/h) Legend Installation and servicing instructions strictly reserved for qualified gas installers Speed III 1 By-pass fully shut 2 Open 1/4 turn 3 Open 1/2 turn 4 Open 2 turns Speed II 5 By-pass fully shut 6 Open 1/4 turn 7 Open 1/2 turn Speed I 8 By-pass fully shut 9 Open 1/2 turn 31
7.2 Access to the boilers technical data (for professional and After Sales Service use only) • When “0” and “ ” appear, use the keys + or - until “96” appears on the indicator. The access to the boilers technical data allows you to make some adjustments and to analyse potential malfunctions. • Once again press the “MODE” key to display the first parameters menu, i.e. the heating maximum power (menu COD.1).
COD. 7 COD. 8 outdoor thermostat : regulation slope reference point Move the reference point of the regulation slopes by moving the parameter from -9 to 10. burner forcing Select an operating mode: 0 - normal operation. 1 - forcing at P. mini. 2 - forcing at P. maxi. 3 - forcing at P. ignition COD 8 menus and following would only be used by After Sales Service Engineers. Temperature setting curves.
8 Draining of the appliance 8.1 9 Gas conversion The ISOTWIN CONDENS can be converted to run on LPG-Propane (G31). This conversion should only be carried out by a competent person. Heating circuit • Turn on the drain cock (1) provided at the system low point. • During the conversion to Propane, use of a suitable flue gas analyser is necessary. • Provide an air intake by opening a radiator bleed screw.
• Attach combustion analyser to the combustion test point. • Ensure that the gas analyser is set to the correct fuel setting - Propane. • Turn on the mains electrical supply and turn on the gas service clock. Switch the boiler on. • Attach combustion analyser to the combustion test point. • Turn on the mains electrical supply and turn on the gas service cock. Switch the boiler on. • Fully open a hot water tap. • Wait for 2 minutes or so, until the CO2 reading has stabilized.
10 Fault finding Important: a central heating system cannot operate efficiently if it is not filled with water and if the air it contains at first has not been completely removed. If those requirements are not fulfilled, some noise originated by the water boiling inside the boiler and noise of water chute inside the radiators could appear. You will find the list of some fault codes in the operating instructions.
37 Installation and servicing instructions strictly reserved for qualified gas installers
11 Control / Commissioning 13 Spare parts Once the appliance is installed, check whether it runs: In order to guarantee a long-lasting operating of the parts of the appliance and keep it in good condition, only original spare parts from SAUNIER DUVAL should be used when repairing and servicing the appliance. • Start the appliance according to the indications of the operating instructions and check whether it runs. • Check the appliance for leaks (gas and water) and eliminate any leakage found.
14 Maintenance 14.1.2 Warning! • Remove the front panel (5). • Before starting the maintenance of the appliance, read carefully the chapter “Safety instructions”. • Remove the right side panel retaining screws (7). • Remove the right side panel (6). 14.1 Casing 14.1.3 7 1 Right side panel Inner front panel • Remove the inner front panel retaining screws (3). 2 6 Installation and servicing instructions strictly reserved for qualified gas installers • Remove the inner front panel (2).
14.
14.2.1 14.4 Condensate trap Cold water filter • Turn off the cold water main inlet. • Relieve the filter retaining clip (5). 1 • Remove the cold water filter (6) and clean it. 2 “Foaming” filter 3 The “foaming” filter improves the heating circuit gas purging operation. 4 • Turn off the heating flow and return insulating valves, and then drain the boiler. 5 • Relieve the filter retaining clip (8) located under the pump.
14.
Legend 1 Heat exchanger retaining screws 2 Gasket 3 Viewing window gasket 4 Viewing window circlip 5 Gasket 6 Ignition and controle electrode gasket 7 Ignition and controle electrode 8 Ignition and controle electrode connector Ignition and controle electrode 9 retaining screws 10 Ignition module harness connector 11 Ignition module retaining screws 12 Fan connector 13 Mixing arm 14 Heat exchanger hanging brackets 15 Burner assembly retaining screws 16 Insulation 17 Heat exchanger retaining nuts 18 19 20 21
15 Remplacement of parts • Inspect the burner for any signs of damage. Warning! • Inspect the sealing rings and replace if necessary. • Before starting the remplacement of parts, read carefully the chapter “Safety instructions”. • Removal of the burner is not necessary during a normal service. 14.5.3 Heat exchanger • Remove the 2 mixing arm retaining screws (23) bolted on the fan (33). • Remove the 5 heat exchanger retaining nuts (17). • Remove the “burner + mixing arm” unit from the heat exchanger.
45 Installation and servicing instructions strictly reserved for qualified gas installers
15.
DHW pump or heating • Remove the low water pressure sensor (22). • Loosen the 4 pump retaining screws (1)/(3). 15.1.7 • Remove the pump motor (2)/(4). 15.1.2 • Remove the connector (26). DHW exchanger • Remove the three way valve (21). • Remove both retaining screws (13) accessible from the boiler front face. 15.1.8 DHW safety valve or heating • Relieve the clips (16)/(19). Be careful with the direction of reassembly : the word “TOP”, printed on the edge of the exchanger (25) will be set upward.
15.
15.2.1 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Mixing arm • Remove the “burner + mixing arm” unit of the heat exchanger. • Remove the 2 mixing arm retaining screws (23) bolted on the fan (33) and the burner door. • Remove the heat exchanger retaining screws (1) and relieve the heat exchanger retaining plates (14). • Remove the mixing arm (13). • Relieve the 2 heat exchanger hydraulic coupling (20). • Fit the new mixing arm and the new gaskets in the reverse order. 15.2.
• Remove the screw (25) and the retaining plate (26) from the gas valve connector. electrode retaining screws (11). • Fit the new ignition and controle electrode and the new gasket in the reverse order. • Remove the gas valve connector (28). • Remove the fan retaining screws (34). 15.2.8 • Remove the gas valve (35). • Remove the circlip (4). • Fit the new gas valve and the new gasket in the reverse order. • Remove the gaskets (3) (18), the viewing window (19) and the spring leaf (18).
• Refill, vent and pressurise the boiler. DHW expansion vessel retaining screw DHW expansion vessel Drain nozzle nut DHW storage vessel coupling DHW storage vessel DHW storage vessel coupling 15.3.1 • Check for leaks. 15.3.2 DHW expansion vessel • Relieve the DHW expansion vessel coupling (8). Heating expansion vessel • Relieve the heating expansion vessel coupling (6). • Relieve the DHW expansion vessel retaining screw (9). • Loosen the screws (2) and (3) of the hanging bracket and remove it.
15.4 Condensate trap • Fit the new condenstae trap in the reverse order. 15.5 Control panel 1 15.5.1 6 Access to the printed circuit board 2 3 4 5 1 2 Legend 1 Switchbox protective cover retaining screw 2 Cover retaining plate on the switchbox Legend 1 Flexibles 2 Float 3 Condensate trap retaining screw 4 Condensate trap 5 Draining flexible 6 Siphon adapter • Remove the 2 switchbox protective cover retaining screws (1). • Remove the cover retaining plate on the switchbox (2).
15.5.2 Main board • Fit the new main board in the reverse order. 15.5.
16 Technical data Boiler type C13, C33, C53 Description Gas category Unit ISOTWIN CONDENS F 35 E ll2H3P kW % 7.6 - 28 95.8 - 97.
Combustion Fresh air flow rate (1013 mbar - 0°C) Product outlet flow rate Product outlet temperature Values of product outlet (measured on nominal heating CO2 NOx balance Dimensions: Height Width Depth Net weight Weight of appliance when full Supply voltage Maximum absorbed power Electrical rating Fuse Electric protection Class CE number mm mm mm kg kg V/Hz W A mA 890 700 480 75 120 230/50 241 1.
0020003998-02 - 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.
