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Saunler Dual EnviroPlus F28e SB Instructions For Use Installation And Servicing

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Instructions for Use

Installation and Servicing

F28e
G.C. No. 47-920-39
HIGH EFFICIENCY
CONDENSING COMBINATION
BOILER
F28e SB
G.C. No. 41-920-37
HIGH EFFICIENCY
CONDENSING SYSTEM
BOILER
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT
To b e l e f t w i t h t h e u s e r
2000225242A.10.03

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  • Page 1: Instructions For Use

    2000225242A.10.03 Instructions for Use Installation and Servicing To b e l e f t w i t h t h e u s e r F28e G.C. No. 47-920-39 HIGH EFFICIENCY CONDENSING COMBINATION BOILER F28e SB G.C. No. 41-920-37 HIGH EFFICIENCY CONDENSING SYSTEM BOILER Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire.

  • Page 2: Guarantee Registration

    Guarantee Registration Thank you for installing a new Saunier Duval appliance in your home. Saunier Duval appliances' are manufactured to the very highest standard so we are pleased to offer our customers’ a Comprehensive Guarantee. This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts.

  • Page 3: Table Of Contents

    Contents CONTENTS DESCRIPTION SECTION PAGE No. Important Information Appliance Introduction INSTRUCTION Draining and Filling Maintenance and Servicing FOR USE User Controls and Lighting (F28e ONLY) Optional Programmer Instructions for Use Technical Data and Dimensions General Information Heating System Design Domestic Hot Water System Design Boiler Schematic 15/16 Boiler Location, Flue and Ventilation...

  • Page 4: Important Information

    Important Information Electrical Supply Gas safety (Installation and use) Regulations WARNING: This boiler must be earthed. 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 All system components shall be of an approved type and shall accordance with the regulations.

  • Page 5: Appliance Introduction

    Important Information Safety Discharge Valve Protection Against Freezing A safety discharge valve and discharge pipe is fitted to the The appliance has a built in frost protection programme as long boiler. This valve must not be touched. Should there be any as the electricity and gas are left switched on.

  • Page 6: Draining And Filling

    Draining and Filling 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. If the boiler is to be out of use for any long periods during severe weather conditions, it is recommended that the whole system, including the boiler, be drained to avoid the risk of freezing.

  • Page 7: User Controls And Lighting

    User Controls and Lighting HEATING “ON” HEATING “OFF” 1 - ON/OFF switch 2 - Central heating temperature selector 3 - (F28e ONLY) Domestic hot water temperature control knob 4 - Pressure gauge (bar) and temperature gauge (ºC) 5 - Running lamp illuminated green when boiler is ON (fault indicated by a red flashing light) 6 - (F28e ONLY) Programmer (If fitted) Diagram 1 3.

  • Page 8: (F28E Only) Optional Programmer

    (F28e ONLY) Optional Programmer Instructions for Use General description The programmer is factory preset which switches the boiler “ON” and “OFF” up to three times a day as shown below. FACTORY PRESET TIMES 6.30 8.30 2nd ON 12.00 2nd OFF 12.00 16.30 22.30...

  • Page 9: Instructions For Use

    (F28e ONLY) Optional Programmer Instructions for Use To set the programmer ON and OFF times Note: The programmer can be set to give a minimum of one and a maximum of three ON and three OFF times. Place the slide switch to “SET”. Press the “enter”...

  • Page 10: Technical Data

    1 Technical Data Net lift weight (boiler only) (F28e 47 kg) (F28e SB 42 kg) Gross lift weight (boiler and packaging) (F28e 52 kg) (F28e SB 47 kg) Diagram 1.1 Combustion Heating Products outlet diameter 60 mm Heat input (max) NET Q 29.6 kW Fresh air inlet diameter 100 mm...

  • Page 11: General Information

    2 General Information In IE, the installation must be carried out by a competent person IMPORTANT NOTICE. and installed in accordance with the current edition of I.S.813 Where no British Standards exists, materials and equipment "Domestic Gas Installations", the current Building Regulations should be fit for their purpose and of suitable quality and and reference should be made to the current ETCI rules for workmanship.

  • Page 12: Heating System Design

    3 Heating System Design Diagram 3.1 2000225242A...

  • Page 13: Water Treatment

    3 Heating System Design • The EnviroPlus F28e and F28e SB are for use with sealed Where an additional bypass is fitted, it must be placed at least central heating systems. 1.5 metres from the appliance, see diagram 3.2. • The safety valves are an integral part of the boiler and cannot 3.2 (F28e ONLY) Filling the Sealed System be adjusted.

  • Page 14: Domestic Hot Water System Design

    3 Heating System Design METHOD 1 t onal o ler ex an on BOILER ve el Double check valve Temporary filling device remove Control immediately Drain valve after filling point Supply ra n o nt eat n METHOD 2 Diagram 3.2a BOILER TYPE CA Back flow...

  • Page 15: Boiler Schematic

    5 Boiler Schematic (F28e ONLY) Diagram 5.1 2000225242A...

  • Page 16: Boiler Schematic 5

    5 Boiler Schematic (F28e SB ONLY) Diagram 5.1a 2000225242A...

  • Page 17: Boiler Location, Flue And Ventilation

    6 Boiler Location, Flue and Ventilation 6.1 Location This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements.
  • Page 18 6 Boiler Location, Flue and Ventilation 6.3 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 a minimum of 50mm clearance from any part of the terminal and to be central over the terminal.

  • Page 19: Installation Preparation And Appliance Fixing

    7 Installation Preparation and Appliance Fixing 7.1 Unpacking of Boiler When using extension pipes with the horizontal rear flue, a core drill size of 125mm should be used to allow the extension pieces IMPORTANT: With regards to the Manual Handling Operations, to slope at 35mm/metre (2.5 ) towards the boiler.

  • Page 20: Horizontal Top Flue Preparation And Fitting

    8 Horizontal Top Flue Preparation and Fitting The standard horizontal flue is fitted onto the top of the boiler WALL THICKNESS 'X' = 75 TO 527mm using the flue adaptor. See diagrams 8.1 to 8.3 to determine whether a standard flue can be used.
  • Page 21 8 Horizontal Top Flue Preparation and Fitting 8.2 Rear Flue (LIPS POINT INWARDS) FLUE ELBOW Mark the air duct assembly and the flue duct at the lengths shown in diagram 8.4. Then cut to length, cutting square and removing any burrs. 8.3 Standard Side Flue Fit the flue spigot ‘H’, supplied with the boiler with the three securing screws to the top of the boiler.

  • Page 22: Flue Assembly

    8 Horizontal Top Flue Preparation and Fitting 8.5 Flue Assembly 8.6 Flue Attachment to Boiler, refer to Diagram 8.6. The flue assembly is an entirely push fit design. The lip seals should be fitted in the correct orientation into the Internal rear flue fitting.

  • Page 23: Vertical Flue Preparation And Fitting

    8 Vertical Flue Preparation and Fitting ROOF TERMINAL Pt.No. 85103 1M EXTENSION Pt.No. 85099 VERTICAL FLUE 45° BEND ADAPTOR KIT Pt.No. 85102 Pt.No. A2024900 FLAT ROOF WEATHER COLLAR Pt.No. 85107 90° BEND Pt.No. 85101 FIXING PITCHED ROOF BRACKET WEATHER COLLAR Pt.No.
  • Page 24 8 Vertical Flue Preparation and Fitting FITTING FLAT ROOF FLASHING FITTING PITCHED ROOF FLASHING VERTICAL ROOF TERMINAL TERMINAL FLAT ROOF FLASHING 1x90° or 2x45° ELBOWS 1 METRE EXTENTION 1 METRE EXTENSION PITCHED ROOF FLASHING Fit flat roof or pitched weather collar onto vertical roof terminal.

  • Page 25: Twin Flue Preparation And Fitting

    8 Twin Flue Preparation and Fitting TWIN FLUE 1M EXTENSION ADAPTOR KIT Pt.No.85478 (Aluminium) Pt.No.A2025000 PITCHED ROOF 0.5M EXTENSION TWIN PIPE TO WEATHER COLLAR CONCENTRIC Pt.No.85476 (Aluminium) Pt.No.85105 ADAPTOR Pt.No.85118 1M EXTENSION AIR DUCT Pt.No.85474 (Plastic) FLAT ROOF 0.5M EXTENSION AIR DUCT WEATHER COLLAR Pt.No.85472 (Plastic) Pt.No.85107...
  • Page 26 8 Twin Flue Preparation and Fitting FLUE CONFIGURATION EXAMPLE INCLUDING DIMENSIONS TO AID CUTTING AND INSTALLATION AIR DUCT 45°ELBOW TERMINAL 1000 1 METRE EXTENSION 1 METRE EXTENSION 1 METRE FLUE DUCT 90°ELBOW EXTENSION TERMINAL TWIN FLUE ADAPTOR Diagram 8.11 TWIN FLUE ADAPTOR SUPPORT BRACKET...
  • Page 27 8 Twin Flue Preparation and Fitting 90°ELBOW SEALING COLLARS 1 METRE EXTENSION (cut to fit) 90°ELBOW AIR DUCT TERMINAL SEALING COLLARS FLUE DUCT TERMINAL Diagram 8.13 1 METRE EXTENSION CONCENTRIC EXTERNAL INTERNAL HORIZONTAL CONCETRIC SEALING SEALING TERMINAL ADAPTOR COLLAR COLLAR Diagram 8.14 2000225242A...
  • Page 28 8 Twin Flue Preparation and Fitting FLAT ROOF FLASHING VERTICAL ROOF TERMINAL VERTICAL ROOF TERMINAL After installation the vertical roof terminal must be secured with a Fit flat roof or pitched fixing bracket weather collar onto SINGLE CONCETRIC vertical roof terminal. PIPE ADAPTOR Make sure a weather...

  • Page 29: Gas/Water Connections

    9 Gas/Water Connections These packs are for the (F28e ONLY) Packs supplied with the boiler 4. Pipe pack containing 1. Isolating valve pack containing Central heating pipe (2 off) Heating isolating valves (2 off) Domestic water pipe (2 off) Domestic cold water isolating valves (1 off) Gas pipe (1 off) Domestic hot water elbow (1 off) 1/2 in.
  • Page 30 9 Gas/Water Connections ISOLATING VALVE ON/OFF LEVER ISOLATING VALVE (F28e ONLY) CENTRAL DOMESTIC COLD WATER ISOLATING INLET ISOLATING ALL VALVES SHOWN IN HEATING VALVE VALVE CLOSED POSITION FLOW AND RETURN ISOLATING (F28e ONLY) (F28e ONLY) VALVES DOMESTIC TAP EXTENSION HOT WATER KNOBS (a) and (b) OUT ELBOW CENTRAL...
  • Page 31 9 Gas/Water Connections These packs are for the (F28e SB ONLY) 4. Pipe pack containing Central heating pipe (2 off) Packs supplied with the boiler Domestic water pipe (2 off) 1. Isolating valve pack containing Gas pipe (1 off) Heating isolating valves (2 off) 1/2 in.

  • Page 32: Safety Valve Discharge And Condensate Connections

    10 Safety Discharge Valve and Condensate Connections 10.1 Safety Valve Discharge SAFETY VALVE A short discharge pipe with nut and washer are supplied in a DISCHARGE pack at the bottom of the boiler packaging. Connect the discharge tube to the heating safety valve.This must be extended, using not less than 15mm o.d.

  • Page 33: Electrical Connections

    11 Electrical Connections WARNING: This appliance must be earthed. This appliance Lower the control panel. must be wired in accordance with these instructions. Any fault This boiler will operate continuously on heating as supplied, if arising from incorrect wiring cannot be put right under the terms the wire link (E), fitted between the two terminals of the heating of the Saunier Duval guarantee.
  • Page 34 11 Electrical Connections 11.2 External Controls - Mains Voltage CABLE EXIT WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS MAINS CONNECTION PLUG. CABLE Remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fittings pack and install on the STRAIN 230V control board as the following text describes.

  • Page 35: Commissioning

    12 Commissioning Please ensure the “Benchmark” logbook is completed and left with the user. The commissioning and first firing of the boiler must only be Undo cap on automatic air vent on top of boiler done by a competant person. and leave undone.

  • Page 36: Initial Lighting

    12 Commissioning 12.3 Initial Lighting 12.5 Instruct the User • Adjust heating temperature to maximum, refer to User Controls Instruct and demonstrate the lighting procedure and advise the and Lighting. user on the safe and efficient operation of the boiler. •...

  • Page 37: Servicing

    13 Servicing 13.1 General RETAINING Measurement of the products of combustion can be achieved by connection of a probe to the flue elbow or alternatively to the LUGS sample point at the base of the flue outlet pipe inside the boiler, see diagram 3.2.

  • Page 38: Servicing

    13 Servicing 13.3 Burner and Fan SECURING PLATE SCREW Refer to diagram 13.4. HEATING FLOW (Slacken pull ELECTRICAL Remove spark electrode lead, heating flow thermistor electrical forwards connections and electrical connections to the fan and gas valve. CONNECTIONS to remove) Remove gas pipe securing clip.
  • Page 39 13 Servicing 13.5 Condensate Drain FIXING Refer to diagram 13.5 and 13.6. BRACKET Remove condensate drain pipe. Slide fixing bracket forward and remove, ease condensate CONDENSATE drain down off the inlet connection. DRAIN Carefully remove the condense drain taking care not to spill any water which may be in the unit.
  • Page 40 13 Servicing Adjustment of the CO at minimum rate is very coarse so OFFSET carefully adjust the CO with the offset adjustment to 8.3%, see ADJUSTMENT diagram 13.9. Rotate the service potentiometer fully clockwise, see diagram 13.8 and recheck the maximum rate combustion, which should be 9.3% ±...
  • Page 41 13 Servicing 13.9 Draining of Boiler Heating Circuit Drain down the Heating Circuit of the boiler only, by closing the heating flow and return isolating valves, see diagram 9.1. Refer to diagram 13.12. Attach a length of hose to the drain point and open the drain valve.

  • Page 42: Fault Finding

    14 Fault Finding When trying to operate the boiler make sure that : WARNING. Always isolate the boiler from the electrical supply before carrying out any electrical replacement work. • All gas supply cocks are open and that the gas supply has been purged of air.
  • Page 43 14 Fault Finding (F28e SB ONLY) Diagram 14.1a To carry out the electrical test, gain access to the Control Box PCB, as follows: Hinge down the control box. Remove Torx screws and unhook the rear panel. For layout of PCB, see (F28e) diagram 15.1 or (F28e SB) diagram 15.1a To check components see (F28e) Table 1 or (F28e SB) Table 1a .
  • Page 44 14 Fault Finding (F28e ONLY) Table 1. (F28e SB ONLY) Table 1a. COMPONENT 10K Ω @ 25°C C.H. thermistor 24V DC accross terminals on fan, 40V dc in standby mode, see diagram 14.2. Check 3.15 AT fuse on DC fan supply. 24VDC/55 Ω...

  • Page 45: Wiring Diagram

    15 Wiring Diagram MAINS VOLTAGE HEATING CONTROLS PLUG REMOVE VOLTAGE FREE LIN 230V SWITCHED LIVE FROM O TIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS. VOLTAGE REE HEATING CONTROLS PLUG CONTROLS REMOVE THE LIN IF FITTING INTERFACE C VOLTAGE FREE OR 230V S STEM CONTROLS.
  • Page 46 15 Wiring Diagram REMOVE THE LINK WHEN USING 230V EXTERNAL CONTROLS. IF THE LINK IS NOT REMOVED THE BOILER WILL RUN CONTINUOUSLY. 230V SWITCHED LIVE INPUT CONNECTION 230V SWITCHED LIVE INPUT CONNECTION CONTROLS INTERFACE PCB (F28e SB ONLY) Diagram 15.1a 2000225242A...

  • Page 47: Replacement Of Parts

    16 Replacement of Parts 16.5 DC Fan supply 16.1 General For access, refer to section 16.1. Replacement of parts must be carried out by a competent person. Refer to diagram 16.2. Before replacing any parts the boiler should be isolated from the Unplug electrical connection from the DC fan supply.
  • Page 48 16 Replacement of Parts 16.6 Gas Control Valve For access, refer to section 16.1. Refer to section 13.3 for removal of the fan/gas control valve and silencer assembly. Remove the gas control valve and plate which is held by the three plate securing screws, see diagram 16.4.
  • Page 49 16 Replacement of Parts 16.9 ( F28e ONLY) Plate to Plate Heat 16.10 Pump (head only) Exchanger For access, refer to section 16.1. Drain the heating circuit, see section 13.8. Drain the boiler heating circuit, see section 13.8. Drain the hot water circuit, see section 13.9. Make sure that the filling loop valves are closed, then proceed Release Rhd.
  • Page 50 16 Replacement of Parts 16.11 (F28e ONLY) Expansion Vessel 16.10 Expansion Vessel For access and to hinge Rhd. side panel, refer to section 16.1. For access and to hinge R/H side panel, refer to section 16.1. Drain the boiler heating circuit, see section 13.8. Drain the boiler heating circuit, see section 13.8.
  • Page 51 16 Replacement of Parts 16.12 Safety Valve Discharge For access, refer to section 16.1. Refer to section 13.9 and drain the boiler heating circuit. Refer to diagram 16.9 Undo the safety discharge valve coupling and remove from the pipework. Remove the securing clip and withdraw the safety discharge valve.
  • Page 52 16 Replacement of Parts 16.15 (F28e ONLY) Heating Return Thermistor For access, refer to section 16.1. Refer to diagram 16.12. Remove the electrical connections from the thermistor. Remove the thermistor and retaining clip from the flow pipe. Fit the replacement thermistor using the heat sink compound supplied.
  • Page 53 16 Replacement of Parts 16.18 (F28e ONLY) Flow Sensor AIR VENT For access, refer to section 16.1. Refer to section 13.10 and drain the boiler hot water circuit. Refer to diagram 16.15. Remove the electrical connection to the flow sensor. Remove the securing clip between the flow sensor and the plate to plate heat exchanger.
  • Page 54 16 Replacement of Parts 16.21 (F28e ONLY) Three Way Valve ELECTRICAL Refer to sections 13.9 and 13.10. CONNECTIONS Remove the Reduced Pressure Zone Valve Refer to Section 16.19. Remove the electrical connection from the three way valve, see diagram 16.7. Remove the pipe assembly from between the cold water inlet isolation valve to cold water filter housing, see diagram 13.10.
  • Page 55 16 Replacement of Parts 16.25 Condense Drain RETAINING For access, refer to section 16.1. LATCHES Refer to section 13.5. 16.26 Access to Switches, User Interface and Programmer For access, refer to section 16.1. Release the front of the fascia by carefully unclipping the two retaining latches, see diagram 16.19.
  • Page 56 16 Replacement of Parts 16.32 Control Box For access, refer to section 16.1. Remove relevant plugs and connectors, refer to wiring diagrams section 15. Withdraw grommets and leads so they are hanging loose. Unthread the retaining cord and remove the control box by THREE WAY drawing it outwards away from its retaining slots, see relevant part of diagram 11.1.
  • Page 57 16 Replacement of Parts 16.35 Heat Exchanger Refer to section 16.1. Drain the boiler heating circuit, see section 13.8. Drain the boiler hot water circuit, see section 13.9. Remove the flue elbow, water and gas connections at the bottom of the boiler, any electrical connections. Lift the boiler up and off the hanging bracket, carefully lay the boiler on its back on the floor.

  • Page 58: Spare Parts

    17 Spare Parts When ordering spare parts, contact Saunier Duval service organisation using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance and serial number, to be found on the data label. If ordering from British Gas also quote the G.C.
  • Page 59 2000225242A...
  • Page 60 Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. 2000225242A...

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Enviroplus f28e

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