Saunier Duval THELIA SB 23 User manual

1
THELIA
THIS IS A CAT II2H3+ APPLIANCE
01773 828100
IN WARRANTY
TECHNICAL HELPLINE
01773 828400

2
INSTALLATION AND OPERATING INSTRUCTIONS
THELIA 23, THELIA 23 E, THELIA SB 23
Mandatory warning notice for CEE countries
WARNING, this appliance was designed, approved and inspected to meet the requirements of the
English market. The identification plate located on the inside of the appliance certifies the origin
where the product was manufactured and the country for which it is intended.
If you see any exception to this rule, please contact your nearest Saunier Duval dealer.
Thank you in advance for you assistance.
Note!
The boiler serial number is marked on the label attached to the inside of the door. Refer to the
“Introduction” section page 3 for a description of the basic functions of the boiler. The “Users”
section describes how to safely operate the boiler.
Introduction .................................................. Page 3
Commisioning ........................................................ 3
Controls & lighting ................................................. 4
Operation - Checks ............................................... 5
Clock - instructions for use ............................... 6 - 8
Draining................................................................... 9
Servicing/maintenance ........................................ 9
USERS SECTION INSTALLATION SECTION
Introduction .................................................. Page 3
Technical data .............................................. 10 - 11
Dimensions ............................................................ 11
Boiler schematic ........................................... 12 - 13
Connection plate ................................................ 14
Piping system installation .................................... 15
Heating system design ........................................ 15
Hot water system design ..................................... 16
Boiler location ............................................... 16 - 17
Boiler installation .................................................. 18
Flue installation .............................................. 18 - 23
Electrical connection ................................... 24 - 25
Commissioning .............................................. 26 - 27
Operating safety devices ................................... 28
Settings ........................................................... 28 - 29
Changing gas type ............................................. 29

3
INTRODUCTION
The boilers have a fan assisted balanced flue
which both discharge the products of combustion
to and draws the combustion air from the outside
air.
The boiler is supplied for rear outlet flue connection.
Alternatively, the boiler is designed to allow the
flue system to be connected to the top of the
boiler, top outlet flue connection. Refer to the flue
fitting instructions.
The boilers can be installed on either an external
wall or on an adjacent inside wall, that is, the flue
system will pass directly to the rear or to either side
to the terminal fitted on the outside wall face.
Ancillary equipment
A range of accessories are available including, ver-
tical flue coponents, bends ....
For further information contact your supplier.
Boilers burning LPG or similar gas MUST NOT be
fitted in basements or below ground level.
The Thelia 23 and Thelia 23E range of boilers are
wall mounted combination boilers providing cen-
tral heating and instantaneous domestic hot wa-
ter.
The Thelia SB23 boiler is a wall mounted boiler pro-
viding central heating only. This boiler can be used
in combination with a hot water tank to supply
domestic hot water.
The boilers are of the II2H3+ Gas Category for use
with natural gas (G20) as distributed in the United
Kingdom or with butane or propane gas (G30/31).
These instructions should be carefully followed for
the safe and economical use of your boiler.
Once the pilot has been lit (Thelia 23 and Thelia
SB23 only) the boiler is automatic in operation.
COMMISSIONING
Gas Safety (Installation and Use) Regulations
In your interests and that of gas safety, it is the law
that ALL gas appliances are installed and serviced
by a competent person in accordance with the
above regulations.
Gas leak or fault
If a gas leak or fault exists or is suspected, turn the
boiler off and consult the local gas undertaking or
your installation/servicing company.
Boiler controls
The control panel, located at the lower front of
the boiler casing allows the boiler to be started,
shut down, controlled and monitored during use,
see diagram 2 (Thelia 23 and Thelia 23E) or dia-
gram 3 (Thelia SB23).
Flue
Do not obstruct the outside terminal of the boiler.
Note. At stand-by, the boiler fan will run at low
speed, this is quite normal.
Starting the boiler
Before starting the boiler check that:
- The gas meter tap is open. If using butane or pro-
pane, check that valve on storage cylinder or tank
is open.
- The boiler gas service cock is open.
- The boiler is connected to the electrical supply
and switched on.
- The selector lever is in the left hand position.

4
Diagram. 1
OPENING THE CONTROL PANEL COVER
CONTROLS AND LIGHTING
Hab 129
Lighting the THELIA 23 and THELIA SB 23 boilers
+
1 / ON
1 / ON
3 - Wait for
20 seconds
2 - The pilot lights.
Check that pilot
is alight by look-
ing through the
viewing window.
1 - Push in and hold
4 - Release : the
pilot must remain
ON, if the pilot
does not remain
lit, repeat the
previous steps.
bar
0 / OFF
1 / ON
0
1
2
3
4
30
50 70 90
110
21
674
5
Diagram. 3
Hab 044a
BOILER CONTROL PANEL THELIA SB 23
bar
0 / OFF
1 / ON
0
1
2
3
4
30
50 70 90
110
21
6730 4
5
BOILER CONTROL PANEL THELIA 23, THELIA 23 E
Diagram. 2
Hab 043a
Hab 130
Note : On pressing the ‘ON’ button, the fan will be heard
to run at full speed after which the ignition sequence will
start and the pilot will light.
Should the pilot fail to remain alight or go out for any
reason, intentionally or unintentionally, always wait at
least 3 minutes before trying to relight.
Lighting the THELIA 23 E boiler
1 / ON
Push in and release
The control panel, located at the lower front of the
boiler casing diag. 1 allows the boiler to be started,
shut down, controlled and monitored during use.
Control panel description (diag. 2 and 3) :
1-"ON" push - button.
2-"OFF" push - button.
4-Boiler thermostat.
5-Temperature gauge.
6-Pressure gauge.
7-Summer - Winter lever (THELIA 23, THELIA 23 E).
Summer - Winter switch (THELIA SB 23).
30 - Domestic hot water temperature
adjustment.

5
THELIA SB 23
THELIA 23, THELIA 23 E
●Hot water : Turn the
knob (diagram. 5) in or-
der to obtain a water
temperature suited to
the demand.
Reg 012
Diag. 5
Reg 012
Diag. 6
Note : If you are out for a few days, set the button
(diagram. 6) to the minimum value in order to
protect the boiler from frost. In case of prolonged
absence, refer to “Draining” section page 9.
●Heating : turn the knob
(diagram. 6) in order to
obtain a water tempera-
ture suited to the de-
mand, and adjust the
room thermostat to the
desired temperature.
HOT WATER ONLY
●Place the selector lever (diagram. 4)
to position (summer).
Heating is switched OFF. The boiler will provide hot
water only. Turn the knob (diagram. 5) in order to
obtain a water temperature suited to the
demand.
STOPPING THE BOILER
●Press the (O/OFF)
push-button (dia-
gram. 7) : this will clo-
se OFF the gas supply
valve. Electrical power
supply to the boiler will
be automatically swit-
ched OFF.
➞
Hab 133
Diag. 7
HEATING + HOT WATER
●Place the selector lever (diagram. 4)
to position (winter). In this position the domestic
hot water will have PRIORITY.
HEATING ONLY
●Turn the selector switch (diagram. 8)
to position (winter).
●Heating : turn the knob
(diagram. 9) in order to
obtain a water tempera-
ture suited to the de-
mand, and adjust the
room thermostat to the
desired temperature.
Note : If you are out for a few days, set the button
(diagram. 9) to the minimum value in order to
protect the boiler from frost. In case of prolonged
absence, refer to “Draining” section page 9.
Reg 012
Diag. 9
STOPPING THE BOILER
●Press the (O/OFF)
push-button (dia-
gram. 10) : this will clo-
se OFF the gas supply
valve. Electrical power
supply to the boiler will
be automatically swit-
ched OFF.
➞
Hab 133
Diag. 10
ALTERNATIVE OPERATING MODE THELIA SB 23
You may select the operating mode using the
switch (diagram. 8) :
Winter Heating only
Summer Domestic hot water only mode.
The boiler will keep the separate
storage cylinder, where fitted, at
the desired temperature.
Winter Heating and domestic hot water
mode
Hab 128
Diagram. 4
Hab 131
Diagram. 8
OPERATION - CHECKS

6
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
12.00
Diagram. 11
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
13.00
Diagram. 12
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
7.50
ON
Diagram. 13
The boiler is connected to the electrical supply
and switched on.
IF FITTED, SET THE CLOCK TO WORK, AS THE
INSTRUCTIONS BELOW.
General Description
The timeclock has an internal, factory set
programme which switches the boiler "On" and
"Off" three times a day as below.
1st ON 06.30
1st OFF 08.30
2nd ON 12.00
2nd OFF 12.00
3rd ON 16.30
3rd OFF 22.30
It also has an advance feature, a hold or holiday
feature, details on how to set these are given
further on in these instructions.
Setting the Time
Withtheelectrical supply to the boiler switchedon,
place the slide switch to " ".
Pressthe"Reset"(res)buttonforafewseconds,using
a pointed object, such as a pencil. When released
the display will begin to flash, see diagram 11.
Using the " "and " " buttons, set the display to
the correct time in twenty four hour format, for
example, 1300 for 1pm, see diagram 12.
Helpful Hint
The " " and " " buttons are used to change
times. Press and release for small changes. If you
press and hold down the time will "run".
To Set the Programme "On" and "Off" Times
At this stage, if you want to use the internal, factory
set, programmes simply place the slide switch to
"Auto". The display will show the current time. The
"On" or "Off" symbol will be shown according to the
time of day.
To Override or Advance the Timeclock
To advance the time clock operation, that is,
switch the heating "On" when it is "Off" or the other
wayround,pressthe"On/Off" button. Thetimeclock
will switch the heating "On" or "Off" as desired and
the "On" or "Off" symbol will flash to show that it has
been overridden. See diagram 13.
Note. The boiler will stay "On" or "Off", as selected,
until the timeclock programme reaches its next
"On" or "Off" time. From then on, the timeclock will
switch the boiler "On" and "Off" according to the
internal programme. When the boiler is again
controlled by the internal programme the "On" or
"Off" symbol will stop flashing. The timeclock
operation can be overridden in this way at any
time.
CLOCK - INSTRUCTIONS FOR USE

7
To Set Your Own Programme "On" and "Off" Times
Note. The timeclock can be set to give a minimum
of one and a maximum of three "On" and "Off"
times.
Place the slide switch to "C1". Press the "Enter"
button. The display will show the first "On" time, see
diagram 14.
Using the " " and " " buttons, change the first
"On" time to the time you require. Press the "Enter"
button twice. This stores the new time and shows
it to confirm it has been stored in the timeclock
memory.
Press the "Enter" button again. The display will
show the first "Off" time, see diagram 15.
Using the " " and " " button, change the first
"Off" time to the time you require. Press the "Enter"
button twice. The display will show the first "On"
time. Press the "Enter" button again. The display
will now show the first "Off" time you have just
entered.
Repeattheaboveforthe remaining "On" and "Off"
times.
When you have set the "On" and "Off" times you
require, place the slide switch to "Auto".
Note. If you do not want to set all three "On" and
"Off" times, follow the above instructions, but, after
you have set the times you require, set the other
timesto show a series ofdashes, using the " "and
" " button, see diagram 16.
The series of dashes are between times 23.59 and
0.00.
Helpful Hint.
If you get confused and wish to start again, press
the "Reset" (res) button and the timeclock will go
back to the internal factory set programme. You
can now reset the current time and start again.
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
6.30
ON
Diagram. 14
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
-.--
ON
Diagram. 16
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
8.30
OFF
Diagram. 15
CLOCK - INSTRUCTIONS FOR USE

8
CLOCK - INSTRUCTIONS FOR USE
To Check the Programme "On" and "Off" Times
The programmed "On" and "Off" times can be
checked at any time by moving the slide switch
from "Auto" to "C1".
Successive presses of the "Enter" button will then
show the "On" and "Off" times.
Always return the slide switch to "Auto" to return to
normal timed working.
To Set the "Hold" or "Holiday" Feature
The timeclock has a "Hold" or "Holiday" feature
which can be set, if required, to keep the central
heating "On" or "Off" for a period between one
hour and twenty seven days. This can be used, for
example to keep the central heating "Off" during
a holiday. After the programmed time has gone
by, the boiler returns to its normal programmes.
To set the "Hold" or "Holiday" feature carry on as
follows:
Place the slide switch to "Timer", the letter "h" will
appear on the display, see diagram 17.
Using the " " and " " buttons, set the “Hold”
time required.
After a hold period of twenty three hours has been
exceeded,the "h"symbolon thedisplaywill change
to a "d". The "hold" time will now be in days, instead
of hours, see diagram 18.
Use the "On/Off" button to set the boiler to the
required operation during the "Hold" period.
Place the slide switch to "Auto". After the
programmed hold time, the boiler will return to
normal timed working.
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
- H
OFF
Diagram. 17
Saunier Duval
AUTO
TIMER
C1
on
off enter
res
13
OFF
Diagram. 18

9
Protection against freezing
If the boiler is to be out of use for any long periods
during severe weather conditions, it is recom-
mended that the whole system, including the
boiler, be drained to avoid the risk of freezing.
If in doubt, consult your servicing company.
Draining and filling
Caution : the boiler is installed as part of a sealed
system which must only be drained and filled by a
competent person.
Note : If there is persistent loss of system pressure,
indicated by the pressure gauge, you must con-
tact the installer or servicing company.
Safety valve
CAUTION. A safety valve with a discharge pipe is
fitted to this boiler.
The valve MUST NOT BE TOUCHED except by a
competent person. If the valve discharges at any
time, switch the boiler off and isolate it from the
electrical supply. Contact your installation/servic-
ing company.
DRAINING
SERVICING/MAINTENANCE
To ensure the continued efficient and safe
operation of the boiler it is recommended that it is
checked and serviced at regular intervals. The
frequency of servicing will depend upon the ins-
tallation conditions and usage but, in general,
once a year should be enough
Cleaning
The boiler casing can be cleaned with a damp
cloth followed by a dry cloth to polish.
Do not use abrasive or solvent cleaners.
Boiler casing
CAUTION. Do not remove or adjust the casing in
any way, as incorrect fitting may result in faulty
operation. If in doubt contact your installation/
servicing company.

10
TECHNICAL DATA
THELIA 23
THELIA 23 E
THELIA SB 23
Heating useful output, adjustable from... (kW) 8,9 8,9 8,9
(BTU/H) 30,000 30,000 30,000
to... (kW) 23,3 23,3 23,3
(BTU/H) 80,000 80,000 80,000
Efficiency (%) 82,3 82,3 82,3
Heating max. output temperature (°C) 87 87 87
Heating regulation adjustable by user between 30 and 87°C
Heating system expansion vessel, effective capacity (l) 6,5 6,5 6,5
System max. capacity at 75°C (l) 140 140 140
Safety valve, maximum service pressure (bar) 3 3 3
Products outlet (Ø) 60 60 60
Fresh air inlet (Ø) 100 100 100
Output in hot water mode, automatically variable from... (kW) 8,9 8,9 —
(BTU/H) 30,000 30,000 —
to... (kW) 23,3 23,3 —
(BTU/H) 80,000 80,000 —
Max. hot water temperature (°C) 65 65 —
Operating threshold flow rate in sanitary hot water mode (l/min.) 3 3 —
Specific flow rate (for 30°C temperature rise) (l/min.) 11 11 —
Mini. supply pressure (bar) 0,3 0,3 —
Max. supply pressure (bar) 10 10 —
Electrical supply (V) 230 230 230
Amperage (A) 0,73 0,73 0,73
Max. power absorbed (W) 130 130 130
Ø Pilot injector (mm) 0,28 — 0,28
Ø Burner injector (mm) 1,20 1,20 1,20
Inlet pressure (mbar) 20 20 20
Gas rate (maximum) (m3/h) 2,70 2,70 2,70
Gas rate (minimum) (m3/h) 1,13 1,13 1,13
Ø Pilot injector (mm) 0,18 — 0,18
Ø Burner injector (mm) 0,73 0,73 0,73
Inlet pressure (mbar) 29 29 29
Gas rate (maximum) (kg/h) 2,01 2,01 2,01
Gas rate (minimum) (kg/h) 0,84 0,84 0,84
Ø Pilot injector (mm) 0,18 — 0,18
Ø Burner injector (mm) 0,73 0,73 0,73
Inlet pressure (mbar) 37 37 37
Gas rate (maximum) (kg/h) 1,98 1,98 1,98
Gas rate (minimum) (kg/h) 0,83 0,83 0,83
Ø Pilot injector (mm) — — —
Ø Burner injector (mm) — 2,40 —
Inlet pressure (mbar) — 8 —
Gas rate (maximum) (m3/h) — 3,88 —
Gas rate (minimum) (m3/h) — 1,63 —
Natural Gas
(G20)
Butane
(G 30)
Propane
(G31)
Town gas
(G130)

11
DIMENSIONS
OPENING THE CONTROL PANEL COVER
Hab 129
Hab 132
THELIA 23, THELIA 23 E
Net weight : 41 kg
Gross weight : 43 kg
THELIA SB 23
Net weight : 40 kg
Gross weight : 42 kg
The boiler is delivered in three separate packages :
- the boiler itself
- its connection plate
- the flue system.
Diagram. 20
378
410
857
234
623
802
TECHNICAL DATA
Burner pressure (mbar)
Pom 023
Diagram. 19
Pump
The performance of the pump, running
at maximum speed, varies according to
the pump bypass setting, see diagram
19.
5
4
3
2
1
0500 1000
Water flowrate (l/h)
by pass fully closed
by pass fully open
open 1 turn
open 3 turns
open 2 turns
Pressure loss between flow and return boiler connections (metres head)
Heat output
(kW) 8,9 10 11 12 13 14 15 16 17 18 19 20 21 22 23,3
(Btu/h) 30387 34142 37557 40971 44385 47799 51214 54628 58042 61456 64871 68285 71699 75113 79552
Heat input
(kW) 11,9 13,1 14,2 15,3 16,4 17,5 18,7 19,9 21,1 22,2 23,4 24,6 25,6 26,8 28,3
(Btu/h) 40678 44631 48410 52326 56042 59742 63794 67819 71897 75872 79910 83836 87545 91412 96602
GAS
G 20 (mbar) 1,8 2,2 2,6 3,1 3,5 4,0 4,5 5,1 5,8 6,4 7,1 7,8 8,5 9,3 10,4
G 30 (mbar) 4,1 5,0 5,9 6,8 7,8 8,9 10,2 11,5 12,9 14,4 15,9 17,5 19,1 20,9 23,3
G 31 (mbar) 5,3 6,4 7,5 8,7 10,0 11,4 13,0 14,7 16,5 18,4 20,4 22,4 24,5 26,7 29,8
G 130 (mbar) 0,5 0,6 0,7 0,8 0,9 1,0 1,2 1,3 1,5 1,7 1,8 2,0 2,2 2,4 2,7

12
BOILER SCHEMATIC
Shy 067a
Diagram. 21
THELIA 23, THELIA 23 E
ABCDF
4
30
5
6
1
2
14
21
19
3
18
17
15
16
7
8
9
10
11
13
23
22
12
20
1-"ON" push - button.
2-"OFF" push - button.
3-Spark generator.
4-Central heating water
temperature adjustment.
5-Temperature gauge.
6-Pressure gauge.
7-Summer - Winter lever.
8-Expansion vessel.
9-Pump.
10 - Automatic air vent.
11 - Burner.
12 - Heat exchanger air vent.
13 - Heat exchanger.
14 - Multi - functional control.
15 - Safety electrovalve (THELIA 23 E only).
16 - Hight limit thermostat.
17 - Ignition electrode.
18 - Pilot (not THELIA 23 E)
19 - Hot water thermistor.
20 - Flame sense electrode (THELIA 23 E only).
21 - Loss of water switch.
22 - Fan.
23 - Airflow switch.
30 - Domestic hot water
temperature adjustment.
A-Heating return
B-Cold water
C-Heating flow
D-Domestic hot water out
F-Gas inlet

13
Shy 068a
Diagram. 22
THELIA SB 23
14 - Multi - functional control.
16 - Hight limit thermostat.
17 - Ignition electrode.
18 - Pilot
19 - Hot water thermistor.
21 - Loss of water switch.
22 - Fan.
23 - Airflow switch.
A-Heating return
C-Heating flow
F-Gas inlet
1-"ON" push - button.
2-"OFF" push - button.
3-Spark generator.
4-Central heating water
temperature adjustment.
5-Temperature gauge.
6-Pressure gauge.
8-Expansion vessel.
9-Pump.
10 - Automatic air vent.
11 - Burner.
12 - Heat exchanger air vent.
13 - Heat exchanger.
ACF
4
5
6
1
2
14
21
19
3
18
17
16
8
9
10
11
13
23
22
12
BOILER SCHEMATIC

14
THELIA 23, THELIA 23 E
From left to right, the connection plate is equipped with :
THELIA SB 23
From left to right, the connection plate is equipped with :
Filters and washers :
1 - Fibre washer
2 - Metal filter
3 - Flow regulator
4 - Plastic filter
5,6 & 7- Black graphite
Filters and washers :
1 - Fibre washer
2 - Metal filter
5& 7 - Black graphite
Pla 105a
A- Heating return with isolating valve (m).
B- Cold water inlet with isolating valve (p).
C- Heating flow with isolating valve (q), drain
screw (r) and safety valve (s).
D- Domestic hot water out.
E- Electrical connector.
F- Gas service cock.
A- Heating return with isolating valve (m).
C- Heating flow with isolating valve (q), drain
screw (r) and safety valve (s).
E- Electrical connector.
F- Gas service cock.
Diagram. 23
12
3
5
67
4
55 55
57,5 57,5
r
p
q
34
25
23
113
s
33
A
B
C
D
F
E
m
CONNECTION PLATE
12
5
7
r
p
q
25
23
113
s
A
C
F
E
m
115
110
Pla 116a

15
Water connection
Connect the water pipes to the fixing jig con-
necting plate using the copper tails supplied.
Warning : To prevent damage to the isolating
cocks, do not solder joints or fittings with the cop-
per tails connected.
Safety valve discharge
WARNING. It must not discharge above an
entranceorwindoworanytypeof public access
area.
Connect the safety valve discharge pipe to the
valve, the discharge must be extended, using
not less than 15 mm o.d. pipe, to discharge, in a
visible position, outside the building, facing
downward, preferably over a drain. The pipe
must have a continuous fall and be routed to a
position so that any discharge of water, possibly
boiling or steam cannot create any danger to
persons, damage to property or external
electrical components and wiring. Tighten all
pipe connection joints.
Gas connection
●The supply from the governed gas meter must
be of adequate size to provide a constant inlet
working pressure of 20 mbar (8 in wg).
To avoid low gas pressure problems, it is
PIPING SYSTEM INSTALLATION
recommended that the supply is connected using
22 mm pipe wherever possible.
●On completion the gas installation must be tested
using the pressure drop method and purged in
accordance with the current issue of BS6891
●Connect the gas supply to the gas service cock
and then the gas service cock to the union on the
gas inlet elbow, see diagram 24.
●If it is an existing LPG installation ensure that it is
capable of providing sufficient additional quantity
of gas.
Gas Safety (Installation and Use) Regulations
In your interests and that of gas safety, it is the law
that ALL gas appliances are installed and serviced
by a competent person in accordance with the
above regulations.
Ins 016b
Diagram. 24
●The boilers are compatible with any type of
installation.
●Heating surfaces may consist of radiators,
convectors or fan assisted convectors.
Caution : if the materials used are of different
types, corrosion phenomena may develop. In
such case, adding a corrosion inhibitor in heating
system water is recommended, in the propor-
tions specified by the manufacturer, to prevent
gas and oxide formation.
●Pipe sectional areas shall be determined in
accordance with normal practices, using the
output/pressure curve (diagram. 19). The distri-
bution system shall be calculated in
accordance with the output corresponding to
the actual system demand, not the maximum
output of that the boiler. However, provision shall
be made to ensure sufficient output so that the
temperature difference between the flow and
return pipes be less than, or equivalent to 20°C.
The minimum flow is 500 l/h.
●The piping system shall be routed so as to avoid
any air pockets and facilitate permanent
venting of the installation. Bleed fittings shall be
provided at every high point of the piping system
and on all radiators.
● The total volume of water permitted for the
heating system depends, amongst other things, on
the static head in cold condition. The expansion
vessel integrated into the boiler is pressurised at 0.5
bar in the delivered condition (corresponding to a
static head of 5 m WG) and allows a maximum
volume of 140 litres for an average temperature of
75°C in the radiator system, and a maximum ser-
vice pressure of 3 bar. This pressure setting can be
modified at boiler commissioning stage if the static
head is different.
●Provision shall be made for a drain valve at
system's lowest point.
●Where thermostatic valves are fitted, not all
radiators must be equipped with this type of valve
and particulary where the room thermostat is
installed.
In the case of an existing installation, it is essential
that the radiator system be thoroughly flushed prior
to installing the new boiler.
HEATING SYSTEM DESIGN

16
DOMESTIC HOT WATER SYSTEM DESIGN
●Copper tubing must be used for the domestic
hot water system. Unnecessary pressure losses
should be avoided.
●The boiler may operate with a minimum supply
pressure of 0.3 bar, but under reduced flow rate.
Best operating comfort will be obtained from a
supply pressure of 1 bar.
●In some installations it will be necessary to pro-
vide a means of accommodating expansion
water. A domestic hot water expansion vessel
is available as an accessory from your supplier.
BOILER LOCATION
234
50
mini
29
60
255 mini
Clearances
The position of the boiler must be such that there
is adequate space for servicing.
The recommended clearances are:
50mm either side of the boiler.
600mm at the front of the boiler.
300mm below the boiler.
Fixing jig
The fixing jig is supplied in three parts :
1) The connecting plate which allows the connec-
tion and soundness testing of all the pipework
before the boiler is fitted and helps support the
weight of the boiler.
2) The hook which supports the weight of the boil-
er.
3) The template which ensures the hook and the
connecting plate are correctly fitted relative to
one another.
Place template on wall in required position mak-
ing allowance for the necessary clearances etc.
Mark the position of the holes for the hook and
the connecting plate.
Drill, plug and fix the connecting plate and hook
to the wall using suitable screws.
Check that both the connecting plate and hook
are level.
If the boiler is not installed immediately, protect
the various couplings to prevent any ingress of
foreign materials E.G. plaster, paint, etc.
Terminal position
The minimum acceptable spacings from the ter-
minal to obstructions and ventilation openings are
as shown in diagram 26.
The boiler must be installed so that the terminal is
exposed to the external air.
Note. Under certain weather conditions the flue
may produce a plume of condensation.
If the terminal is fitted within 850mm of a plastic or
painted gutter or 450 mm of painted eaves, an
aluminium shield of a minimum length 750 mm
should be fitted to the underside of the gutter or
painted surface.
Terminal guard
If a terminal guard is required, a suitable guard
with integral deflector can be obtained from your
supplier, Saunier Duval part number 85373.
Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or com-
partment as long as adequate permanent high
and low level ventilation is provided in accord-
ance with ventilation requirements.
Ins 012a
Diagram. 25

17
BOILER LOCATION
Ven 060a
NC
D
M
O
PAB
EF
G
IHL
Diagram. 26
A-under a window ........................................................................................ 600
B-under an air vent ....................................................................................... 600
C-under a gutter............................................................................................ 300
D-under a balcony........................................................................................ 300
E-from an adjacent window ....................................................................... 400
F-from an adjacent air vent ........................................................................ 600
G-from vertical or horizontal air pipes ........................................................... 600
H-from an external corner of the building ................................................. 300
I-from an internal corner of the building................................................. 1000
L-from the ground or from another floor ....................................................... 1800
M-between two terminals vertically ......................................................... 1500
N-between two terminals horizontally ...................................................... 1000
Minimum dimensions (in mm) for the positioning of flue terminals

18
The boiler is supplied for rear outlet flue connec-
tion.
Alternatively, the boiler is designed to allow the
flue system to be connected to the top of the
boiler, top outlet flue connection.
For top outlet flue installation refer to "Top outlet
flue".
Rear outlet flue - Kit 104294
The rear outlet flue system consists of two parts, a
PVC outer pipe and an aluminium inner, they are
positively locked together when assembled.
The flue kit 104294, see diagram 29, is 750 mm long
and comprises :
- Outer PVC pipe ................................................... A
- Inner aluminium pipe ........................................... B
- External rubber sealing collar ............................ C
- Rubber connecting sleeve................................. D
- Flue elbow ............................................................. E
- Internal rubber flange .......................................... F
A - Direct rear outlet flue
Mark correct position of hole from template using
hole between hook and connecting plate.
B - Rear outlet side flue
Mark the horizontal centre line for the hole on the
rear wall. Extend the horizontal centre line to the
side wall and mark the vertical centre line of the
flue hole as shown in diagram 30.
Statutory requirements
The installation of this boiler must be carried out
by a competent person in accordance with the
relevant requirements of the current issue of:
The Gas Safety (Installation and Use) Regulations
The Building Regulations
The local water company Byelaws
The Building Standards Regulations (Scotland)
The Health and Safety at Work Act
Sheet metal parts
WARNING. When installing or servicing this boiler,
care should be taken when handling the edges
of sheet metal parts to avoid the possibility of per-
sonal injury.
Installing the boiler
Prior to starting work, the system must be thoroughly
flushed with a suitable cleaning agent so as to
eliminate any foreign bodies and contaminants
such as filings, weld particles, oil, grease etc.
NOTE : solvent products could cause damage to
the system.
●Engage boiler upper part onto the retaining strip
(diagram 27).
●Allow the boiler to seat down into position onto
the support plate (diagram 28).
●Fit the filter and washers, strictly adhering to the
sequential order and directions shown on diagram
23. Connect the various couplings between the
boiler and connection plate.
BOILER INSTALLATION
➞
Diagram. 27 Diagram. 28
➞
Ins 021
Ins 020
REAR OUTLET FLUE ASSEMBLY

19
Important : when cutting the flue hole and when
extending the flue centre line to a side wall
remember that the flue system must have a fall of
about 35 mm per metre of flue DOWNWARD from
the boiler. There must NEVER be an upward incline.
From the back of the boiler, loosen the screws
holding the two flue connector clamps (diag. 31)
and slide them away from flue outlet.
Remove straight flue connector and fit elbow (E)
into rear of the boiler, fitting flush end of elbow into
position and tighten screws, see diag. 32.
REAR OUTLET FLUEASSEMBLY
Diagram. 29
E F D C B A
234
50
mini
29
60
255 mini
Diagram. 30
Cutting the flue hole
Making allowance for the slope of the flue, cut
the hole in the external wall, preferably using a
115 mm diameter core drill. If necessary, make
good at both the inner and outer surface of the
wall.
Important : before cutting the hole for flues directly
to the rear of the boiler, always cover the fixing jig
to make sure it is not damaged.
Calculation of flue cutting lengths
Measure the wall thickness e(mm).
For side flues, measure distance from inside face
of the side wall to the centre line of the boiler and
subtract 205 mm to get dimension a (mm), see
diagram 33 or 34.
Diagram 32
Diagram 31
Diagram 33 Diagram 34
ea
X
e
a
X
Pho 025 Pho 086
Pho 026
Ins 012a
Hab 208
Hab 209

20
Refer to table 1 for the cutting lengths of both the
PVC and the aluminium flue pipes for each of the
various flue options available.
Important. All cutting lengths must be measured
from the locking fitting end of the flue pipes, see
diagram 35.
Extension kits
When the distance X measured on site is greater
than given in table 1, a flue extension kit will be
required, refer to table 2.
Assembly of extended flue
The flue extension kit, see diagram 36, comprises:
- PVC pipe .............................................................A
- PVC connector ................................................... B
- Aluminium pipe with fitted connector ............ C
- Triangular pipe support ...................................... D
- Two fixing screws .............................. (not shown)
Diagram 35
Cutting length
PVC pipe
Aluminium pipe
Cutting length
Locking fitting end
Diagram 36
AB
DC
REAR OUTLET FLUEASSEMBLY
Fixing screws
Connector
Aluminium
extension
pipe
Flue option Dimension "X" N°of
extension kits
Side flue 797 to 1527 mm 1
(left) 1527 to 2257 mm 2
Side flue 739 to 1469 mm 1
(right) 1469 to 2199 mm 2
Table 2
Important : all cutting lengths should be measu-
red from the locking fitting end of the pipe.
Check before cutting. If the distance between the
end of either of the cut pipes or the pipe connec-
tor will be 30 mm or less, refer to diagram 39, it will
be necessary to reduce the length of both the PVC
and aluminium extension pipes, and those sup-
plied with the boiler, to achieve the required ove-
rall cutting length for the extended flue pipes.
Note : if the length of any aluminium pipes other
than the final extension pipes have to be redu-
ced in this way, it will be necessary to drill two fixing
holes in these pipes to match the fixing holes in
the aluminium connector.
The PVC connector is used to connect the PVC
extension pipe to the PVC pipe supplied with the
boiler or to another extension pipe, if more than
one is used. It is a secure push fit onto the pipe
ends, no adhesive is required.
The connector fitted to the aluminium extension
pipe is fitted to the next extension pipe, if more
than one is used. The two screws provided must
be used to fasten the two pieces together once
assembled, using the pre-drilled holes in both the
connector and pipe end, see diagram 37.
The triangular pipe support should be slid onto the
aluminium pipe before final assembly and positio-
ned near the pipe joint to support and locate the
inner pipe correctly within the outer PVC pipe.
Cutting lengths for extended flues
Using the correct number of the extension kits, as
table 2, assemble both the extended PVC and
aluminium pipes by adding the extension pieces
to the flue pipes supplied with the boiler. Do not
fasten the aluminium pipes together at this stage.
Mark and cut both extended flue pipes, referring
to diagram 38, using the cutting lengths given in
table 1.
Table 1
Cutting length (mm)
Flue option PVC aluminium Comments
outer pipe inner pipe
Back outlet e + 70 e + 195 maximum
Rear flue wall thickness "e"
without
extension 511 mm
Back outlet e + a + 35 e + a + 155 maximum
Side flue to left distance "X"
(diagram 5) without
extension 797 mm
Back outlet e + a + 90 e + a + 215 maximum
Side flue to right distance "X"
(diagram 6) without
extension 739 mm
Ven 083
Ven 084
Ven 085
Aluminium
flue pipe
Diagram 37