Saunier Duval SD 30e Operating manual

Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
All replacement parts
All labour charges
All call-out charges
221873B.07.01
Instructions for Use
Installation and Servicing
Tobeleftwiththeuser
This is a Cat I2H Appliance
7086
Fanned Flue
Combination Boiler
SD 30e
❑
✔
❑
✔
❑
✔
Guarantee Registration
REGISTER YOUR SAUNIER DUVAL APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Thank you for installing a new Saunier Duval appliance in your home.
Saunier Duval appliances' are manufactured to the very highest standard so we are pleased
to offer our customers' a Comprehensive First Year Guarantee.
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
return as soon as possible.
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Service number 01773 828100.
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
The instructions consist of three parts, User, Installation and Servicing Instructions, which include the Guarantee Registration Card.
The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety (Installation and Use)
Regulations, be handed to the user on completion of the installation.
G.C. No. 47-920-16

2
221873B
Testing and Certification
This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler,
without permission, in writing, from Hepworth Heating Ltd.
Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the
current issue of the Statutory Requirements, see Section 1.4.
CE Mark
This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is
deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels.
Type test for purposes of Regulation 5 certified by: Notified body 0086.
Product/production certified by: Notified body 0086.
The CE mark on this appliance shows compliance with:
1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning
gaseous fuels.
2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment
designed for use within certain voltage limits.
3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic
compatibility.
Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
These can cause irritation to skin, eyes and the respiratory tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is
broken.
Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or
going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention.
Spare Parts
REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and
performancespecificationthatwerequire. DonotusereconditionedorcopypartsthathavenotbeenclearlyauthorisedbyHepworth
Heating Ltd.
Important Information
Introduction 3
Clock Settings 4
Lighting the Boiler 5
General Data 1 7
Boiler Position 2 9
Flue and Ventilation 3 10
Heating System 4 11
Domestic Hot Water System 5 12
Installation Preparation and
Gas/Water Connections 6 13
Flue Preparation 7 13
Mounting the Boiler 8 16
Electrical Connections 9 20
Commissioning 10 22
General Data 11 25
Servicing 12 25
Fault Finding 13 27
Replacement Parts 14 32
Spare Parts 15 43
CONTENTS DESCRIPTION SECTION PAGE No.
INSTRUCTIONS
FOR USE
INSTALLATION
INSTRUCTIONS
SERVICING
INSTRUCTIONS

3221873B
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Introduction
Pleaseread theseinstructions andfollowthemcarefullyfor the
safe and economical use of your Combination boiler.
This boiler must have been installed by a competent person in
accordance with the current rules in force in the countries of
destination at the time of installation.
Once the controls are set, the boiler is automatic in operation.
The 30e combination boiler is able to provide room heating as
part of a central heating system and domestic hot water direct
from the cold water supply, without the need for secondary
storage.
The boiler can be fitted with one of two makes of clock, which
look like this:-
IMPORTANT NOTICE:
This boiler is for use only on G20 gas.
Gas Leak or Fault
Ifagasleakorfaultexistsorissuspected,turntheboileroffand
consult your local gas company or your local installation/
servicing company.
Mains Water Temperature
NOTE: The mains incoming water temperature in the winter is
lower than in summer.
To achieve the same outlet water temperature in the winter, it
will be necessary to reduce the water flow rate using the hot
water tap.
Boilers Installed in Compartments
Ifthe boiler hasbeen fittedintoa compartmentorcupboard, do
not obstruct the compartment air supply vents.
Do not use the compartment for storage.
Electrical Supply
WARNING. The boiler must be earthed.
The boiler must be connected to a 230V~50Hz permanent
supply.
Connection of the whole electrical system of the boiler and any
heatingsystemcontrolstotheelectricalsupply,mustbethrough
one common isolator.
Isolation should preferably be by a double pole switched fused
spurbox. The fusedspur boxshould bereadily accessibleand
preferably adjacent to the appliance. It should be identified as
to its use.
Alternatively a fused 3A 3 pin plug and shuttered unswitched
socket may be used.
Thecoloursofthreecoreflexiblecableare,blue-neutral,brown
- live, green and yellow - earth.
As the markings on your plug may not correspond with these
colours continue as follows:-
The wire coloured blue must be connected to the terminal
marked “N” or “Black”.
The wire coloured brown must be connected to the terminal
marked “L” or “Red”.
The wire coloured green and yellow must be connected to the
terminal marked “E” or “Green” or the earth symbol .
PVC flexible cable having a conductor size of 0.75mm2(24/
0.20mm)mustbeusedwithintheboilercasingtoconnecttothe
boiler.
Electrical Supply Failure
The boiler will not work without an electrical supply.
Normaloperationoftheboilershouldresumewhentheelectrical
supply is restored.
Note. The boiler safety cutoff may have operated, please refer
to the following section to reset.
Reset any external controls, to resume normal operation of the
central heating.
Boiler Safety Cutoff Reset Button
Theboilerisfittedwithasafetycutoffdevicetopreventdamage
through overheating.
Shouldthemainburnergooutduring ademandthered lockout
light “F” will illuminate on the control fascia situated above the
Reset Button “G”, see diagram 4.
The red light will not illuminate if there is no system demand.
Allow the boiler and system to cool down waiting at least
a minimum of four minutes before pressing the Reset
button “G”.
The boiler will take a few seconds to reset after the button is
pressed.
Ifthe problem persists, turn the boiler off and consult your
installation/ servicing company.
The Gas Safety (Installation & Use)
Regulations
In your interests and that of safety it is the law that ALL gas
appliances are installed by competant persons in accordance
with the current issue of the above regulations.
6937
Clock / Timers
Electro / mechanical
clock / timer
Instructions for Use

4
221873B
To Light the Boiler
1. Checkthatallfourisolatingvalvesareopen,theleversinline
with the valvebody, see diagram 2.
2. Openthecontrolscoverdoorandfamiliariseyourselfwiththe
controls, see diagram 3.
3. CAUTION. A sealed pressurised system must be filled and
pressurisedby a competentperson. (Optionalextra filling loop
kit No. 457120).
Only operate the boiler when you are sure that the system has
been filled and pressurised. Check this by looking at the
pressure gauge “A”, it should read 0.7bar minimum.
4. Open a hot water tap, check that water flows, then close it.
5. Ifyouare inanydoubtabouttheboilerbeingfilled withwater
contact your installation/servicing company or the local gas
company.
6. Check that the electrical supply to the boiler is ON at the
external isolator.
7. Check lockout light, refer to boiler safety cutoff reset button.
8. Set the switch “B” to 1 situated on the control fascia.
9. Set the summer / winter button “J”, light “L” or “K” will
illuminate.
10. Set “C”, clock/timer and any remote controls as required.
11. Check the lights “D” and “E” are illuminated on the control
fascia.
Close the controls cover door.
Incertain circumstances, asurgein water pressuremay cause
the appliance to operate momentarily, this will be indicated by
the pump starting and the fan speed increasing. This is quite
normal.
Domestic Hot Water Temperature
The sanitarywater temperature controlknob“M”, see diagram
4, willcontrolthedesiredtemperatureofthewateruntiltheflow
exceeds the capability of the boiler to give the required
temperature rise.
Thenthetemperatureisdeterminedbycontrollingthehotwater
flow from the tap ie: reduce flow - increase temperature
increase flow - reduce temperature
NOTE : Themains incoming watertemperature in thewinter is
lower than in the summer.
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Setting Instructions for Electro/mechanical
Clock
This clock has a twenty four hour dial, that is, 1pm is 13.
To set the time, turn the whole face clockwise until the pointer
is against the time of day.
To set any “Off”time, push the tappets outwards.
To set any “On”time, push the tappets inwards.
Timecanbe set either “On”or“Off”in fifteen minute segments.
Note. Theclocksuppliedcouldbefittedwithanoverridedevice,
see diagram 1, which switches the clock programme “On”or
“Off”permanently.
Theswitchwillneedto berepositionedtoresumeprogrammed
working.
Diagram 1
OVERRIDE
SWITCH
POINTER
TAPPETS
CLOCK FACE
CONSTANT OFF
PROGRAMMED
CONSTANT ON
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6938
Instructions for Use

5221873B
Diagram 2
GAS
SERVICE
COCK
HOT
WATER
OUT
COLD
WATER
SUPPLY IN
HEATING
FLOW
HEATING
RETURN
LEVER (OPEN)
COLD WATER
SUPPLY IN/OUT
Instructions for Use
SLOT (OPEN)
GAS SERVICE
COCK
LEVER (OPEN)
HEATING
FLOW/ RETURN
7013
SAFETY VALVE
DISCHARGE PIPE POSITION
Summer / Winter Selector Button
Adjustthecentralheatingwatertemperaturecontrolknob“N”to
desired setting.
Forcentralheatingsetbutton“J”toWinterlight“K”willilluminate.
The main burner will light. The burner ON light “D”will
illuminate.
When the heating is controlled by a room thermostat and/or a
time switch, button “J”must be set to Winter light “K”will
illuminate.
If a hot water tap is opened while the boiler is on for heating,
priority will be given to hot water.
Toturntheheatingoffforshortperiods,setbutton“J”tosummer
“Off”light “L”will illuminate.
To turn on again set button “J”to winter “On”, light “K”will
illuminate.
To Turn the Boiler Off
To turn the boiler off, set switch "B" to O.
To turn on again follow the operating instructions.
Maintenance and Servicing
To ensure the continued efficient and safe operation of the
appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
If this appliance is installed in a rented property there is a duty
of care imposed on the owner of the property by the current
issue of the Gas Safety (Installation and Use) Regulations,
Section 35.
Servicing/maintenance should be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
Toobtainservice,pleasecallyourinstallerorHeatcall(Saunier
Duval's own service organisation) using the telephone number
behind the controls cover door.
Please be advised that the ‘Benchmark’logbook should be
completed by the installation engineer on completion of
commissioning and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on :- 01256 372300.
Clearances
The boiler requires a clearance in front, below and at the sides
ofthecasingforsafety,servicingandmaintenanceaccess,see
diagram 2.1.
Protection Against Freezing
Theboilerhasa2stagebuiltinfrostprotection. Providedpower
and gas are available and there is adequate pressure in the
system,ifthewatertemperaturewithintheappliancefallsbelow
10oC approx. the pump only will come on. If the water temp
continues to fall to 6oC approx. the main burner will fire at min
rateuntilthewaterintheapplianceisgreaterthan15oCapprox.
This is a separate function to any remote frost protection fitted.

6
221873B
Instructions for Use
6941
MAINS
ELECTRIC
SWITCH ‘B’
SANITARY WATER
TEMPERATURE
CONTROL KNOB ‘M’
RESET
BUTTON ‘G’
SUMMER/ WINTER
BUTTON ‘J’
PRESSURE
GAUGE ‘A’
Diagram 3
CENTRAL HEATING
WATER
TEMPERATURE
CONTROL KNOB ‘N’
‘F’
‘H’
‘L’
‘D’
‘E’
‘K’
‘P’
‘Q’
CONTROLS
COVER
CONTROLS
FASCIA
CLOCK TIMER
‘C’
Other system pipework external to the boiler may require frost
protection.
Iftheboileristobeoutofuseforanylongperiodsduringsevere
weather, it is recommended that the whole system, including
theboiler,should bedrainedto avoidtheriskoffreezing. Make
sure that, if fitted, the immersion heater in the cylinder is
switched off.
Ifindoubt,contactyouinstallation/servicingcompanyforadvice.
Draining and Filling
CAUTION. This boiler works in a pressurised system which
must only be drained, refilled and pressurised by a competent
person.
Note: Ifthepressuregaugeindicatesalossofsystempressure,
that is, less than 0.7bar, YOU MUST CONTACT YOUR
INSTALLER.
Pressure Relief Safety Valve
CAUTION. Apressure reliefsafety valveanddischargepipeis
fittedtotheboiler. Thisvalvemustnotbetouched. Shouldthere
be any discharge from the pipe, turn the boiler off, isolate from
the electrical supply and contact your installation/servicing
company.
Cleaning
WARNING. Thisappliancecontains metal parts(components)
and care should be taken when handling and cleaning with
particular regard to edges.
The boiler casing can be cleaned using a mild liquid detergent
with a damp cloth, then a dry cloth to polish.
Do not use any form of abrasive or solvent cleaner as you may
damage the paint work
Boiler Casing
CAUTION. Do not remove or adjust the casing in any way, as
incorrect fitting may result in incorrect operation or failure to
operate at all. If in doubt seek advice from the local gas
company or your installation/servicing company.
Replacement Parts
If replacement parts are required apply to your local supplier or
British Gas.
Please quote the name of the appliance.
KEY TO NEON LIGHTS
‘F’ BOILER LOCKOUT
‘H’ LOW WATER PRESSURE
‘L’ SUMMER SETTING
‘K’ WINTER SETTING
‘D’ BURNER IGNITED
‘E’ POWER ‘ON’
‘P’ SANITARY DEMAND
‘Q’ CENTRAL HEATING DEMAND
7565

7221873B
1 General Data
6942
1.1 Installation
Materials and equipment should be fit for their purpose and of
suitable quality and workmanship.
1.2 Important Notice
This boiler is for use only on natural gas, G20.
1.3 Sheet Metal Parts
WARNING. Wheninstallingorservicingthis boilercare should
betakenwhenhandlingtheedgesof sheetmetalpartsto avoid
any possibility of personal injury.
1.4 Requirements
Theinstallationofthisboilermustbecarriedoutbyacompetent
person in accordance with the current rules in force in the
countries of destination at the time of installation.
Manufacturer’s instructions, supplied.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
1.5 Data Label
The data label is on the inner case front, see diagram 1.2.
1.6 Data
See table 1 and diagrams 1.1, 1.2 & 1.3.
The Seasonal Efficiency Domestic Boilers UK (SEDBUK) is
78.3%.
ThevalueisusedintheUKGovernment’sStandardAssessment
Procedure (SAP) for energy rating of dwellings. The test data
from which it has been calculated have been certified by B.S.I.
Diagram 1.1
Optional flue kits are available
Horizontal top outlet and Vertical.
Lift Weight 31.7kg (69.89b)
Total Weight 41.1kg (90.61lb)
Gas connection Ø15mm compression
Heating and return Ø22mm compression
Domestic hot water Ø15mm compression
Safety valve Preset 3bar (43.5lbf/in2)
Safety valve discharge Ø15mm copper
Water content 1.42 litres (0.31 gallon)
■Expansion vessel capacity 6 litres (1.32 gallons)
Heating cold fill 0.7bar
pressure minimum (10.1lbf/in2)
❋D.H.W 0.8 to 10bar
working pressure
■Maximum Heating 60 litres
system water (13.2 gallons)
content using with a cold
fitted expansion fill pressure
vessel. of 0.7bar
Electrical supply 230V~50Hz
Electrical rating 150W fused 3A
Internal Fuse rating 1) Type T2A
■For larger systems use an additional expansion
vessel, see Section 4.
❋Boiler starts at an inlet pressure of 0.5bar but
requires 0.8bar for maximum output.
TABLE 1
CM
N
P
A
D
E
B
G
C
L
C
L
H
9mm
J
L
K K
F
D
E
Approximate gas 3.03m3/h
rate at max input (107ft3/h)
EXTD. EASYFIT
A B C D E F G H J K L M N P
450 700 300 100 75 138 142 18 135 65 110 138 85 115 103

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221873B
1.7 Gas Supply
Thegasinstallationshallbeinaccordancewiththerulesinforce
in the countries of destination.
The supply from the governed meter must be of adequate size
toprovideasteadyinletworkingpressureof20mbar(8inwg)at
the boiler. With all other appliances operating.
1.8 Electrical Supply
WARNING. This boiler must be earthed.
All system components shall be of an approved type.
Theelectricalinstallationshallbeinaccordancewiththecurrent
rules in force in the countries of destination at the time of
installation.
Connection of the whole electrical system of the boiler and any
heatingsystemcontrolstotheelectricalsupply,mustbethrough
one common isolator.
Isolation should be by a double pole switched fused spur box,
having a minimum contact separation of 3mm in each pole.
Thefusedspurboxshouldbereadilyaccessibleandpreferably
adjacent to the appliance. It should be identified as to its use.
Alternatively, a fused 3A 3pin plug and unswitched socket may
beused,providedtheyarenotusedinaroomcontainingabath
or shower.
The mains supply cable and other cables connected to the
boiler must be the PVC flexible type of at least 0.75mm2 (24/
0.20mm) .
1 General Data
Diagram 1.2
1.9 Heating System Controls
The heating system should have installed: a timer and room
thermostat controlling the boiler.
Thermostatic radiator valves may be installed, however they
must not be fitted in a room where the room thermostat is
located.
Note:All systems musthave at leastone radiatornotfitted with
a thermostatic valve.
Note: For further information, see The Building Regulations
1991-Conservationoffueland power,1995edition-Appendix
G, table 4b.
7664
Diagram 1.3
7641
FANNED FLUE
AUTOMATIC
AIR VENT
EXPANSION
VESSEL
MAIN BURNER
HEAT EXCHANGER
PLATE TO PLATE
HEAT EXCHANGER
PUMP
HOUSING
LOW WATER
PRESSURE
SWITCH
PRESSURE
DIFFERENTIAL
MICRO SWITCH
GAS VALVE
SAFETY
VALVE
DISCHARGE
OVERHEAT
CUT-OFF
TEMP.
SENSOR
TEMP.
SENSOR
MOTORISED
3 WAY VALVE
HOUSING
VALVE
BYPASS
VALVE
D.H.W.
COLD
INLET
D.H.W.
HOT
OUTLET
C.H.
FLOW
C.H.
RETURN
D.H.W.
MICRO SWITCH
GAS
SAFETY
VALVE
The appliance flue type is a C12 and C32. This refers to a concentric
fluewhere the fan isdownstream of the heatexchanger. TheC12 is
ahorizontalfluetermination,andtheC32 isaverticalfluetermination.

9221873B
25 ABOVE THE TOP OF THE BOILER CASE
OR THE FLUE ELBOW IF FITTED
5
5450
150
To achieve minimum "Installation" clearance of 5mm.
The side panels will have to be fitted prior
to boiler mounting.
7087
DIMENSIONS IN MILLIMETRES Diagram 2.1
2.1 Location
This boiler must be installed in accordance with the rules in
force in the countries of destination.
This boiler is not suitable for fitting outside.
Any electrical switch must be positioned so that it cannot be
touched by a person using the bath or shower.
The boiler must be mounted on a flat wall which is sufficiently
robust to take its weight, refer to Table 1, “Data”.
If the location of the boiler or any part of the system is subject
to severe cold weather conditions, it is recommended that a
frost thermostat is fitted. Any part of the system that may be
vulnerable to freezing must be protected.
2.2 Boilers in a compartment
Wheretheinstallationoftheboilerwillbeinanunusualposition,
the current issue of BS6798 gives detailed guidance on these
requirements.
Anexisting cupboard orcompartment modified forthe purpose
may be used, providing minimum clearances are maintained.
Detailsofessentialrequirementsfor cupboardorcompartment
design are given in the current issue of BS6798.
The door way opening should be of sufficient size to allow for
easy removal of the boiler.
Where the boiler is fitted in a cupboard or compartment,
permanent ventillation is not required.
Any existing compartment air vents must not be removed or
blocked off.
2.3 Clearances
The boiler should be positioned so that at least the minimum
operationalandservicingclearancesareprovided,seediagram
2.1. Additionalclearancesmayberequiredaroundtheboilerfor
installation.
2.4 Timber Frame Buildings
If the boiler is to be installed in a timber frame building it should
be fitted in accordance with the Institute of Gas Engineers
documentIGE/UP/7/1998. Ifindoubtseekadvicefromthelocal
gas undertaking or Hepworth Heating Ltd.
2 Boiler Position

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221873B
3 Flue andVentilation
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
UNDER CAR PORT etc.
H,I
JD
F
K
MINIMUM
SPACING
2816
Diagram 3.1
MINIMUM SITING DIMENSIONS FOR
FANNED FLUE TERMINALS
POSITION mm
A DIRECTLY BELOW, ABOVE OR HORIZONTALLY
TO AN OPENING, AIR BRICK,
OPENING WINDOWS, AIR VENT OR ANY OTHER
VENTILATION OPENING. 300
B BELOW GUTTER, DRAIN/SOIL PIPE 25
C BELOW EAVES 25
D BELOW A BALCONY 25
OR CAR PORT 200
E FROM VERTICAL DRAIN PIPES AND
SOIL PIPES 25
F FROM INTERNAL OR EXTERNAL
CORNERS 25
G ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
H FROM SURFACE FACING THE
TERMINAL 600
I FACING TERMINALS 1200
J FROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
K VERTICAL FROM A TERMINAL 1500
L HORIZONTALLY FROM A TERMINAL 300
TERMINAL GUARD TYPE K3
SUPPLIED BY :
Tower Flue Components Ltd.
Morley Road
Tonbridge
Kent
TN9 1RA
3.1 General
The flue must be installed in accordance with the rules in force
in the countries of destination.
3.2 Terminal Position
The minimum acceptable siting dimensions for the terminal
fromobstructions, otherterminalsand ventilationopenings are
shown in diagram 3.1.
The terminal must be exposed to the external air, the position
allowing free passage of air across it at all times.
Carportorsimilarextensionsofaroofonly,orroofandonewall,
require special consideration with respect to any openings,
doors, vents or windows under the roof. Care is required to
protect the roof if made of plastic sheeting. If the car port
comprisesof aroofand twoor morewalls seekadvicefrom the
local gas undertaking before installing the boiler.
Iftheterminal is fittedwithin 600mm below plasticguttering, an
aluminium shield 1500mm long should be fitted immediately
beneath the guttering or eaves. If the terminal is fitted within
450mm below painted eaves or a painted gutter, an aluminium
shield 750mm long should be fitted immediately beneath the
guttering or eaves.
3.3 Flue Options
There are various flue systems to choose from, as follows:
Easyfit Top Outlet Flue Pack - Pt.No. 232057
Standard Rear Outlet Flue Pack - Pt.No. 230482
Extended Top Outlet Flue Pack - Pt. No. 230487
1 Metre Extension Kit - Pt. No. 230484
Optional Wall Liner Kit No. 900862
A Flue Bend Kit or Vertical Flue Kit can be supplied, see
Hepworth Heating "Flue Options Guide" for configurations
available.
45oFlue Bend Pack - Pt. No. 230485
90oFlue Bend Pack - Pt. No. 230486
In Line Flue Adapter Kit - Pt. No. 230488
Vertical Flue Kit No. 458115
3.4 Internal Access Flue
All flue assemblies are designed for internal installation, given
that there is sufficient clearances opposite to the flue for the
installation of the flue.
If there is insufficient clearance the flue can be installed from
outside.
For a wall thickness up to 300mm, provided that there is
sufficient space and the optional wall liner kit is used, the flue
can be installed from the inside.
For a wall thickness of over 300mm the external flue hole will
need to be made good from the outside, this also applies if you
use the flue kit without the optional wall liner kit, irrespective of
wall thickness.
3.5 Terminal Guard
A terminal guard is required if persons could come into contact
with the terminal or the terminal could be subject to damage.
If a terminal guard is required, it must be positioned to provide
aminimumof50mmclearancefromanypartoftheterminaland
be central over the terminal.
The guard should be similar to that shown in diagram 3.1 .
3.6 Room Ventilation
Ventilation must be provided in accordance with the rules in
forceinthe countries ofdestination. Theboiler is room sealed,
sowherethe boiler isfitted in aroom or space,apermanent air
vent is not required.
3.7 Cupboard/Compartment Ventilation
If the boiler is to be fitted in a cupboard or compartment. Refer
to Section 2.2.

11 221873B
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 5 10 15 20 25 30
Circuit flow rate (l/min)
Remaining conveying capacity (m H2O)
0
10
20
30
40
50
60
∆t (°C)
Dt at 100000 btu output
Dp (M H2O)
4.1 General Notes
The boiler is intended for use in a sealed system only.
4.2 Safety Valve
The safety valve is an integral part of the boiler.
It cannot be adjusted but has a manual test device.
4.3 Pressure Gauge
A pressure gauge is incorporated into the boiler to indicate the
system pressure.
The gauge has a cold fill set pointer.
4.4 Pump
The circulation pump is integral with the boiler.
The remaining circulating pressure head available from the
boiler is shown in diagram 4.1, Saunier Duval pump.
4.5 Expansion Vessel
The boiler has an integral expansion vessel with a capacity of
6 Litres. If the system water content exceeds the maximum
quotedinTable1,Data,anadditionalvesselshouldbeconnected
intothesystemascloseaspossibletothecentralheatingreturn
connection of the boiler, see diagram 4.2.
Thechargepressureshall notbelessthat thestaticheadatthe
point of connection, that is, the height of the top point of the
system above the expansion vessel.
4.6 Flow Rate
A valve must be incorporated in the main flow or return of the
system, valve “A”shown in the flow diagram 4.2. This valve
must be lockable and positioned so that inadvertent closure or
unauthorisedinterferenceisnotpossible. Thedesigndifferential
canbebetween11°C(20°F)and17°C(30°F),dependentupon
the system resistance and the available pump head.
Diagram 4.1
4 Heating System
4.7 Bypass
The bypass is an integral part of the boiler.
4.8 Filling Sealed Systems
An optional extra filling loop is available Part No. 457120
Provision for filling the system at a low level must be made.
Three methods of filling are shown in diagram 4.3.
There must be no permanent connection to the mains water
supply, even through a non-return valve.
NOTE:Itisimportantthatfittingsusedforconnectiontopotable
water comply with the water undertakers requirements.
4.9 Corrosion Inhibitor
If an inhibitor is to be used in the system, contact the inhibitor
manufacturer so that they can recommend their most suitable
product.
When fitting the boiler into an existing system, special care
should be taken to drain the entire system, including radiators,
thenthoroughly cleaning outbeforefitting theboilerwhether or
not adding an inhibitor.
4.10 Draining
A draining tap must be provided at the lowest points of the
system, which will allow the entire system to be drained. An
additional draining tap MUST be fitted close to the boiler.
The flow and return isolation valves are provided with drain
points for boiler heat exchanger drainage.
7486

12
221873B
BOILER
DOMESTIC
WATER
HOT
COLD SUPPLY
FILLING
POINT
OPTIONAL FILLING
KIT AVAILABLE
No. 457120
DRAIN
POINT
’A’
FLOW
CONTROL
VALVE
HEATING
CIRCUIT
RETURN
ADDITIONAL
EXPANSION
VESSEL
(if required)
Diagram 4.3
METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
HEATING
SYSTEM
TEMPORARY
HOSE
HOSE
UNIONS SERVICING
VALVE
SUPPLY
PIPE
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HEATING
SYSTEM
SERVICING
VALVE
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS DOUBLE CHECK
VALVE ASSEMBLY
OVERFLOW
CISTERN
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
PRESSURE
REDUCING
VALVE
3132
6951
Diagram 4.2
4 Heating System
5.1 General
Thedomestic hot waterservice mustbe in accordancewith the
rules in force in the countries of destination.
5.2 Water Pressure
For the minimum and maximum working pressures of the
domestic hot water circuit of the boiler refer to diagram 1.2.
If the cold water supply pressure exceeds the maximum, a
governor must be fitted in the supply to the boiler to reduce the
pressure to within the limits given.
ALTERNATIVE METHODS OF FILLING
5.3 “Hard”Water Areas
In areas where the water is “hard”, more than 200mg/litre, it is
recommended that a proprietary scale reducer is fitted in the
coldwatersupplytotheboiler. Consultthelocalwatercompany
for additional advice.
A double check valve assembly must be fitted upstream of the
scalereducer. Fortherelativepositionofthescalereducerand
pressurereducingvalve,ifrequired,refertothemanufacturer’s
instructions.
5 Domestic Hot Water System

13 221873B
Diagram 6.1
6956
GAS
SERVICE
COCK
HOT
WATER
OUT
COLD
WATER
SUPPLY
IN
HEATING
FLOW HEATING
RETURN
LEVER (OPEN)
COLD WATER
SUPPLY IN/OUT
SLOT (OPEN)
GAS SERVICE
COCK
LEVER (OPEN)
HEATING
FLOW/ RETURN
SAFETY DISCHARGE PIPE
ROUTING POSITION
The installation requires the following components :-
1. Plumbing jig Carton
2. Boiler Carton
3. Flue Pack
6.1. Plumbing Jig
Remove from the wall template, then follow the instructions
given on the template.
Note:Leaving theservice cockbracket(lower jig)fixing screws
loose will make the fitting of the boiler service elbows on to the
servicecocks easier. Once theserviceconnections are made,
tighten service cock bracket (lower jig) fixing screws. It is
important that the wall hanging bracket and the service cock
bracket(lowerjig)arefittedtoaflatandtruewallareaforcorrect
alignment with the boiler. If this cannot be achieved it is
acceptable to pack out the service cock bracket (lower jig) to
obtain the correct alignment with the wall hanging bracket.
6.2 Gas Connection
Provision is made for the gas supply to be connected from
below the boiler, see diagrams 1.1 and 6.1 for position.
Refer also to “Gas Supply”, Section 1.7.
Makethegas supply connectionto the gas servicecock. While
making the connection, do not subject the gas service cock to
heat as you may damage the seals.
6.3 Water Connections
Provision is made for the domestic cold water inlet to be
connected from below or through an internal wall at the rear of
the boiler, see diagram 1.1 and 6.1 for position.
Refer also to Section 5 “Domestic Hot Water System”.
Provision is made for the water connections to be connected
from below or from above, passing down either side of the
boiler. Take care that any pipework connected from above will
clear the expansion vessel. Refer to the wall template. If
connecting from above a vertical piping kit 457160 is available
and is recommended.
NOTE:Top rearflue outletisnot possiblewith averticalpiping
kit.
If necessary, temporarily fit the boiler.
Flush out the domestic water and heating system before
connecting the boiler.
Make the connections to the domestic hot water outlet and the
heating system by means of the isolating valves, see diagram
6.1.
While making the connections. Do not subject any of the
isolating valves to heat as you may damage the seals.
Make sure that the drain and operating screw heads on the
isolating valves are accessible.
6 Installation Preparation and Gas / Water Connections
6.4 Safety Valve Discharge
WARNING. Itmustnotdischargeaboveanentranceorwindow
or any type of public access area.
A short discharge pipe is supplied loose with the boiler, which
when fitted to the safety valve, will end below the boiler the
position is next to the heating return, for position see diagram
6.1.
This must be extended, using not less than 15mm od metal
pipe, to discharge, in a visible position, outside the building,
facingdownwards,preferablyoveradrain. Thepipemusthave
a continuous fall and be routed to a position so that any
dischargeofwater,possiblyboiling,orsteamcannotcreateany
danger to persons, damage to property or external electrical
components and wiring.
Note. Toeasefutureservicingitisadvisabletouseacompression
type fitting to extend the discharge pipe.

14
221873B
7 Flue Preparation
Diagram 7.1
9360
TOP OUTLET/
REAR FLUE
TOP OUTLET/
SIDE FLUE
15mm
VIEW 'B'
VIEW 'B'
15mm
EASYFIT/EXTENDEDTOP OUTLET FLUE PACK & 1 METRE EXTENSION KIT
SCREW
& TAPE
SCREW
& TAPE
SCREW
& TAPE
9359
SCREW
& TAPE
3 x 1 metre extension kits may be joined together.
NOTE: REMOVE HEAT EXCHANGER BAFFLE OVER 2.5M.
FLUE LENGTH
MAX 840mm (extended)
MAX 570mm (easyfit)
FLUE LENGTH
MAX 840mm (extended)
MAX 570mm (easyfit)
15mm
SCREW
& TAPE
239mm*
54mm*
TOP OUTLET FLUE PACK
'X'
SIDE FLUE
EXTENDED
'X' plus 254mm (RH) = flue length
'X' plus 10mm (LH) = flue length
EASYFIT: 'X' plus 282mm (RH) 'X' plus 38mm (LH) = flue length
'Y'
'X'
15m
m
SCREW
& TAPE
'Y'
EXTENDED 'Y' plus 69mm = flue length
EASYFIT 'Y' plus 97mm = flue length
'Y'
FLUE LENGTH
510mm MAX.
15mm
80mm
REAR OUTLET FLUE PACK
SCREW
& TAPE SCRE
W
& TAPE
FOAM
SEAL
5mm*
'Y' plus 95mm = FLUE LENGTH
'Y'
80mm
REAR OUTLET FLUE PACK & 1 METRE EXTENSION KIT
FOAM
SEAL
'Y' plus 95mm = FLUE LENGTH
2 x 1 metre extension kits may be joined together.
EXTENDED
'X' plus 254mm (RH) = flue length
'X' plus 10mm (LH) = flue length
EASYFIT
'X' plus 282mm (RH) = flue length
'X' plus 38mm (LH) = flue length
(must include 50mm min.
side clearance)
REAR FLUE
EXTENDED 'Y' plus 69mm = flue length
EASYFIT 'Y' plus 97mm = flue length
*EXTENDED flue only
EASYFIT
REAR
SIDE R.H.
SIDE L.H.
TOP EXTD.
REAR
SIDE R.H.
SIDE L.H.
REAR STD.
REAR 75 170 510 415 -
MINIMUM
WALL
THICKNESS
MINIMUM
FLUE
LENGTH
MAXIMUM
FLUE
LENGTH
"Y"
BOILER MOUNTING FACE
TO EXTERNALWALL FACE
"X"
BOILER CASINGTO
EXTERNALWALL FACE
MAXIMUM DISTANCE FROM
144
334
90
500
-
-
-
316
560
75
75
75
75
75
75
144
334
90
840
840
840
770
-
-
-
586
830
570
570
570
FLUE
PACKS
NOTE :
IF IT IS NECESSARY TO CUT THE DUCTS
TO ACHIEVETHE "FLUE LENGTH" MAKE SURE
THAT THE OVERLAPS ARE AS FOLLOWS :-
THE OVERLAP FOR AIR DUCT = 25mm
THE OVERLAP FOR FLUE DUCT = 50mm
THE MAXIMUM LENGTHS CAN BE INCREASED
BY AN ADDITIONAL 2 METRES WITH THE USE
OF THE 1 METRE EXTENSION KITS.
NOTE :THIS APPLIES TO STANDARD KITS ONLY.

15 221873B
7.1 Flue Position and Length
Determine flue application, length and terminal position before
starting.
Refer to diagram 7.1.
Note: The Easyfit Top Outlet Flue Pack and the Extended Top
OutletFluePackcontainsa flueductextensionpiececomplete
with "O" rings, this should be discarded.
Ifyou areusing aFlue Bendor aVertical FlueKit, pleasefollow
the instructions supplied with the kit.
To make a neat finish to the flue outlet a flue collar kit, part No.
443286, with instructions, is available, see diagram 7.2.
Note: If required an optional wall liner kit, part no. 900862, is
available complete with instructions.
7.2 Flue Assembly
Extend the telescopic flue to the required length, making sure
thattheminimumoverlapisnolessthan25mm,andthattheflue
terminalprojects15mmminmumbeyondwallface,seediagram
7.1.
Carefully drill though air duct pilot hole and secure with self
tapping screw provided in fittings pack, see diagram 7.1.
Seal the joint with the tape provided.
If the flue system requires the addition of flue extension kits,
drill,sealand secure themwiththe self tapping screwand tape
provided.
Note: Should any one of the flue sections require cutting to
obtain desired flue system length, cut at the end opposite the
expanded end.
Ifthe boiler isnot to befitted for sometime cover thehole in the
wall.
7.3 Internal Access Flue
Ifaccess totheoutsidewallisnotpractical, theflue systemcan
be installed from inside. Use of the optional wall liner kit is
required.
7.4 Rear Outlet Flue Fixing
Fittheselfadhesivefoam sealprovidedintheflue packaround
the air duct at the position shown in diagram 7.1.
Makegoodaroundtheflueoutsideafterinstallationoftheboiler.
Important:Ifthewalllinerkitisused,theselfadhesivefoamseal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 7.3 for position of self
adhesive seal.
7.5 Top Outlet Side or Rear Flue Fixing
Make good the area around the flue inside and outside after
installation of the boiler.
Important:Ifthewalllinerkitisused,theselfadhesivefoamseal
included in the wall liner kit must be used in place of the one
supplied with the flue pack, see diagram 7.3 for position of self
adhesive seal.
7.6 Flue Positioning
Push the flue assembly into and through the hole such that it is
withinthewall,anddoesnotstickoutintotheroom. Donotpush
theflueassemblytoofarintotheholeasithastobepulledback
into the boiler and secured
Diagram 7.2
7148
OPTIONAL
FLUE
COLLAR
Diagram 7.3
FOAM SEAL
FOAM SEAL
WALL THICKNESS-
OVER 300mm
15mm
WALL THICKNESS-
UP TO 300mm
Q-35mm
Q
Q
7102
WITH WALL LINER KIT ONLY
7 Flue Preparation

16
221873B
8 Mounting the boiler
7011
Diagram 8.2
COMBUSTION
CHAMBER PANEL
RETAINING
LUG (4)
6984
Diagram 8.3
AIR
PRESSURE
TUBE (3)
ELECTRICAL
CONNECTIONS
RETAINING LIP
AT REAR
Pull
Forward
FAN
TRANSIT
SCREW (2)
RED
CLEAR
8.1 Boiler Mounting
Remove the inner case front, secured by two clamps at the
bottomliftup andunhookfrom thethreadedlugs atthetop,see
diagram 8.1.
Remove the combustion chamber panel transit screws, see
diagram 8.2. (It will not be necessary to refit these).
Slide the combustion chamber panel upwards to disengage
from the retaining lugs, pull forward to remove, see diagram
8.2.
Remove the fan electrical connections by pulling the plastic
boots not the wires. Remove the tubes from fan, noting the
colour tubes positions. see diagram 8.3.
Removethefanandfluecollectorassemblybypullingitforward
see, diagram 8.3.
Remove the rear outlet restrictor plate and retain if using the
rear flue outlet, see diagram 8.4.
REARFLUEONLY Fitthefluespigotsuppliedseperately,see
diagram 8.5.
TOP FLUE ONLY Remove the blanking plate from the top of
the boiler and use to blank the hole where the rear restrictor
plate (discard) was fitted.
Note: Shouldthe sideclearances beless than30mm. It willbe
necessary to fit the side panels before mounting the boiler.
Refer to Section 10.10 for fitting.
Remove the protective caps from the boiler water pipes.
Fit the sealing washers (supplied in the fittings pack) to the
boiler water pipes by inserting them into the tubing nuts (the
nipples on the washers will hold them in position), see diagram
8.8.
Lift the boiler into position on the top mounting brackets use
hand holes provided, see diagram 8.6.
Diagram 8.1
6965
INNER CASE
FRONT
SECURING
CLAMP (2)
THREADED
LUG (2)

17 221873B
8.2 Water and Gas Connections
Locate the boiler water pipes and gas supply pipe making sure
the washers are retained in the tubing nuts onto the isolation
valves, fully push the boiler back, see diagram 8.8.
Ensure the bottom boiler bracket is sitting on top of the service
cock bracket, see diagram 8.6.
Secure all the tubing nuts finger tight, plus 3/4turn maximum.
Connect the gas pipe to the isolation valve ensuring that the
sealing washer (supplied fitted) is in position.
8.3 Boiler Securing
Secure the boiler to the service cock bracket with the screws
provided in the fittings pack, see diagram 8.6.
An anti theft kit is available, Kit No. 457110.
8.4 Discharge Pipe
Fittheshortdischargepipetothesafetyvalveusingthenutand
sealing washer supplied in the fittings pack, see diagram 8.9.
Extendthedischargepipe,usingonlyacompressiontypefitting
tojointhedischargeextension,referalsotoSection6.4“Safety
Valve Discharge”.
8 Mounting the boiler
7303
Diagram 8.4
RESTRICTOR
PLATE
7304
Diagram 8.5
FLUE
SPIGOT
SECURING
SCREW (3)
AIR PRESSURE
SWITCH
SECURING
SCREW (3)
Diagram 8.6
SECURING SCREW
6955
TOP MOUNTING
BRACKET
BOILER
RETAINING LUG
SERVICE COCK
BRACKET
BOILER BRACKET
(On Top)
HAND
HOLES
GASKET

18
221873B
Diagram 8.10
AIR
DUCT
FLUE
SPIGOT
TAB (2)
CUTOUT (2)
7305
8.6 Top Outlet Side or Rear Flue Fixing
Position the restrictor plate supplied in the loose items pack,
betweentheflueelbowandboiler, (gasketfacingupwards). Fit
the flue elbow to the restrictor plate and top of the boiler using
the four screws supplied, see diagram 8.7.
Tighten the four screws of the flue elbow evenly to ensure a
good seal at the gasket.
Note:Itisimportantthecorrectrestrictorplateisfittedoromitted
where instructed.
For top flue outlet be sure to use the correct restrictor plate, all
restrictors are supplied with the appliance, see restrictor table.
7022
Diagram 8.9
UNION CONNECTION
DISCHARGE
PIPE
8 Mounting the boiler
SAFETY
VALVE
DISCHARGE
8080
Diagram 8.8
FITTED TO HYDRO BLOCK
SERVICE
COCKS (4)
GAS SUPPLY
SEAL
PRESSURE
GAUGE
CONNECTION
DISCHARGE
PIPE
7405
Diagram 8.7
8.5 Rear Outlet Flue Fixing
Make sure that the ductings do not slope down towards the
boiler.
Fittheair duct into the fluespigotby pulling the air ductintothe
flue,locatingcutouts. Turntheairductanti-clockwisetolockthe
tabs into the cutouts, see diagram 8.10.
Refit the restrictor plate that was supplied fitted & marked as
Restrictor Table below.
Fit the flue connecting sleeve onto the fan, see diagram 8.11.
Fit the fan to the flue ducting, see diagram 8.11.
Fit the fan and flue collector the electrical connections and air
pressure tubes to the fan.
Refit the combustion chamber panel.
Make the outer wall weatherproof. A Flue Collar Kit Part No.
443286 is available.
RESTRICTOR
/ GASKET
FLUE ELBOW
(REAR FLUE
SHOWN)
SECURING SCREW (4)
PRODUCTS
PROBE
SEALING
WASHER (4)
(INSERT INTO
TUBING NUT)

19 221873B
7308
Diagram 8.11
FAN
FLUE
DUCTING
FLUE
CONNECTING
SLEEVE
8 Mounting the boiler
7404
Diagram 8.12
7307
Diagram 8.13
7306
Diagram 8.14
FAN
FLUE
DUCTING
FLUE
CONNECTING
SLEEVE
Push
to fit
FAN
FLUE
CONNECTING
SLEEVE SECURING
SCREW
RETAINING
LIP
FLUE
DUCTING
FLUE
CONNECTING
SLEEVE
FLUE
COLLECTOR
RETAINING
LIP
FAN
(Push up
to fit)
AIR
PRESSURE
TUBE (2)
ELECTRICAL
CONNECTIONS
CLEAR
RED
Make sure that the ductings do not slope down towards the
boiler.
Remove the fan from the flue collector, secured with a screw
and retaining lip.
Fit the flue connecting sleeve onto the fan, see diagram 8.12.
Fitthefan totheflue ducting, Holdingitupinpositionfittheflue
collector, see diagram 8.13.
FLUE MAX FLUE RESTRICTOR MAX FLUE RESTRICTOR
OUTLET LENGTH PLATE LENGTH PLATE
CASE REAR UP TO 2.5m G N/A N/A
TOP LHS UP TO 2.5m C 2.5m TO 3.5m NON
TOP RHS UP TO 2.5m C 2.5m TO 3.5m D
TOP REAR UP TO 2.5m C 2.5m TO 3.5m D
RESTRICTORTABLE
Secure the fan to the flue collector with the securing screw and
retaining lip, see diagram 8.14.
Fit the electrical connections and air pressure tubes to the fan.
Refit the combustion chamber panel.
Make the outer wall weatherproof. A Flue Collar Kit Part No.
443286 is available.

20
221873B
9 Electrical Connections
9.1 Supply Cable Connection
CAUTION: To prevent an induced current from switching the
central heating on, when not required, it is important that the
heating system control cables are separated from the other
mains supply cables.
Openthecontrolscoverdoor.Removethetwoscrewssecuring
the controls facia, see diagram 9.1.
Hinge the control fascia open.
The boiler requires a permanant mains supply through an
external isolator which must also isolate any heating system
controls, see diagram 9.2.
Any heating system controls must not interrupt the permanent
mains supply to the boiler.
Using PVC cable of a suitable length and rating as stated in
Section 1.8 “Electrical Supply”, route the mains supply cable
andconnecttotheappropriateterminalsoftheconnectorblock,
restrain with the cable clamp supplied, see diagram 9.2.
Standard colours are, Brown - Live, Blue - Neutral, Green and
Yellow - Earth.
Make the earth cable of a greater length so that if the cable is
strained the earth would be the last to become disconnected.
CAUTION: It is ESSENTIAL to make sure that the polarity is
correct.
9.2 Heating System Controls
All external controls and wiring are required to provide a
minimumofreinforcedinsulationat250Vrmsbetweentheparts
ofthose devicesoperating atmains hazardousvoltageandthe
user accessible parts af those devices.
Note: For further information, see The Building Regulations
1991-Conservationoffueland power,1995edition-Appendix
G, table 4b.
If electrical controls are not to be used to regulate the heating
system, do not remove the red link cable.
When any form of external electrical control is being used to
regulate the heating system, remove the red link cable and
connect heating system controls in series.
The mains cable outer insulation must not be cut back external
to the plug.
9.3 Frost Thermostat
If the installation requires protection by a “frost thermostat”,
connect a single pole type, to the appropriate terminals of the
connector.
Keep all cables away from hot surfaces.
9.4 Electrical Test
Carry out preliminary electrical system checks as below:
1. Test insulation resistance to earth of mains cables.
2. Test earth continuity and short circuit of all cables
3. Test the polarity of the mains.
Refit the control fascia.
Diagram 9.1
6964
CONTROLS COVER
SECURING
SCREW (2)
CONTROLS
FASCIA
R2
R1
N
L
Diagram 9.2
7024
CABLE
CLAMP
MAINS
CABLE
SCREW (2)
GROMMET
CONNECTION
BLOCK
RED
LINK