Saunier Duval SB30e Instructions For Use Installation And Servicing
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Saunier Duval SB30e Instructions For Use Installation And Servicing

Saunier Duval SB30e Instructions For Use Installation And Servicing

Fanned flue system boiler
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Installation and Servicing

SB30e
Fanned Flue System Boiler
G.C. No. 41 920 31
This is a Cat I
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)
Saunier Duval appliances' are manufactured to the very highest standard so we are pleased
In the centre pages are to be found your Guarantee Registration Card, which we recommend you complete and
If this card is missing you can obtain a copy or record your registration by telephoning the Heatcall Customer
Our Guarantee gives you peace of mind plus valuable protection against breakdown by covering the cost of:
All replacement parts
All labour charges
All call-out charges
One Contact Local Service

Instructions for Use

To b e l e f t w i t h t h e u s e r
Appliance
2H
Regulations, be handed to the user on completion of the installation.

Guarantee Registration

Thank you for installing a new Saunier Duval appliance in your home.
to offer our customers' a Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR SAUNIER DUVAL APPLIANCE
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Nottingham Road, Belper, Derbyshire. DE56 1JT
Tel: (01773) 824141 Fax: (01773) 820569
221872B.07.01
Hepworth Heating Ltd.,
General/Sales enquiries:

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Summary of Contents for Saunier Duval SB30e

  • Page 1: Instructions For Use

    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 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.

  • Page 2: Table Of Contents

    Important Information 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.

  • Page 3: Introduction

    Instructions for Use Introduction colours continue as follows:- The wire coloured blue must be connected to the terminal Please read these instructions and follow them carefully for the marked “N” or “Black”. safe and economical use of your boiler. The wire coloured brown must be connected to the terminal This boiler must have been installed by a competent person in marked “L”...
  • Page 4 Instructions for Use Setting Instructions for the 7 Day Digital Programmer This is a 24 hour programmer, that is 1pm is 13:00, and has two sets of 8 “ON” and 8 “OFF” daily switching actions (P1 and P2). It is fitted with a lithium battery back up which protects the programme in the event of an electrical failure.
  • Page 5 Instructions for Use To Light the Boiler When the boiler switches off, the burner will go out. The automatic lighting sequence will operate again when heat 1. Check the two isolating valves are open, the levers in line with is required. the valve body, see diagram 3.
  • Page 6 Instructions for Use Protection Against Freezing SAFETY VALVE The boiler has a 2 stage built in frost protection. Provided power DISCHARGE PIPE POSITION and gas are available and there is adequate pressure in the system, if the water temperature within the appliance falls below C approx.

  • Page 7: General Data

    1 General Data Optional flue kits are available Horizontal top outlet and Vertical. Diagram 1.1 EXTD. EASYFIT 1.1 Installation TABLE 1 Materials and equipment should be fit for their purpose and of Lift Weight 30Kgs (66Ibs) suitable quality and workmanship. Total Weight 39.5Kgs (88Ibs) 1.2 Important Notice...

  • Page 8: Gas Supply

    1 General Data 1.7 Gas Supply Thermostatic radiator valves may be installed, however they must not be fitted in a room where the room thermostat is The gas installation shall be in accordance with the rules in force located. in the countries of destination. Note: All systems must have at least one radiator not fitted with The supply from the governed meter must be of adequate size a thermostatic valve.

  • Page 9: Boiler Position

    2 Boiler Position 2.1 Location 25 ABOVE THE TOP OF THE BOILER CASE OR THE FLUE ELBOW IF FITTED 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.

  • Page 10: Flue And Ventilation

    3 Flue and Ventilation 3.1 General 3.6 Room Ventilation The flue must be installed in accordance with the rules in force Ventilation must be provided in accordance with the rules in in the countries of destination. force in the countries of destination. The boiler is room sealed, so where the boiler is fitted in a room or space, a permanent air 3.2 Terminal Position vent is not required.

  • Page 11: Water System

    The circulation pump is integral with the boiler. loop. The remaining circulating pressure head available from the boiler is shown in diagram 4.1, Saunier Duval pump. 4.9 Filling Sealed Systems Provision for filling the system at a low level must be made.

  • Page 12: Domestic Hot Water

    4 Water System ALTERNATIVE METHODS OF FILLING METHOD 1 COMBINED CHECK VALVE HEATING TEMPORARY AND VACUUM SYSTEM HOSE BREAKER BOILER SERVICING HOSE ADDITIONAL VALVE UNIONS EXPANSION VESSEL (if required) SUPPLY STOP SUPPLY VALVE PIPE METHOD 2 HEATING DOUBLE CHECK TEMPORARY SYSTEM FILLING VALVE ASSEMBLY...

  • Page 13: Installation Preparation And Gas/Water Connections

    6 Installation Preparation and Gas / Water Connections The installation requires the following components :- SAFETY DISCHARGE PIPE Plumbing jig Carton ROUTING POSITION Boiler Carton Flue Pack 6.1. Plumbing Jig Remove from the wall template, then follow the instructions given on the template. Note: Leaving the service cock bracket (lower jig) fixing screws HEATING HEATING...
  • Page 14 7 Flue Preparation EXTENDED TOP OUTLET FLUE PACK 'X' plus 254mm (RH) = flue length 'X' plus 10mm (LH) = flue length FLUE LENGTH FLUE LENGTH MAX 840mm (extended) MAX 840mm (extended) EASYFIT MAX 570mm (easyfit) MAX 570mm (easyfit) 'X' plus 282mm (RH) = flue length 5mm* 15mm 'X' plus 38mm (LH) = flue length...
  • Page 15 7 Flue Preparation 7.3 Internal Access Flue If access to the outside wall is not practical, the flue system can be installed from inside. Use of the optional wall liner kit is required. 7.4 Rear Outlet Flue Fixing OPTIONAL Fit the self adhesive foam seal provided in the flue pack around FLUE the air duct at the position shown in diagram 7.1.

  • Page 16: Mounting The Boiler

    8 Mounting the boiler 8.1 Boiler Mounting COMBUSTION Remove the inner case front, secured by two clamps at the CHAMBER PANEL bottom lift up and unhook from the threaded lugs at the top, see RETAINING diagram 8.1. LUG (4) Remove the combustion chamber panel transit screws, see diagram 8.2.
  • Page 17 8 Mounting the boiler 8.2 Water and Gas Connections RETAINING LUG 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. BOILER Ensure the bottom boiler bracket is sitting on top of the service cock bracket, see diagram 8.6.
  • Page 18 8 Mounting the boiler Note: It is important the correct restrictor plate is fitted or refitted, see restrictor table. Fit the flue connecting sleeve onto the fan, see diagram 8.11. DISCHARGE Fit the fan to the flue ducting, see diagram 8.11. PIPE PRESSURE Fit the fan and flue collector the electrical connections and air...
  • Page 19 8 Mounting the boiler RESTRICTOR TABLE FLUE OUTLET Max. flue length Restrictor Plate Max. flue length Restrictor Plate Case Rear Up to 2.5M Top LHS Up to 2.5M 2.5 to 3.5M Top RHS Up to 2.5M 2.5 to 3.5M Top Rear Up to 2.5M 2.5 to 3.5M Fit the flue connecting elbow onto the fan, see diagram 8.12.

  • Page 20: Electrical Connections

    9 Electrical Connections 9.1 Supply Cable Connection 9.4 Frost Thermostat CAUTION: To prevent an induced current from switching the If the installation requires protection by a “frost thermostat”, appliance on, when not required, it is important that the system connect a single pole type, to the appropriate terminals of the control cables are separated from the other mains supply connector.

  • Page 21: Electrical Connections

    9 Electrical Connections CONNECTION PROGRAMMER PLUG BLOCK MAIN TERMINAL CABLE BLOCK BRACKET CLAMP SCREW (2) MAINS PROGRAMMER CABLE SCREW (2) CONNECTION BLOCK PROGRAMMER BRACKET GROMMET SCREW (2) MAINS SUPPLY ROUTING MAIN TERMINAL BLOCK BRACKET Diagram 9.2 221872B...

  • Page 22: Commissioning

    10 Commissioning Commissioning must only be carried out by a competent person Check that the maximum burner pressure is 14.3 mbar +/-0.2 in accordance with the current issue of BS6798. mbar. Adjust the pressure if required by removing the screw cap and turning the maximum rate adjustment screw on the gas Please ensure the “Benchmark”...
  • Page 23 10 Commissioning 10.7 Instruct the User Instruct and demonstrate the lighting procedure, then advise the user of the efficient and safe operation of the boiler. Instruct and demonstrate the operation of any heating system controls. Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents.
  • Page 24 10 Commissioning WRAP AROUND CASE SECURING SCREWS BASE DATA LABEL CUTOUT CUTOUT Diagram 10.3 SECURING NUT (6) SIDE OUTER PANEL CASE FRONT SECURING SECURING SCREW (2) SCREW (4) Diagram 10.5 Diagram 10.4 221872B...

  • Page 25: General Data

    11 General Data Dispose of all used sealing washers, gaskets and “O” rings SPARE PARTS when renewing components. REMEMBER, When replacing a part on this appliance, use Use the new ones supplied with the replacement. only spare parts that you can be assured conform to the safety and performance specification that we require.

  • Page 26: Servicing

    12 Servicing Before replacing any of the parts removed during servicing, 12.4 Cleaning Main Burner inspect the condition of all seals and joints, renewing them as Use a vacuum cleaner or suitable brush to clean the burner necessary. thoroughly, making sure that all burner ports are clear and Check the condition of the combustion chamber insulation.

  • Page 27: Fault Finding

    12 Servicing 12.6 Spark Gap 3.5mm Check that the spark and sensing gaps are as shown in diagram 12.6. 12.7 Operational Checks Light the boiler, carry out operational checks and any necessary adjustments as described in “Commissioning” in the Installation Instructions.
  • Page 28 13 Fault Finding 13.2 Electrical Test the fuse on the main control board and renew as necessary. Fuse 1 type (2AT). If a fuse fails repeatedly or the initial fault- Preliminary electrical system checks, as outlined in a Multimeter finding checks described in Section 13.1 indicate a boiler fault, Instruction book, are the first checks to be carried out during a check the boiler electrical circuits and follow the fault finding fault finding procedure.
  • Page 29 13 Fault Finding TO TEST FOR COMPONENT OPERATION / FAILURE Power to the appliance :- Test for 230V~ across live (brown) and earth (yellow and green), 230V~ across live and neutral (blue), and zero potential across neutral and earth. Thermistor :- With the power off unplug the connector and test resistance is 10k at 25 C Differential pressure switch :- With the power off separate the in-line connector and test for continuity across male end.
  • Page 30 13 Fault Finding Boiler Fault Finding Check gas,water and electricity are available at the boiler. Before commencment of test, isolate the boiler electricity supply, ensure that the remote controls are not calling for duty. Check appliance installation and that it is mechanically correct, ensure all circuit valves are open. Refer to tests for component operation/falure for individual checks.
  • Page 31 13 Fault Finding Boiler Fault Finding Continued Does the ignition electrode Is the air pressure Replace begin to spark? switch functioning?. air pressure switch. Change P.C.B. Does the gas control valve open to Is the voltage at the Replace P.C.B. ignition rate between (5 and 7mbar)?.
  • Page 32 13 Fault Finding 13.2 Programmer ELECTRICAL If the programmer has failed it can be bypassed by disconnecting CONNECTION (2) the plug, see diagram 13.4. Gain access by removing the two screws securing the controls facia, see diagram 9.1. Hinge the control facia forward. PROGRAMMER Remove the programmer cover, see diagram 10.2.

  • Page 33: Replacement Of Parts

    14 Replacement of Parts 14.6 Boiler Overheat Cutoff 14.1 Fan Before starting refer to Section 11. Before starting refer to Section 11. Disconnect the electrical connections, unclip to remove the Disconnect the two electrical connectors at the fan by pulling the overheat cutoff, see diagram 14.3.
  • Page 34 14 Replacement of Parts 14.8 Pressure Gauge THERMISTOR GAS CONTROL CENTRAL VALVE Before starting refer to Section 11. HEATING CLIP Remove case base, see diagram 10.3. Open the controls cover door. Remove the two screws securing the controls facia, see diagram 9.1. OVERHEAT CUTOFF Hinge the control fascia open.
  • Page 35 14 Replacement of Parts SECURING SCREW CONTROL BOARD SENSING SUPPORT IGNITION LEADS Diagram 14.7 LEAD POSTS (4) MULTI PIN CONNECTORS MULTI PIN SECURING CONTROL CONNECTOR SCREWS (8) VALVE CAREFULLY BEND THE RETAINING CLIPS FORWARD TO RELEASE MULTI PIN Diagram 14.6 CONNECTORS 14.11 Pump Before starting refer to Section 11.
  • Page 36 14 Replacement of Parts Remove the clip to remove the water pressure switch, see 14.16 Hydro Block Assembly Right hand side diagram 14.10 (see diagram 14.12) Remove the plastic cover. Before starting refer to Section 11. Remove the electrical connectors. Remove the case base refer to Section 10.6 and diagram 10.3.
  • Page 37 14 Replacement of Parts 14.17 Bypass Tube Before starting refer to Section 11. Remove the two screws securing the controls cover door and controls fascia, see diagram 9.1. Hinge the assembly open. Release the water pressure and drain the boiler, refer to Section 11.3 and 11.6.
  • Page 38 14 Replacement of Parts 14.19 Expansion Vessel CENTRAL Before starting refer to Section 11. HEATING Remove all panels refer to the relevant parts of Section 10. RETURN Renewal of the expansion vessel requires the boiler to be PIPE removed from the wall. As an alternative, a separate expansion RIGHT HAND vessel of the same specification may be connected as close as possible to the boiler on the return side of the system, leaving the...
  • Page 39 14 Replacement of Parts Remove the two screws at the service cock bracket, see diagram 8.6. Ease the boiler from the isolating valves. Unhook the boiler at the top, easing the boiler from the flue outlet and lift off. Carefully lay the boiler down on its side for access to the expansion vessel.
  • Page 40 14 Replacement of Parts 14.21 Heat Exchanger 14.22 Combustion Chamber Insulation Before starting refer to Section 11. Remove outer case front as section 11.4. Unhook the combustion chamber front, see diagram 8.2. Remove the inner case front as Section 11.5. Remove the fan and flue collector, refer to Section 14.1.
  • Page 41 14 Replacement of Parts COMBUSTION CHAMBER FRONT PANEL REAR INSULATION SIDE INSULATION SIDE INSULATION FRONT INSULATION Diagram 14.21 14.23 Viewing Window Before starting refer to Section 11. MICA WINDOW Remove the old self adhesive aluminium foil gasket and the old mica window.
  • Page 42 14 Replacement of Parts AIR PRESSURE SWITCH GREY WHITE ORANGE BLUE bk- BLACK YELLOW br - BROWN PURPLE g/y- GREEN/ YELLOW THERMISTOR BOILER OVERHEAT Programmer (If fitted) CUT-OFF To System Controls PRESSURE SWITCHED LIVE DIFFERENTIAL FROM EXTERNAL MICRO SWITCH SOURCE PUMP PLUG 230V-50Hz...

  • Page 43: Spare Parts

    15 Spare Parts 15.1 Part Identification The key number in diagram 15.1 and the first column of the list will help identify the spare part. 15.2 Ordering When ordering any spare part, please quote the part number and the description from the list together with the model name and serial number information from the data label.
  • Page 44 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221872B...

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