Saunier Duval Xeon 80ff Instructions For Use Installation And Servicing
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Saunier Duval Xeon 80ff Instructions For Use Installation And Servicing

Saunier Duval Xeon 80ff Instructions For Use Installation And Servicing

Fanned flue boiler (s.i.t.)
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Instructions for Use

Installation and Servicing

Fanned Flue Boiler
(S.I.T.)
This is a Cat I
Reference in these instructions to British Standards and Statutory
Regulations/Requirements apply only to the United Kingdom.
For Ireland the rules in force must be used.
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes 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.
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
In the center 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
To b e l e f t w i t h t h e u s e r
80ff
Appliance
2H

Guarantee Registration

to offer our customers' a Comprehensive First Year Guarantee.
return as soon as possible.
Service number 01773 828100.
REGISTER YOUR SAUNIER DUVAL APPLIANCE
FOR 1ST YEAR GUARANTEE PROTECTION
CALL 0208 247 9857
Customer Services:
Tel: (01773) 828100
Fax: (01773) 828070
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: (01773) 824141 Fax: (01773) 820569
221972A.11.01

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Summary of Contents for Saunier Duval Xeon 80ff

  • 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 center 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 Instructions for Use To obtain service, please call your installer or Heatcall (Saunier Introduction Duval’s own Service Organisation) using the telephone number WARNING. It is important that the case (not the controls tray) given on the controls tray. is not disturbed or removed other than for servicing by a Please be advised that the ‘Benchmark’...
  • Page 4 Instructions for Use To Light the Boiler Cleaning WARNING. Sealed Systems WARNING. This appliance contains metal parts (components) and care should be taken when handling and cleaning, with A sealed water system must be filled and pressurised by a particular regard to edges. competent person.

  • Page 5: General Data

    1 General Data WATER CONNECTIONS 22mm COPPER PIPE GAS CONNECTIONS in. BSPT) SIDE ELEVATION FRONT ELEVATION MODEL 80ff Diagram 1.1 1.1 Statutory Requirements Important Notice The installation of the boiler must be carried out by a competent This boiler is for use only on G20 gas. person in accordance with the relevant requirements of the This boiler can be used on open vented or sealed water current issue of:-...
  • Page 6 1 General Data On completion test the gas installation for soundness using the DATA TABLE 1. pressure drop method and suitable leak detection fluid, purge in accordance with the above standard. MODEL 80ff 1.6 Electrical Supply TOTAL DRY WEIGHT 51 kg (112 lb) WARNING.
  • Page 7 1 General Data 1.9 Drain System A drain tap must be provided at the lowest points of the system which will allow the entire system, boiler and hot water cylinder be drained. Draining taps should be to the current issue of BS2879. 500mm Boiler A draining point is fitted at the bottom right hand side of the heat...

  • Page 8: Flue & Ventilation

    2 Flue and Ventilation Note. Detailed recommendations for flue are given in the current issue of BS5440 Part 1. 2.1 Terminal Position The minimum acceptable siting dimensions for the terminal from obstructions, other terminals and ventilation openings are shown in diagram 2.1. The terminal must be exposed to the external air, the position allowing free passage of air across it at all times.

  • Page 9: Water Systems

    3 Water Systems The installation of the boiler must comply with the requirements of the current issue of BS6798. 1000 3.1 Frost Protection If the position of the boiler is such that it may be vulnerable to freezing it should be protected as specified in the current issue of BS5422.
  • Page 10 3 Water Systems OPEN VENTED FULLY PUMPED WATER SYSTEM FLOW RECOMMENDED RELATIONSHIP BETWEEN PUMP COLD FEED AND VENT RETURN 28mm 22mm VENT (MIN.) PIPE 450mm MIN. HEIGHT 15mm (MINIMUM) COLD FEED FEED AND EXPANSION 22 X 28 CISTERN UNION 1150mm CONNECTION MIN.

  • Page 11: Domestic Hot Water Cylinder

    3 Water Systems 3 LITRES (0.66 gals) MAKE-UP BOTTLE RELEASE (if required) POINT AUTO VENT NON-RETURN VALVE FILLING POINT IF REQUIRED 22mm (min) BY-PASS WITH LOCKSHIELD VALVE FLOW CIRCULATING SAFETY PUMP VALVE PRESSURE GAUGE RETURN DRAIN COCK (Make-up BOILER alternatives) EXPANSION VESSEL Diagram 3.4...

  • Page 12: Flue And Appliance Preparation

    4 Flue and Appliance Preparation 4.1 Unpacking If there is insufficient clearance the flue can be installed from outside. Open the carton, check the items supplied against the boiler For a wall thickness up to 300mm, provided that there is pack contents list on the flap, see diagram 4.1.
  • Page 13 4 Flue and Appliance Preparation For a wall thickness of over 300mm the external flue hole will need to be made good from the outside. This applies also if you use the flue kit without the optional kit, irrespective of wall thickness.
  • Page 14 4 Flue and Appliance Preparation 4.7 Flue Duct Mark the duct to the length required, this length allows for expansion, see diagram 4.6 for rear flue and diagram 4.7 for side flue, then cut square and remove any burrs. 4.8 Air Duct/Terminal Mark the duct length, see diagram 4.8 for rear flue and diagram 4.9 for side flue, then cut square and remove any burrs.
  • Page 15 4 Flue and Appliance Preparation 4.10 Rear Fitting Fit the self adhesive foam seal provided in the flue pack around the air duct/terminal at the position shown in diagram 4.13. 4.11 Side Fitting Fit the self adhesive foam seal around the air duct/terminal such that, when installed, the seal will be within the wall, see diagram 4.14.
  • Page 16 4 Flue and Appliance Preparation 4.12 Flue Assembly - Installation If the boiler is not to be fitted for some time cover the hole in the wall. On limited access installations push the flue assembly into and through the hole such that it is within the wall and does not stick out into the room, see diagram 4.12.

  • Page 17: Boiler Installation

    5 Boiler Installation 5 Boiler Preparation CONTROLS With the boiler still in the bottom tray, slide the controls tray COVER upwards and remove it as shown in diagram 5.1. Remove the front cover by undoing (and keeping) the screw and wing nuts and lifting the front cover off, see diagram 5.1.
  • Page 18 5 Boiler Installation 5.3 Water Circulation System ELECTRICAL AIR PRESSURE TUBES CONNECTIONS Complete the water connections to the boiler. CLEAR RED Fill, vent and flush the system. Check for any water leaks and put right. 5.4 Safety Valve Discharge Fit a suitable discharge pipe to the safety valve and route it to outside the building so that any discharge can be seen but will not cause injury to persons, damage to property or any electrical installation.
  • Page 19 5 Boiler Installation SCREW SIDE REAR RIGHT 2.5mm dia.drill JUBILEE CLIP DUCT EXTENSION LEFT RIGHT REAR VERTICAL SIDE LEFT DUCT EXTENSION Cutting 'MARK' lengths. Lefthand flue does not require cutting. FLUE ELBOW Diagram 5.6 5.7 Electrical Connection (REAR FLUE OUTLET ILLUSTRATED) WARNING.
  • Page 20 5 Boiler Installation Make sure that the supply cable and all external cables are secured and away from hot surfaces. FIXING SCREWS 5.10 Testing Checks to ensure electrical safety must be carried out by a competent person. After installation of the system, preliminary electrical system checks as below should be carried out.

  • Page 21: Commissioning

    6 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. OVERHEAT 6.1 All Systems SAFETY CUT-OFF Commissioning should be carried out by a competent person in accordance with the current issue of BS6798. Make sure that the system has been thoroughly flushed out with cold water without the pump in place.
  • Page 22 6 Commissioning Stick the self adhesive arrow indicator to the data label, against the rating that the boiler is going to be set to, for future reference. The arrow is in the loose items pack. Loosen the main burner pressure test point screw and connect SECURING a suitable pressure gauge, see diagram 6.2.
  • Page 23 6 Commissioning Turn the control thermostat knob fully anticlockwise to “O”. Remove the pressure gauge from the test point and refit screw, SEAL making sure a gas tight seal is made. SIDE When the control thermostat is turned to the “Off” position, by SEAL hand, wait at least 30 seconds before turning “On”...

  • Page 24: Instructions To The User

    7 Instructions to the User Instruct and demonstrate the safe and efficient operation of the It is the Law that servicing is carried out by a competent person. boiler, heating system and domestic hot water system. Advise the user of the precautions necessary to prevent damage Advise the user, that to ensure the continued efficient and safe to the system and building in the event of the heating system operation of the boiler it is recommended that it is checked and...
  • Page 25 8 Servicing Remove the securing screw from the burner support bracket, see diagram 8.4. Remove the main burner from the main injector at the rear. Raise the burner up and forwards, easing the pilot pipe down, to clear, take care not to damage the combustion chamber insulation or the pilot p[pipe.

  • Page 26: Fault Finding

    9 Fault Finding 9.1 Electrical 9.2 Electrical Supply Failure Important. On completion of the Service/Fault Finding task Failure of the electrical supply will cause the burner to go out. which has required the breaking and remaking of the electrical Operation will normally resume on restoration of the electrical connections the earth continuity, polarity, short circuit and supply.
  • Page 27 9 Fault Finding Before detailed checking of electrical components ensure that remote controls are calling for heat. Check the gas supply is free of obstructions and purged of air. Check the overheat cutoff has not operated. For fully pumped systems only. Isolate the electrical supply and physically check ALL cables, connections and the printed circuit board fuse.
  • Page 28 9 Fault Finding Pump Overrun Operation For Fully Pumped System Only The PCB has a timed pump overrun facility. The pump should run for several minutes after remote controls have stopped calling for heat. Before using the fault finding chart ensure all wiring is correct and in good condition, the pump is not faulty and check the PCB fuse F2 Does the pump run when SL is applied ? Faulty PCB.
  • Page 29 9 Fault Finding bk BLACK or ORANGE br BROWN w WHITE BLUE PURLPLE YELLOW LINK PUMP SPARK ELECTRODE O/H CUTOFF FUSE F1 & F2 (F1A) CONTROL STAT (N/O) PRESSURE SWITCH (N/C) PILOT SOLENOID MAIN SOLENOID Remove red link between 9 and SL when fitting a time control etc (if no switch is fitted, link will make the circulation pump run constantly) AIR PRESSURE SWITCH CONNECTIONS...
  • Page 30 9 Fault Finding KEY: FULLY PUMPED OPEN - BLUE VENTED OR SEALED bk - BLACK WATER SYSTEM - BROWN g/y - GREEN/YELLOW - ORANGE - RED MULTI-FUNCTIONAL - YELLOW CONTROL - WHITE - PURPLE PRESSURE SWITCH ELECTRODE PLUG CHASSIS CHASSIS EARTH EARTH Remove red link between 9 and SL when fitting a time control etc (If no switch is fitted, link...

  • Page 31: Replacement Of Parts

    10 Replacement of Parts 10 Replacement of Parts CONTROL THERMOSTAT Note. Replacement of parts must only be carried out by a SHAKEPROOF competent person. WASHERS AND Before replacing any parts isolate the boiler from the electrical SCREWS supply and turn the gas supply off at the gas service cock, indicator slot should be vertical.
  • Page 32 10 Replacement of Parts BOILER PHIAL THERMOSTAT ELECTRICAL PLUGS POCKET ELECTRICAL SPLIT CONNECTION NO.3"YELLOW" THERMOSTAT CABLE PUMP OVERHEAT OVERRUN CUTOFF PHIAL ELECTRICAL CONNECTION OVERHEAT "WHITE" CUTOFF PHIAL CABLE DEVICE POCKET PHIAL CHASSIS EARTH CONNECTION SUPPORT IGNITION POST (4) LEAD SPLIT RETAINING CLIP MAIN...
  • Page 33 10 Replacement of Parts 10.8 Solenoid - diagram 10.3 Remove the electrical plug from the multifunctional control. Remove the securing screw and then the solenoid Assembly. RESTRICTOR 10.9 Main Burner Remove the main burner as Section 8.3. PILOT PIPE 10.10 Main Injector TUBING NUT Remove the main burner as Section 8.3.
  • Page 34 10 Replacement of Parts OPENING (INSIDE FACE OF THE BOILER FRONT COVER) MICA WINDOW RETAINING SCREW PEEL FRONT INSULATION BACKING PAPER SELF ADHESIVE ALUMINIUM FOIL GASKET Diagram 10.5 CLEAR AIR PRESSURE SWITCH TUBES SECURING SCREWS SIDE INSULATION REAR INSULATION PRESSURE SWITCH Diagram 10.4 ELECTRICAL...
  • Page 35 10 Replacement of Parts 11.1 Part Identification The key number on the diagram and the list will help to identify the part. 11.2 Ordering When ordering any spare parts please quote the number and description from the list together with the model name and serial number.

  • Page 36: Spare Parts

    11 Spare Parts Diagram 11.1 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 221972A...

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