Sauner Duval Isomax F28E
ISOMAX
IN WARRANTY
TECHNICAL HELPLINE
THIS IS A CAT I2E+ APPLIANCE
01773 828400
01773 828100
1
INSTALLATION AND OPERATING INSTRUCTIONS
ISOMAX F 28 E
Note!
The boiler serial number is marked on the label attached to the inside of the drop down 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.
USERS SECTION
Introduction .................................................... Page 3
Commissioning .......................................................... 3
Controls & lighting .................................................... 4
Control options ......................................................... 5
Draining ..................................................................... 5
Servicing/maintenance .......................................... 5
INSTALLATION SECTION
Introduction .................................................. Page 3
Technical data ...................................................... 6
Dimensions ............................................................. 7
Heating system design ......................................... 7
Domestic hot water system design ..................... 8
Boiler schematic .................................................... 8
Fixing jig .................................................................. 9
Piping system installation ............................... 9 - 10
Boiler location ...................................................... 11
Boiler installation .................................................. 12
Flue installation ............................................. 12 - 13
Electrical installation ........................................... 14
Commissioning .............................................. 15 - 18
Safety devices .............................................. 18 - 19
Settings .................................................................. 20
SERVICING SECTION
Routine cleaning and inspection ........................... Page 21 - 22
Replacement of parts ......................................................... 22 - 26
Boiler schematic .......................................................................... 27
Technical data ............................................................................ 28
Schematic wiring diagram ........................................................ 29
Fault finding ........................................................................... 30 - 32
Spare parts ................................................................................... 32
Mandatory warning for CEE countries
Warning: This appliance is 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 your assistance.
2
INTRODUCTION
The ISOMAX F boiler is a wall mounted modulating
combination boiler with electronic ignition providing central heating and stored hot water.
The installation must be carried out by a qualified
registered person in accordance with the relevant
requirements of The Building Regulations, The Water Byelaws, The Building Standards (Scotland)
Regulations and any applicable local regulations.
The boiler is of the I2E+ category for use with Natural Gas (G20) as distributed in the United Kingdom,
or Butane (G30), Propane (G31) or Towns Gas
(G130) with the appropriate conversion kit.
These instructions should be carefully followed for
the safe and economical use of your boiler.
The boiler has a fan assisted balanced flue which
both discharges the products of combustion to and
draws the combustion air from the outside of the
room.
The boiler is suitable for top outlet flue connection
only but, can be fitted with horizontal flue, vertical
flue or twin-pipe flue. Refer to flue catalogue for
further details.
Ancillary equipment
A range of flue accessories are available including vertical flues, twin-pipe flues, bends etc.
For further information contact your supplier.
Substances Hazardous to Health
The adhesives and sealants used in this appliance
are cured and give no known hazard in this state.
Both the central heating and domestic hot water
temperature are user adjustable from the boiler
control panel.
Domestic hot water demand always has priority
over heating demand.
The boiler is designed for use as part of a sealed
water central heating system with fully pumped
circulation. The pump, expansion vessel and associated safety devices are all fitted within the boiler.
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
complaints you may be susceptible to irritation. High
dust levels are usual only if the material is broken.
Normal handing should not cause discomfort, but
follow normal good hygiene and wash your hands
before eating, drinking or going to the toilet.
If you do suffer irritation to the eyes or severe irritation
to the skin, seek medical attention.
The boiler can be installed against 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.
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 qualified registered person in accordance with
the above regulations.
Overheating safety
In the event of a problem, the overheating safety
devices cause safety shutdown of the boiler. If this
happens, call your Installation/Servicing company.
Boiler controls
The control panel, located at the lower front of the
boiler casing, see diagram 1, allows the boiler to
be started, shut down, controlled and monitored
during use.
Gas leak or fault
If a gas leak or fault exists or is suspected, turn the
boiler off and consult the local gas supply company or your installation/service company.
8
7
Flue
Do not obstruct the outside terminal of the boiler.
6
5
4
3
2
1
O
1
2
3
4
5
6
7
8
-
On/Off button
Summer/Winter mode selector
Hot water temperature adjuster
Hot water set point display
Graphic display
Heating temperature adjuster
Heating set point display
Display backlight
Diagram 1
1.5 bar
I
mode
Hab 222
Air in the heating system
Persistent air in the heating system may indicate
leaks in the system or corrosion taking place. Call
your Installation/Servicing company.
3
CONTROLS AND LIGHTING
Lighting the boiler :
Make sure that:
The boiler is connected to the electrical supply.
The gas service cock is open.
Then follow the instructions below :
1
Press the On/Off button (1)
The pressure must be between 1 and 2 bar. If not, the system must be filled by a competent person.
O
I
1
Hab 264
1.5 bar
mode
To stop the boiler : Press button (1)
2
Press the sur
mode
button
select the winter
symbol
Appuyer
mode
pourto
sélectionner
la position
hiver
Appuyer
mode
pourto
sélectionner
la position
été
Press
the sur
mode
button
select the summer
symbol
1.5 bar
10 °C
mode
The
actual temperature
Température
actuelle
of
thele
heating
system
dans
circuit chauffage
The
flamelorsque
symbolleappears
Apparaît
brûleur
when
the
boiler is running
est en
fonctionnement
Adjusting the hot water temperature
Press + orsur
- to
theajuster
maximum
temperature
Appuyer
+ adjust
ou - pour
la température
of the hot de
water
(38
°C to 60sanitaire
°C)
maximale
l'eau
chaude
(38°C à 60°C)
Visual indication
set temperature
Visualisation
de laof
température
demandée
50°C
mode
Setting to the WINTER position
(Heating + hot water)
3
1.5 bar
mode
Illuminates
when
Apparaît
lorsque
le
the boiler
lights
brûleur
fonctionne
Adjusting the heating temperature
Press + orsur
- to+ adjust
the ajuster
maximum
temperature
Appuyer
ou - pour
la température
of the heating
(38°Cdu
to circuit
87°C) chauffage
maximale
souhaitée
Visual indication
set temperature
Visualisation
de laof
température
demandée
60°C
mode
To obtain domestic hot water, open a hot water tap. Hot water always has priority over central heating.
4
Hab 261
Setting to the SUMMER position
(Hot water only)
CONTROL OPTIONS
(a) Programmable room stat Part N° 40010,
(b) Isocom combined boiler control
programmable room stat part N° 85915.
&
ISOCOM
Diagram 2
DRAINING
Protection against freezing
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.
If in doubt, consult your servicing company.
The ISOMAX has a built in frost protection device
that protects the boiler from freezing. If the boiler is
to be left and there is a risk of frost, ensure that the
gas and electrical supplies are left connected. The
frost protection device will light the boiler when the
temperature of the boiler water falls below 6°C.
When the temperature reaches 16°C, the boiler
stops.
Note: This device works irrespective of any room
thermostat setting and will protect the complete
heating system.
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.
Heating safety valve
CAUTION: A heating safety valve with a discharge
pipe is fitted to this boiler.
The valve MUST NOT BE TOUCHED except by a
qualified registered person. If the valve discharges
at any time, switch the boiler off and isolate it from
the electrical supply. Contact your installation/service company.
Pressure/temperature relief valve
CAUTION: A domestic hot water pressure relief
valve, with a discharge pipe is fitted to this boiler.
The valve MUST NOT BE TOUCHED except by a
qualified registered person. If the valve discharges
at any time, switch the boiler off and isolate it from
the electrical supply. Contact your installation/service company.
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
installation 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, consult your installation/service company.
5
TECHNICAL DATA
Heating
Electrical
Heating output
Electrical supply
Maximum absorbed power
Level of protection
ajustable from 10,4 kW
to 27,6 kW
from 35,484 BTU/H
to 94,170 BTU/H
Efficiency
91 %
Maximum heating temperature
87 °C
Expansion vessel effective capacity
8l
Expansion vessel charge pressure
0,5 bar
Maximum system capacity at 75°C
180 l
Safety valve,
maximum service pressure 3 bar
Products outlet diameter
60 mm
Fresh air inlet diameter
100 mm
230 V
235 W
IP44
Natural Gas (G20)
Ø Burner injector
Inlet pressure
Maxi. Burner pressure
Mini. Burner pressure
Gas rate maximum
Gas rate minimum
1,20 mm
20 mbar
13,8 mbar
2,16 mbar
3,20 m3/h
1,32 m3/h
Hot water
Butane Gas (G30)
Hot water output, automatically variable from 10,4 kW
to 27,6 kW
from 35,484 BTU/H
to 94,170 BTU/H
Storage capacity
43 l
Maximum hot water temperature
60 °C
Minimum hot water temperature
37°C
Ø Burner injector
Inlet pressure
Maxi. Burner pressure
Mini. Burner pressure
Gas rate maximum
Gas rate minimum
2
3
4
5
Bypass fully shut
Open 1/4 turn
Open 1/2 turn
Open 1 turn
Open 2 turns
Propane Gas (G31)
Ø Burner injector
Inlet pressure
Maxi. Burner pressure
Mini. Burner pressure
Gas rate maximum
Gas rate minimum
60
1
50
2
3
40
4
5
30
20
10
0
0
200
(10 kPa = 1 m WG)
6
0,77 mm
37 mbar
30,8 mbar
3,6 mbar
2,35 kg/h
0,97 kg/h
Pom 010 a
1
Available pressure (kPa) between
heating supply and return lines
Specific flow rate (for 30°C temp rise)
13,2 l/min.
Threshold flow rate
1 l/min.
Nominal water flow rate
11,3 l/min.
Temp./pressure relief valve opening pressure
7 bar
Temp./pressure relief valve opening temperature 90°C
Cylinder heat up time
7 min.
Time to reheat 70% of storage to 60°C
3 min.
Expansion valve setting
6 bar
Maximum supply pressure
8 bar
Minimum operating pressure
0,7 bar
0,77 mm
29 mbar
23,8 mbar
3,6 mbar
2,39 kg/h
0,99 kg/h
400
600
800
1000
1200
Flow rate through heating system (I/h)
DIMENSIONS
The ISOMAX is delivered in three separate packages:
- the boiler itself
- the fixing jig
- the flue system
23
4
1
3
1
60
0
Hab322
890
Weight: 71 kg
0
48
Diagram 5
HEATING SYSTEM DESIGN
● The ISOMAX is compatible with any type of installation.
● Heating sur faces may consist of radiators,
convectors or fan assisted convectors.
● The ISOMAX can be piped directly to an underfloor heating system without the need for a mixing
bottle. The maximum central heating flow
temperature can be set to 53°C on the boiler
printed circuit board during commissioning.
● Pipe sectional areas shall be determined in accordance with normal practices, using the output/
pressure curve (diagram 4). The distribution system
shall be calculated in accordance with the output
requirements of the actual system, not the
maximum output of the boiler. However, provision
shall be made to ensure sufficient flow so that the
temperature difference between the flow and return pipes be less than or equal to 20°C. The minimum flow is 400 l/h.
● The piping system shall be routed so as to avoid
any air pockets and facilitate permanent venting
of the installation. Bleed fittings must be provided
at every high point of the system and on all radiators.
● The total volume of water permitted for the heating system depends, amongst other things, on the
static head in the cold condition. The expansion
vessel on the boiler is pressurised at 0,5 bar (corresponding to a static head of 5 m w.g.) and allows
a maximum system volume of 160 litres for an average temperature of 75°C and a maximum service
pressure of 3 bar. This pressure setting can be modified at commissioning stage if the static head differs. An additional expansion vessel can be fitted
to the system if required, see diagram 8.
● Provision shall be made for a drain valve at the
lowest point of the system.
● Where thermostatic radiator valves are fitted, not
all radiators must be fitted with this type of valve,
and in particular, where the room thermostat is installed.
● In the case of an existing installation, it is ESSENTIAL that the system is thoroughly flushed prior to
installing the new boiler.
Filling the system
A filling device must be fitted to the system to initially
fill the system and replace water lost during
servicing,see diagram 8.
7
DOMESTIC HOT WATER SYSTEM DESIGN
● Copper tubing or plastic Hep20 may be used for
the domestic hot water system. Unnecessary
pressure losses should be avoided.
● A flow restrictor limiting the flow through the boiler
to a maximum of 16 l/min is fitted to the boiler.
● The boiler will operate with a minimum supply
pressure of 0,7 bar, but under reduced flow rate.
Best operating comfort will be obtained from a supply pressure of 1 bar.
'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 cold water supply to
the boiler.
BOILER SCHEMATIC
-
Domestic thermistor
Three way valve
Gas valve
Gas valve ignition module
Temperatur sensor for accumulation vessel
Accumulation vessel
Burner
Ignition electrode
Combustion chamber
Heating safety valve (3 bar)
Main heat exchanger
Air pressure switch
Flow detector
DHW pump
Non return valve
Bypass
Domestic heat exchanger
Heating pump
Heating expansion vessel
Heating thermistor
Overheat safety thermostat
Flame sensor electrode
Fan
Domestic safety valve (6 bar)
Loss of water sensor
Domestic expansion vessel
Pressure/temperature relief (7 bar)
Domestic safety valve (10 bar)
A
B
C
D
E
D1
D2
D3
-
Heating return
Cold water inlet
Heating flow
Domestic hot water outlet
Gas
Discharge from HTG safety valves
Discharge from DHW safety valves
Discharge from temp/press (to tundish)
23
12
27
11
21
8
19
3
18
17
1
14
15
13
Diagram 6
22mm
28 mm
35 mm
up to 9 m
up to 18 m
up to 27 m
0.8 m
1.0 m
1.4 m
G 3/4
22 mm
28 mm
35 mm
42 mm
up to 9 m
up to 18 m
up to 27 m
1.0 m
1.4 m
1.7 m
G1
28 mm
35 mm
42 mm
54 mm
up to 9 m
up to 18 m
up to 27 m
1.4 m
1.7 m
2.3 m
24
2
16
A
15 mm
26
4
20
10
Valve
Minimum Minimum
Maximum
Resistance
outlet size size of
resistance
created by
size of
discharge discharge
allowed
each elbow or
to tundish pipe D2 expressed as a
bend
length of
from
straight pipe
tundish
i.e. no elbows
or bends
8
5
7
22
25
G 1/2
6
9
Shy 163cUK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
28
B
C
D E
D1
D2
D1
Discharge from HTG+
domestic prv on jig
D1
D3
D1
Discharge from DHW
safety valves
D2
D3
Tundish
Gully
Diagram 6a
FIXING JIG
The fixing jig is made up, from left to right, as follows:
A - Heating return fitting with isolating valve(v) and
drain knob (u).
B - Cold water inlet fitting with isolating valve
(m)and factory fitted flow regulator and filter (not
shown).
C - Heating flow fitting with isolating valve (q),
drain knob (r) and safety valve (10).
D - Domestic hot water outlet fitting with safety
valve (28).
E - Gas fitting.
Diagram 7
B
A
C
D
u
E
r
➜
➜
q
10
m
Pla 213
v
28
PIPING SYSTEM INSTALLATION
Heating system connections - Pipe diam. 22mm
● Hot water system connections - Pipe diam. 15mm
● Gas connection - Pipe diam. 22mm
● Domestic safety valve connection - Pipe
diam.15mm
● Heating safety valve connection - Pipe diam.
15mm
●
Water connection
Connect the copper connections supplied, to the
fixing jig fittings, see diagram 7. Connect the sys-
Domestic
water
Boiler
Return
MIX
Cold supply
H
Hot
Additional
expansion
vessel
(if required)
tem pipework to the boiler observing the correct
flow and return format as shown in diagram 8.
There are two sets of two safety valves fitted to this
appliance. Two are located on the jig diagram 7,
(10) heating safety valve 3 bar, and (28) DHW
safety valve 10 bar. The other two are located inside
the boiler (diagram 6,) (27) pressure/temperature
relief safety valve 7 bar/90°C, and (24) DHW safety
valve 6 bar.
Bypass
valve
Thermostatic
C mixing valve
Temperature
adjustment
Pressure
reducing
valve
(supplied)
Thermostaticaly
Boiler
controlled
"set temperature"
hot water
hot water
Filling device
Flow
control valve
Drain point
Sch 173a
Heating
circuit
Diagram 8
9
PIPING SYSTEM INSTALLATION
Step. 1
The internal safety valves have been tee'd together
and the discharge pipe run so that it exits at the
right hand bottom of the boiler (diagram 6) (D2).
The tundish (supplied) must be used with this outlet
within the normal guidelines and code of practice
(diagram 6a).
Step 2
Tee the domestic safety valve (diagram 7) (28)
outlet to the heating safety valve (10) outlet
together. You can either extend this pipe
horizontally to the outside wall. WARNING, It must
not discharge above an entrance or window or
any type of public access area, the discharge must
be extend using no less than 15 mm o.d. pipe to
discharge in a visible position outside the building,
facing downard preferably over a drain. The pipe
must have a continuous fall and be routed to a
position so that any discharge of water, possibly
steam, cannot create any danger to persons,
damage to property or external electrical
components and wiring.
alternatively : The discharge pipe can be tee'd into
the other discharge pipe after the tundish (diagram
6) provided that it has a continuous fall and that
provisions are made for the size of discharge pipe
immediately after the tundish (see diagram 6a).
Safety valve discharge
Domestic hot water supply options
Under normal circumstances, the domestic hot
water storage temperature inside the boiler can
be stored between 37 and 60° C. It is
recommended that the boiler storage temperature
is set by the user to the maximum of 60°C - this will
ensure a more plentiful supply of hot water.
It may be desirable to provide hot water to
separate outlets at different temperatures (for
example, to provide a limited temperature to
prevent the risk of scalding). To be able to do this,
a thermostatic mixing valve is supplied with the
Isomax boiler (factory set to 43°C) and can be fitted
during the installation procedure.
There are 2 options for the domestic hot water
supply :
1 - Piping the hot water supply without the use of
the mixing valve to provide hot water to all taps at
the same temperature.
2 - Piping the hot water supply using the mixing
valve (supplied) to provide hot water at boiler hot
water “set temperature” to one tap and
thermostatically controlled hot water to another
tap(s).
10
To pipe the hot water supply using the mixing valve,
refer to diagram 8. This shows one outlet supplying
hot water at the boiler hot water "set temperature"
and one hot water outlet at a temperature pre-set
at the mixing valve. The mixing valve can be set
between 35 and 60°C. It is recommended that the
valve is adjusted (and locked) by the installer to
the desired temperature.
The connections to the mixing valve are :
H
- Hot water supply from boiler
C
- Reduced cold water supply
MIX - Thermostatically controlled outlet
Warning : It is strongly recommended that the cold
water supply to the mixing valve is taken from the
reduced side of the pressure reducing valve
(supplied)
Note 1 : The mixing valve is fitted with two in-line
strainer, one on the hot inlet and one on the cold
inlet. For servicing details of these, refer to the
separate instructions supplied with the mixing valve.
Note 2 : The mixing valve incorporates a "rapid
failsafe" device which will automatically close the
valve to safety in the event of supply failure on
either hot or cold water.
The discharge must be extended using not less than
22 m 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 w.g.).
To avoid low gas pressure problems, it is recommended that the gas supply is connected using 22
mm pipe.
● On completion, the gas installation must be
tested using the pressure drop method and purged
in accordance with the current issue of BS6891.
●
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 qualified registered person in accordance with
the above regulations.
BOILER LOCATION
Clearances
The position of the boiler must be such that there is
adequate space for servicing.
The recommended clearances are:
20 mm either side of the boiler.
600 mm at the front of the boiler.
300 mm below the boiler.
Diagram 9
pour
(type F)
Ø 105 or
125sortie
coreventouse
drill
169
=
20 mm
mini
120
600
For horizontal flue system, mark the position for
the flue hole as follows:
●
Flue to rear of boiler
● Mark correct position of hole from template.
Flue to side of boiler
● 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 flue
hole as shown in diagram 9.
Cutting the flue hole
● Making allowance for the slope of the flue, cut
hole in external wall, preferably using a core drill.
For installations with internal and external access
use a 10 5 mm diameter core drill.
For installations with internal access only use a 125
mm diameter core drill.
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
Ins 090a
Mark the position of the holes for the hanging
bracket and jig.
● Drill, plug and fix the hanging bracket to the wall
using suitable screws.
● Check that the hanging bracket is level.
● Drill plug and fix the fixing jig to the wall.
●
=
20
● Place template on wall in required position, making allowances for the necessary clearances etc.
Note: It is permissible to install the boiler with smaller
clearances than those quoted above PROVIDING
that adequate consideration is given for Servicing/
Repairs at a later date. If any doubt exists, contact
the Saunier Duval Technical Helpline 01773 828400.
4
900
2,10 m au sol (pour les modèles type C)
65
23
per metre of flue DOWNWARD towards the terminal. There must NEVER be a downward incline towards the boiler.
Terminal position
The minimum acceptable spacings from the terminal to obstructions and ventilation openings are
shown in diagram 10.
The boiler must be installed so that the terminal is
exposed to the external air.
Should any doubt exist as to the permissible position of the terminal, contact the Saunier Duval
Technical Helpline 01773 828400.
Terminal guard
If a terminal guard is required, a suitable guard can
be obtained from your supplier, Saunier Duval part
number 85373.
Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or compartment without the need for permanent ventilation.
Minimum dimensions (in mm) for the positioning of flue terminals
-
Under a window .................................................... 300
Under an air vent .................................................. 300
Under a gutter ......................................................... 75
Under a balcony ................................................... 300
From an adjacent window .................................. 300
From an adjacent air vent ................................... 300
From vertical or horizontal air pipes .................... 300
From an external corner of the building ............ 300
From an internal corner of the building ............. 300
From the ground or from another floor .............. 300
Between two terminals vertically ...................... 1500
Between two terminals horizontally .................... 600
Diagram 10
G
N
C
E
F
M
A
B
D
I
H
L
Ven 060b
A
B
C
D
E
F
G
H
I
L
M
N
11
BOILER INSTALLATION
Statutory requirements
The installation of this boiler must be carried out by
a qualified registered 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 personal
injury.
Installing the boiler
Prior to starting work, the system must be thoroughly
flushed using a propriety cleanser such as Sentinel
X300 to eliminate any foreign matter and contamination e.g. metal filings, solder particles, oil, grease
etc.
Note. Solvent products could cause damage to the
system.
● Engage boiler upper part onto the hanging
bracket.
● Fit the washers between the boiler pipes and the
inlet and outlet fittings on the fixing jig and connect the various couplings between the boiler and
jig.
FLUE INSTALLATION
Top outlet flue - kit 85090
The boiler is only suitable for top outlet flue
connection.
Rear flue systems
The calculate the lenght when flueing to the rear
measure e (diagram 11) plus 25 mm outer flue pipe
and e plus 125 mm to inner pipe measurement.
Diagram 11
Diagram 12
Outer pipe
Cutting length
Refer to table 2 for cutting lengths of both inner
and outer flue pipes for each of the various flue
options available.
Inner pipe
Important: All flue cutting lengths must be measured from the terminal end of the flue pipes, see
diagram 12.
Important: All cutting lengths should be measured
from the push fit joint end of the extension pipe.
Do not leave any burrs or sharp edges on the cut
ends of the pipes.
Note : maximum horizontal flue lenght without
bends is 3 m.
e
X
X
●
When the dimension X measured on site is greater
than that given in table 2. Extensions will be required
as necessary.
a
a
Hab 210a
For left hand applications
● Measure distance from inside face of wall to side
of the boiler a (diagram 11) subtract 25 mm for
outer pipe length and add 75 mm to inner pipe
length measurement.
e
Cutting length
Ven 089
Calculation of cutting lengths when flueing to the
right or left
● Measure wall thickness e (mm), see diagram 11.
For right hand applications
● Measure distance from inside face of wall to side
of the boiler a (diagram 11) add 350 mm to outer
pipe measurement and 445 mm to inner pipe
mesurement.
Table 2
Flue cutting lengths (mm)
Rear flue
Outer pipe : e + 25,
inner pipe : e + 120
Comment : maximum distance 'x' without extension 770 mm
Right side flue
Outer pipe : e + a + 350, inner pipe : e + a + 450
Comment : maximum distance 'x' without extension 515 mm
Left side flue
Outer pipe : e - 25,
inner pipe : e + 125
Comment : maximum distance 'x' without extension 1087 mm
Rear flue outer pipe E+55mm, inner pipe E+217mm
RHS flue outer pipe E+A+290mm, inner pipe E+A+452mm
12
LHS flue outer pipe E+A-48mm, inner pipe E+A+114mm
FLUE INSTALLATION
Important: If the flue has been cut, ensure that there
are no burrs that could damage the ‘O’ ring.
● For flue systems less than 1,5 m long, leave the
restrictor (a) fitted in the fan outlet, see diagram
15.
● Remove the backing from the self adhesive gasket (H) and carefully fit gasket to base of flue elbow.
● Fit elbow onto boiler and secure with the four
screws (I).
Diagram 13
A
B
E
G
F
D
I
H
J
Pho 451
C
The flue kit 86285 is 1000 mm long and comprises:
- Outer pipe .............................................................. A
- Inner pipe ................................................................ B
- Flue elbow .............................................................. C
- Fixing collar ............................................................. D
- Locking clips ............................................................ E
- External rubber sealing collar ............................... F
- Internal flange ....................................................... G
- Gasket ..................................................................... H
- Screws ....................................................................... I
- 'O' rings ..................................................................... J
Pho 087
Installation of flue assembly
● Fit rubber sealing collar (F), see diagram 13, into
groove at the outer end of pipe (A).
● Fit outer pipe (A) into wall with groove to the outside.
● Pull pipe inwards to bring rubber sealing collar
hard up against external wall, see diagram 14.
● Fit internal plastic flange (G) onto outer pipe. Push
along the pipe until engaged against internal wall.
● From inside, insert inner pipe (B) into outer pipe.
● Fit both ‘O’ rings (J) into the flue elbow (C), one
at the inlet, one at the outlet. By necessity, they
are a loose fit, apply a small amount of silicone
grease to each ‘O’ ring when fitting.
● Wrap sleeve (D) over outer pipe (A) and elbow
(C) ensuring it is the correct way round.
● Take hold of the inner flue and push gently onto
the elbow outlet taking care not to tear the ‘O’
ring.
● Open fixing collard (D) and locate between
elbow and outer pipe (A). Close fixing jig.
● Engage the two fixing clips (E) onto the colar
onto (D) and press down to lock into position.
Secure clips with screws provided.
Diagram 14
Concentric flue system
The maximum permissible length (L) for the concentric flue system is 3 m. For flue systems up to 1,5 m
length, the restrictor (a) supplied fitted to the boiler, inside the fan outlet, must be left in place. For longer
flue systems, the restrictor must be removed.
For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced
by 1 metre.
L
Gasket
Hab 249a
23
4
65
a
Diagram 15
13
ELECTRICAL CONNECTION
Warning. This boiler must be earthed
All system components must be of an approved
type.
Connection of the whole electrical system and any
heating system controls to the electrical supply must
be through a common isolator.
Isolation should preferably be by a double pole
switched fused spur box having a minimum contact separation of 3 mm on each pole. The fused
spur box should be readily accessible and preferably adjacent to the boiler. It should be identified
as to its use.
A fused three pin plug and shuttered socket outlet
may be used instead of a fused spur box provided
that:
a) They are not used in a room containing a fixed
bath or shower.
b) Both the plug and socket comply with the current issue of BS1363.
The mains electrical supply must be maintained at
all times in order to provide domestic hot water.
Do not interrupt the mains supply with a time switch
or programmer.
The boiler will work for heating without a room thermostat being connected provided that the wire
link fitted between the two terminals of the connector (E) is left in place, see diagram 17.
Alternatively, a 230V room thermostat can be used
but do not make any connection to the compensating resistor, see diagram 17.
ON NO ACCOUNT must any electrical voltage be
applied to any of the terminals of the external controls plug.
Note: For further information, see the building
regulations 1991 - Conservation of Fuel and Power
- 1995 edition - appendix G, Table 4b.
The boiler is supplied with a mains lead attached. Connect this to the electrical supply.
External controls
The ISOMAX boiler is designed to operate at maximum efficiency at all times, but will be most efficient and economical when connected to a room
thermostat.
A suitable room thermostat is available as an accessory, Saunier Duval part number 40011. Please
contact your supplier.
Also available :
For extra control or if the boiler is to be sited in a
garage or utility room an optional remote control
unit with programmable roomstat can be obtained
part number 85915 (Isocom), diagram 2. This is a
dual function unit (a) boiler control (same as boiler
facia) (b) programmable room stat. Full fitting
instructions supplied with the unit.
Diagram 16
Leave link in place for no external controls.
F
Sch 171
Warning: This appliance must be wired in accordance with these instructions. Any fault arising from
incorrect wiring cannot be put right under the terms
of the Saunier Duval guarantee.
Ins 060
WARNING: ON NO ACCOUNT MUST ANY EXTERNAL
VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON
THE HEATING CONTROLS CONNECTION PLUG.
E
Diagram 17
IMPORTANT
With voltage free room
thermostat
¡C
Isocom only
Without room
thermostat
Sch 172
F
E
14
E
COMMISSIONING
The commissioning and first firing of the boiler must
only be done by a qualifed registered person.
Diagram 18
Reg 018
Gas installation
It is recommended that any air is purged from the
supply at the gas inlet test point on the gas valve,
see diagram 18.
Filling the system
1
Press the mains 'On/Off' button
L'afficheur
0 bar0de
pression
etin
clignote
The
display indique
will indicate
bar
pressure
the system
Le
témoin
lumineux
clignote
The
warning
light will
illuminate
O
I
1
Hab 260
0.0 bar
mode
m
Pla 213
q
Undo cap
on automatic air
vent on
top
of
pump and
leave undone.
4
Reg 008
Open the boiler isolating valves (v
and q), the slot of the screw corresponds to flow direction.
Fully open valve m by turning anticlockwise.
The pressure must be between 1 and 2 bar
Open filling device fitted previously, fill the system
until the pressure indicated on the display is between
1 and 2 bar. Close filling device.
1.5 bar
mod
Hab 265
2
v
➜
➜
3
15
COMMISSIONING
5
Bleed each radiator to remove the air, re-tighten
bleed screws.
6
Leave the cap on the
pump auto air vent open.
7
Open various hot
water taps to bleed
system.
➜
Ins 062
Ins 061
Reg 008
➜
8
Make sure the display indicates a system pressure of between 1 and 2 bar. Re-fill system as
necessary.
The pressure must be between 1 and 2 bar
O
mode
Hab 265
1.5 bar
I
16
COMMISSIONING
Lighting the boiler :
Make sure that:
The boiler is connected to the electrical supply.
The gas service cock is open.
Then follow the instructions below :
1
Press the On/Off button (1)
The pressure must be between 1 and 2 bar. If not, the system must be filled by a competent person.
O
I
1
1.5 bar
Hab 264
mode
To stop the boiler : Press button (1)
Setting to the WINTER position
(Heating + hot water)
●
Press the
to select the
winter symbol
Appuyer
sur mode
mode button
pour sélectionner
la position
hiver
2
10
°C
The
actual temperature
Température
actuelle
of
the le
heating
system
dans
circuit chauffage
1.5 bar
Adjust heating temperature to maximum .
Check that any external controls, if fitted, are
calling for heat (set room thermostat to maximum).
● Allow the temperature to rise to the maximum
value, with all radiator valves open. The temperature rise will cause release of the gases contained
in the water of the central heating system.
● Gases driven towards the boiler will be automatically released through the automatic air vent.
● The gases trapped at the highest point of the system must be released by bleeding the radiators.
On reaching maximum temperature, the boiler
should be turned off and the system drained as
rapidly as possible whilst still hot.
● Refill system to a pressure of between 1 and 2
bar and vent as before.
● Restart boiler and operate until a maximum temperature is reached. Shut down boiler and vent
heating system. If necessary, top up heating system and make sure that a pressure of at least 1 bar
is indicated when system is COLD.
●
mode
Illuminates
when
Apparaît
lorsque
le
the boiler
lights
brûleur
fonctionne
Adjusting the heating temperature
Press + orsur
- to+ adjust
the ajuster
maximum
temperature
Appuyer
ou - pour
la température
of the heating
(38°Cdu
to circuit
87°C) chauffage
maximale
souhaitée
Visual indication
set temperature
Visualisation
de laof
température
demandée
3
mode
Hab 261
60°C
17
COMMISSIONING
Setting the heating output
2
20
1
01
mode
Reg 051/UK
Setting the heating output
The heating output can be set without the use of a
pressure gauge; proceed as follows:
● Press the display light button
and keep pressed for 5 seconds, see diagram 20.
Note:The boiler has now been put into 'Service
Mode', allowing certain adjustments to be made
and diagnostic fault codes to be displayed. Refer
to the 'Servicing Instructions' for further details.
The heating output, in kW, is shown on the left hand
side of the display, see diagram 21.
● Remove the blanking plug from the front of the
control panel to gain access to the heating adjusting screw.
● Adjust the heating output by turning the screw
clockwise to increase, anti-clockwise to decrease.
● Refit blanking plug.
Note: Adjustment of the heating output does not
affect the domestic hot water output.
5s
Diagram 20
Setting the heating output
Adjustment screw
For kW to Btu/hr conversion refer to table 5.
Table 5
kW to Btu/hr conversion
Btu/hr
102,360
109,180
116,000
119,420
Btu/hr
68,240
75,060
81,890
88,710
95,540
Setting the maximum heating temperature
The maximum heating temperature can be preset
at commissioning stage to suit the type of heating
system.
For example, for use with underfloor heating, the
maximum heating temperature can be set to 53°C.
To adjust the maximum temperature, proceed as
follows:
Remove the blanking plug (b) from the rear of
the control panel to gain acess to selector switch
SW1 (see diagram 22).
Adjust toggles 1 and 2 to give the desired maximum heating temperature, see diagram
Note: To adjust the maximum heating temperature
it is only necessary to change toggles 1 and 2. Do
NOT touch any other toggles.
Refit blanking plug.
The heating output, in kW,
is shown on the display.
Reg 052
kW
30
32
34
35
kW
20
22
24
26
28
Diagram 21
b
Reg 053
Btu/hr
34,120
40,940
47,770
54,590
61,420
➦
kW
10
12
14
16
18
SW1
Diagram 22
O
N
1 2 3 4 5 6 7
1=ON, 2=ON ➜ 53°C. Maximum.
1=OFF, 2=OFF ➜ 73°C. Maximum.
1=OFF, 2=ON ➜ 87°C. Maximum.
Factory setting ➜ 73°C.
SAFETY DEVICES
The ISOMAX incorporates a visual display that indicates fault conditions, should they occur.
In the event of a fault, the display will indicate, by
means of pictograms and/or letters and numbers,
exactly in which area the fault lies.
18
Should the boiler fail to operate during Commissioning, the most likely fault is that the gas supply
to the boiler has not been turned on or purged sufficiently or that there is no pressure in the heating
system. These are indicated as follows :
SAFETY DEVICES
No gas supply
General safety devices
➜ This will be indicated
on the display as a
pictogram of a spark.
To rectify this, proceed as follows:
Switch off the boiler at the On/
Off push button.
Rectify the gas supply problem.
Restart the boiler by pressing the
On/Off button.
O
I
1
-------------------------Insufficient system pressure
This will be indicated
on the display as a
flashing warning indibar
cating the system
pressure is low.
To rectify this the system must be re-filled, refer to
'Commissioning'.
0.3
-------------------------Other faults
These are indicated on the display by a fault code
and a telephone symbol. Further information on the
fault codes can be found in the 'Servicing Instructions'.
Air flow rate safety device
If an obstruction, even partial, of the flue occurs,
for any reason whatsoever, the built in safety system of the boiler will turn the boiler OFF and the
fan will continue to run.
The boiler will be ready to operate when the fault
has been cleared.
Overheat safety
In case of boiler overheating, the overheat thermostat will turn the boiler off. The thermostat, located on the heat exchanger flow pipe, will need
to be manually reset.
In case of power supply failure
The boiler no longer operates.
As soon as power supply is restored, the boiler will
be automatically restarted.
Frost protection
The ISOMAX has a built in frost protection device
that protects the boiler from freezing. If the boiler is
to be left and there is a risk of frost, ensure that the
gas and electrical supplies are left connected. The
frost protection device will light the boiler when the
temperature of the boiler water falls below 6°C.
When the temperature reaches 16°C, the boiler
stops.
Note : This device works irrespective of any room
thermostat setting and will protect the complete
heating system.
CHANGING GAS TYPE
Should it become necessary to change the gas
type, a modification kit will be required.
This modification must only be carried out by a
suitably qualified engineer.
Conversion natural Gas (G20) to G30/G31 Part No.
86216.
19
SETTINGS
Gas valve setting
All boilers are tested and factory set during manufacture. Should it be necessary to reset a gas valve,
for example, after replacement, proceed as follows:
Shut down boiler.
MODULATING COIL
Electrical
connection
Bypass
The ISOMAX has a built-in bypass. This must be adjusted according to the requirements of the system,
refer to the flow rate pressure curve (diagram 4).
The boiler is supplied with the built-in bypass open
a half a turn. It is adjusted by turning the bypass
screw (a), see diagram 24. Turn the screw clockwise to close the bypass.When using thermostatic
radiator valves (TRV’s) on all of the radiators, it is
essential that a separate, adjustable bypass of 15
mm minimum diameter is fitted between the flow
and return of the heating circuit, see diagram 8.
Any bypass must be fitted before system controls.
20
Diagram 23
a
Diagram 24
Reg 054
Maximum setting
Reconnect the electrical connector removed
from the modulating gas valve coil.
Remove the protective cover from the gas valve
adjuster.
Turn nut ‘B’, see diagram 23:
CLOCKWISE: To increase the pressure.
ANTICLOCKWISE: To decrease the pressure.
After adjustment, refit the cover to the gas valve
adjuster.
Reg 020
Minimum setting
Remove one electrical connector from the
modulating gas valve coil, see diagram 23.
Connect a suitable pressure gauge.
Set the OFF/Summer/Winter switch to the ‘Summer’ position.
Adjust the domestic hot water temperature adjuster to maximum setting.
Remove the protective cover from the gas valve
adjuster.
Turn nut ‘A’, see diagram 23:
CLOCKWISE: To increase the pressure.
ANTICLOCKWISE: To decrease the pressure.
ROUTINE CLEANING AND INSPECTION
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 particular installation conditions and usage, but in general once a year should be enough.
Service Check and Preparation.
• Operate boiler and check for any faults that need
to be put right.
• Isolate boiler from the gas and electrical supplies.
• On completion check all gas carrying parts for
soundness with leak detection fluid.
• Remove boiler casing as follows:
Car 033
It is the law that any servicing is carried out by a
qualified registered person.
Diagram 1
Upper front panel
• Remove the two front panel retaining brackets
from the top of the boiler.
• Remove panel by lifting up and forward.
Sealed chamber cover
• Unclip the toggle clip holding the sealed chamber cover, see diagram. 1.
• Lift cover up and off boiler.
Front control panel
• Lift control panel up and lower forwards to gain
access to lower part of boiler.
Combustion chamber cover
• Unscrew the three screws securing combustion
chamber cover to combustion chamber, see diagram 2.
• Remove combustion chamber cover from boiler.
• Undo, but do not remove, two burner support screws
at rear of burner chamber.
Burner
• Undo main gas supply nut from burner.
• Pull off the ignition and flame sense leads from the
gas valve remove burner from boiler by lifting up and
pulling forwards from keyhole slots.
Note: The washer between main burner and main
bur ner gas supply must be kept for use on
reassembly.
• Remove ignition and flame sense electrodes from
burner.
• Unscrew and remove injector bar retaining
screws and separate injector bar from burner.
• Examine and clean injectors as necessary.
Note: DO NOT use a wire or sharp instrument on
the holes.
Clean burner by washing in soapy water. Dry thoroughly before re-fitting.
Ech 052
Side panels
• Unscrew and remove the four screws securing
lower grille onto boiler. Unhook grille from rear of
boiler and remove.
• Remove three screws from front of each side panel.
• Unclip the toggle clips securing top of each panel.
Lift each panel up and then forward to remove.
Diagram 2
Heat exchanger
• Disconnect power supply leads and earth lead
from fan.
• Unscrew and remove, two fan retaining screws
at front edge of fan mounting plate.
• Remove fan with mounting plate attached by
pulling forwards out of boiler.
• Remove air pressure switch sensing tube from
sensing probe on flue hood.
• Unscrew and remove screws securing flue hood
to rear panel.
• Withdraw flue hood from boiler.
• Examine heat exchanger for any blockages or
build up of deposits.
• Clean heat exchanger with soft brush or vacuum
cleaner. Do not use any tool likely to damage
painted finish of heat exchanger.
Reassembly of parts removed for servicing
All parts are replaced in reverse order to removal.
21
ROUTINE CLEANING AND INSPECTION
Flue system
• Check externally to make sure that flue is not
blocked
• Inspect flue system to make sure that all fittings
are secure.
Operation of fan
• Switch on electrical supply and turn on gas.
• Light burner by opening a hot water tap.
• Without sealed chamber cover in place, burner
should be automatically prevented from lighting
by air flow detection system.
• Refit sealed chamber cover.
• Check that fan operates when burner lights and
stops when it goes out.
Cold water inlet filter
Drain down hot water circuit of boiler only, as fol
lows:
• Close isolating valve/throttle (m) on cold water
isolating cock, see diagram 3.
Note: This valve is closed when screwed fully clockwise.
• Open one or more hot water taps to drain boiler
circuit.
• Undo connecting nut from cold water inlet connection.
• Clean and inspect filter, replace if necessary.
• With both filter and restrictor in place, reconnect connecting pipe to inlet connection and
tighten.
• Fully open isolating valve/throttle on cold water inlet and check for leaks.
Diagram 3
C
A
r
m
Pla 213
v
q
➜
➜
u
REPLACEMENT OF PARTS
For replacement of the following components it will
be necessary to remove boiler casing panels as described in ‘Routine Cleaning and Inspection’.
WARNING: Before commencing the replacement
of any component, isolate appliance from electrical supply and turn off gas at service cock.
To replace domestic hot water thermistor
• Locate domestic hot water thermistor on hot water flow pipe on right hand side of boiler adjacent
to gas valve.
• Unclip thermistor from pipe.
• Disconnect leads from thermistor.
• Fit replacement thermistor.
• Fit leads to replacement thermistor, the polarity
is not important.
To replace central heating thermistor
• Locate central heating thermistor on heating flow
pipe on centre of boiler.
• Unclip thermistor from pipe.
• Disconnect leads from thermistor.
• Fit replacement thermistor.
• Fit leads to replacement thermistor, the polarity
is not important.
To replace storage vessel thermistor
For this operation the boiler must be removed from
the wall.
• Drain down heating and hot water circuit of the
boiler only, as follows:
• Close isolating valves (q) and (v) on central heating isolating cocks (A) and (C), see diagram 3.
22
Note: These valves are closed when slots are at right
angles to direction of flow.
• Drain boiler by opening drain valves (r) and (u),
see diagram 3.
Note: It is not necessary to drain down entire heating system to carry out this work.
• Close isolating valve/throttle (m) on cold water
isolating cock, see diagram 3.
Note: This valve is closed when screwed fully clockwise.
• Open one or more hot water taps to drain boiler
circuit.
• Disconnect flue system.
• Disconnect boiler pipes onto fixing jig.
• Disconnect mains cable and any external controls cables.
• Remove boiler from wall.
• From rear of boiler, disconnect domestic pipes
from storage vessel.
• Disconnect electrical connections from vessel.
• Unclip vessel from boiler frame and remove from
boiler.
• Slide off plastic strap and separate two halves of
vessel insulation.
• Locate thermistor at top of insulation.
• Replace thermistor in same position as old thermistor.
• Refit vessel in reverse order to removal.
• Refit boiler onto fixing jig, tighten all connections
ensuring that all sealing washers are fitted before
tightening.
• Reconnect flue making sure that all joints are
properly connected.
REPLACEMENT OF PARTS
let pipe to flow sensor and carefully remove from
sensor.
• Pull out slotted metal clip securing flow sensor to
pump mounting and carefully remove sensor from
boiler.
• Fit replacement sensor to boiler in reverse order
to removal.
To replace fan
• Remove fan as described in ‘Routine Cleaning
and Inspection’.
• Fit replacement fan in reverse order to removal.
• Reconnect electrical leads.
To replace printed circuit board (PCB)
• Gain access to rear of control panel.
• Unclip and remove external controls/mains connection access cover.
• Unclip side clips and hinge up control panel cover
to gain access to PCB, see diagram 5.
• Carefully pull off electrical connections to PCB.
• Unclip and lift out PCB.
• Fit replacement PCB in reverse order to removal.
Note: 1) Make sure that PCB connections are fully
pushed onto replacement PCB.
2) Set the heating temperature option to the
same value as the old PCB, refer to 'Installation and
User' instructions.
To replace air pressure switch
• Locate air pressure switch situated inside sealed
chamber on top right hand side.
• Remove air pressure switch tube from sensing
probe on flue hood.
• Disconnect air pressure switch electrical connections.
• Undo screws on top of boiler securing air pressure switch to boiler and remove switch.
• Pull sensing tube off switch.
• Fit replacement switch to boiler in reverse order
to removal, noting that pressure sensing tube fits to
left hand connection on switch.
Diagram 4
Diagram 5
Acc 010/Acc011
➜
To replace domestic water flow sensor
• Drain down hot water circuit of boiler only as described previously.
• Undo connecting nut from cold water inlet connection.
• Locate flow sensor on cold water inlet pipe to
boiler inside controls area, see diagram 4.
• Carefuly pull off electrical connector from flow
sensor.
• Pull out slotted metal clip securing cold water in-
Ins 104
• Open isolating valves on flow and return connections, refill, vent and pressurise boiler.
• Check for leaks.
• Reconnect all electrical connections and restore
electrical supply.
• Open gas cock, operate boiler and re-check all
joints for soundness.
23
REPLACEMENT OF PARTS
To replace system pressure sensor
• Drain down heating circuit of boiler only as described previously.
Note: It is not necessary to drain down entire heating system to carry out this work.
• Locate system pressure sensor at front left hand
side of boiler, see diagram 8.
• Remove electrical connections from sensor.
• Pull off slotted metal clip and remove sensor from
boiler.
• Fit replacement sensor in reverse order to removal.
To replace gas valve module
• Locate gas valve module attached to side of gas
valve.
Diagram 6
Pho483
Diagram 7
Pho484
➜
To replace domestic hot water heat exchanger
• Drain down heating and hot water circuits of
boiler only as described previously.
Note: It is not necessary to drain down entire heating system to carry out this work.
• Unscrew and remove cold water inlet pipe from
fixing jig to water flow sensor.
• Supporting domestic heat exchanger, unscrew
and remove two screws securing it onto pump
mounting and 3-way valve/bypass housing.
• Remove heat exchanger from boiler.
• Fit replacement heat exchanger in reverse order
to removal using new seals, supplied.
Note: Heat exchanger mounting screws are offset
to ensure correct fitting of replacement.
pipe from 3-way valve/bypass housing to storage
vessel.
• Undo pipe from 3-way valve/bypass housing to
fixing jig.
• From underneath boiler, undo two screws securing 3-way valve/bypass housing and lift out of
boiler.
• Fit replacement 3-way valve/bypass housing in
reverse order to removal.
To replace 3-way valve head
• Locate 3- way valve in centre of lower controls
area.
• Remove electrical plug from valve head.
• Pull out slotted metal clip from valve body and
remove valve head from body.
• Fit replacement valve head in reverse order to
removal.
Note :
1) When refiting clip, ensure that letters OK are as
shown in diagram 6.
2)It is not necessary to drain boiler to carry out this
work.
To replace 3-way valve/bypass housing
• Drain down heating and hot water circuit of boiler
only as described previously.
Note: It is not necessary to drain down entire heating system to carry out this work.
• Remove 3-way valve head as described previously.
• Remove domestic hot water heat exchanger as
described previously.
• Undo pipe connection from 3-way valve/bypass
housing to primary heat exchanger, see diagram 7.
• Pull out slotted metal clips and remove bypass
pipe.
• Pull out slotted metal clip and remove domestic
Diagram 8
24
Pho485
To replace pump
• Drain down heating circuit of the boiler only, as
described previously.
Note: It is not necessary to drain down entire heating system to carry out this work.
• Undo two fixing screws and remove pump retaining bracket from front of pump.
• Undo clips securing pump outlet hose connection to pump.
• Slide hose along pipe to clear pump outlet.
• Disconnect pump electrical connection from
PCB.
• Transfer automatic air vent to replacement pump
using new washers supplied.
• Re-connect electrical connection to PCB.
• Fit replacement pump in reverse order to removal.
• Open isolating valves on flow and return connections, refill, vent and pressurise boiler.
• Check for leaks.
REPLACEMENT OF PARTS
To replace modulating coil
• Ensure that gas supply to boiler is turned off at
gas cock.
• Disconnect electrical connections to gas valve
modulating coil, see diagram 9.
• Undo two screws securing modulating coil to gas
valve and remove coil.
To replace storage vessel safety valve
If safety valve seating is damaged, it will be necessary to replace safety valve as a complete unit,
repair is not possible.
• Drain down hot water circuit of boiler only as described previously.
• Disconnect safety valve discharge pipe from
safety valve.
• Remove wire clip securing safety valve to fixing
jig and remove safety valve, see diagram 10.
• Fit replacement safety valve in reverse order to
removal.
Note: Apply a small quantity of silicon grease to
the safety valve 'O' ring prior to fitting.
Diagram 10
Pla 214
To replace gas valve
• Ensure that gas supply to boiler is turned off at
gas cock.
• Remove gas valve module as described previously.
• Disconnect electrical connections to gas valve
modulating coil, see diagram 9.
• Undo main gas supply nut from main burner.
Note: The washer must be kept for use on
reassembly.
• Undo main gas union nut between gas valve supply pipe and gas inlet valve.
Note: The washer must be kept for use on
reassembly.
• Disconnect plastic sensing pipe from gas valve
to base of sealed chamber.
• Unscrew and remove screws securing gas valve
bracket to boiler frame.
• Withdraw gas valve assembly.
• Using old gas valve as a guide, transfer gas pipes
from old gas valve to replacement gas valve.
• Fit replacement gas valve into boiler.
• Reconnect gas pipes in reverse order to removal.
• Refit electrical connections in reverse order to removal, the polarity of the wires to the modulating
coil is not important.
Note: Apply a small quantity of silicon grease to
the safety valve 'O' ring prior to fitting.
• Open isolating valves on flow and return connections, refill, vent and pressurise boiler.
• Check for leaks.
➜
Mec 140
• Remove screw securing cover onto gas valve
module, see diagram 9.
• Remove cover and disconnect multi-plug from
module.
• Disconnect ignition and flame sense leads from
module.
• Withdraw module from gas valve.
• Fit replacement module, ensuring it is of the correct type for the boiler, in reverse order to removal.
• Reconnect ignition and flame sense leads, the
connections are uniquely sized to ensure correct
replacement.
• Reconnect multi-plug onto replacement module.
• Refit cover ensuring all sealing grommets are correctly located in module body.
➜
➜
➜
Diagram 9
• Fit replacement coil in reverse order to removal.
• Refit electrical connections in reverse order to removal, the polarity of the wires to the modulating
coil is not important.
To replace central heating safety valve
If safety valve seating is damaged, it will be necessary to replace safety valve as a complete unit,
repair is not possible.
• Drain down heating circuit of boiler only as described previously.
• Disconnect safety valve discharge pipe from
safety valve.
• Remove wire clip securing safety valve to fixing
jig and remove safety valve, see diagram 10.
• Fit replacement safety valve in reverse order to
removal.
• Open isolating valve on cold water inlet connection.
• Check for leaks.
To replace heat exchanger
• Drain down heating circuit of boiler only as described previously.
Note: It is not necessary to drain down entire heating system to carry out this work.
• Remove combustion chamber cover, as described in ‘Routine Cleaning and Inspection'.
• Disconnect electrical connector from high limit
thermostat.
25
REPLACEMENT OF PARTS
• Remove slotted metal clips from heat exchanger connection pipes.
• Undo nut securing pipe from heat exchanger to 3way valve/bypass housing.
• Swing pipe away from 3-way valve/bypass housing
and pull down to disengage from heat exchanger pipe.
• Pull down pipe from pump to heat exchanger to disengage from heat exchanger pipe.
• Slide heat exchanger forwards and remove from
boiler, see diagram 11.
• Fit replacement heat exchanger in reverse order to
removal.
• Reconnect electrical connector to high limit thermostat.
• Open isolating valves on flow and return connections,
refill, vent and pressurise boiler.
• Check for leaks.
To replace combustion chamber insulation
• Remove combustion chamber cover as described in ‘Routine Cleaning and Inspection’.
• Remove heat exchanger as described previously.
• Remove fan and flue hood as described in ‘Routine Cleaning and Inspection’.
Front panel:
• Lift front insulation panel free from retaining lugs
on combustion chamber cover.
Rear panel:
• Pull rear insulation panel free from retaining lug
at rear of combustion chamber by tilting forward.
• Fit replacement insulation panels in reverse order to removal
• Refit combustion chamber cover.
Diagram 11
Ech 040
Side panels:
• Pull out side panels.
To replace central heating expansion vessel
Replacement of the expansion vessel is not possible with the boiler on the wall.
Remove boiler from wall as described in 'To replace
storage vessel thermistor'.
• Undo pipe coupling on expansion vessel.
• Supporting expansion vessel, unscrew and remove screw securing expansion vessel to boiler.
• Lift vessel out of boiler.
• Fit replacement vessel to boiler in reverse order
to removal, ensuring that sealing washer is fitted to
pipe connection before tightening.
• Ensure that expansion vessel charge pressure is
0.5 bar (7.5 psi) using a pressure gauge. If necessary, increase pressure using a car or cycle tyre
pump connected to the Schrader valve.
• Refit boiler onto fixing jig, tighten all connections
ensuring that all sealing washers are fitted before
tightening.
• Reconnect flue making sure that all joints are
properly connected.
• Open isolating valves on flow and return connections, refill, vent and pressurise boiler.
• Check for leaks.
• Reconnect all electrical connections and restore
electrical supply.
• Open gas cock, operate boiler and re-check all
joints for soundness.
To replace high limit thermostat
• Locate high limit thermostat on heating flow pipe
on left hand side of boiler.
• Disconnect electrical connection from thermostat
• Unclip thermostat from heating flow pipe.
• Fit replacement thermostat in reverse order to removal.
• Refit connection to thermostat.
26
To replace burner
• Remove burner as described in 'Routine Cleaning and Inspection'.
Assemble replacement burner, supplied in parts, as
follows:
• Fit burner injectors to burner injector bar and
tighten.
Note: Make sure that injector size, marked on each
injector, is the same as that given in ‘Technical Data’
for the type of gas being used.
• Fit injector bar into burner, secure with retaining rods.
• Fit replacement burner into boiler in reverse order to removal.
To replace burner injectors
• Remove burner as described in 'Routine Cleaning and Inspection'.
• Pull out injector bar retaining rods and separate
injector bar from burner.
• Unscrew and remove injectors from injector bar.
• Fit replacement injectors to injector bar and
tighten.
Note: Make sure that injector size, marked on each
injector, is the same as that given in ‘Technical Data’
for the type of gas being used.
• Reassemble burner and fit into boiler in reverse
order to removal.
To replace ignition electrode
• Remove burner as described in ‘Routine Cleaning and Inspection’.
• Undo and remove screw securing electrode onto
burner.
• Fit replacement electrode onto burner in reverse
order to removal.
• Refit burner into boiler in reverse order to removal.
To replace flame sense electrode
• Remove burner as described in ‘Routine Cleaning and Inspection’.
• Undo and remove screw securing electrode onto
burner.
• Fit replacement electrode onto burner in reverse
order to removal.
• Refit burner into boiler in reverse order to removal.
BOILER SCHEMATIC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
- Domestic thermistor
- Three way valve
- Gas valve
- Gas valve ignition module
- Temperatur sensor for accumulation vessel
- Accumulation vessel
- Burner
- Ignition electrode
- Combustion chamber
- Heating safety valve (3 bar)
- Main heat exchanger
- Air pressure switch
- Flow detector
- DHW pump
- Non return valve
- Bypass
- Domestic heat exchanger
- Heating pump
19
20
21
22
23
24
25
26
27
28
- Heating expansion vessel
- Heating thermistor
- Overheat safety thermostat
- Flame sensor electrode
- Fan
- Domestic safety valve (6 bar)
- Loss of water sensor
- Domestic expansion vessel
- Pressure/temperature relief (7 bar)
- Domestic safety valve (10 bar)
A
B
C
D
E
D1
D2
D3
- Heating return
- Cold water inlet
- Heating flow
- Domestic hot water outlet
- Gas
- Discharge from HTG safety valves
- Discharge from DHW safety valves
- Discharge from temp/press (to tundish)
23
12
27
11
21
6
9
5
7
22
8
19
3
18
26
4
20
24
2
16
17
15
1
14
25
13
A
B
C
D1
Diagram 12
28
D E
D2
D1
D3
D1
Shy 163cUK
10
27
TECHNICAL DATA
Heating
Natural Gas (G20)
Heating output
Ø Burner injector
Inlet pressure
Maxi. Burner pressure
Mini. Burner pressure
Gas rate maximum
Gas rate minimum
ajustable from 10,1 kW
to 27,6 kW
from 35,484 BTU/H
to 94,170 BTU/H
Efficiency
91 %
Maximum heating temperature
87 °C
Expansion vessel effective capacity
8l
Expansion vessel charge pressure
0,5 bar
Maximum system capacity at 75°C
180 l
Safety valve,
maximum service pressure 3 bar
Products outlet diameter
60 mm
Fresh air inlet diameter
100 mm
Butane Gas (G30)
Ø Burner injector
Inlet pressure
Maxi. Burner pressure
Mini. Burner pressure
Gas rate maximum
Gas rate minimum
Hot water
Hot water output, automatically variable from 10,4 kW
to 27,6 kW
from 35,484 BTU/H
to 94,170 BTU/H
Maximum hot water temperature
60 °C
Specific flow rate (for 30°C temp rise)
13,2 l/min.
Threshold flow rate
1 l/min.
Nominal water flow rate
11,3 l/min.
Maximum supply pressure
8 bar
Minimum operating pressure
0,7 bar
2
3
4
5
Ø Burner injector
Inlet pressure
Maxi. Burner pressure
Mini. Burner pressure
Gas rate maximum
Gas rate minimum
Bypass fully shut
Open 1/4 turn
Open 1/2 turn
Open 1 turn
Open 2 turns
60
1
50
2
3
40
4
5
30
20
10
0
0
200
400
(10 kPa = 1 m WG)
1
28
Bypass fully shut
2
0,77 mm
37 mbar
30,8 mbar
3,6 mbar
2,35 kg/h
0,97 kg/h
Pom 010 a
1
0,77 mm
29 mbar
23,8 mbar
3,6 mbar
2,39 kg/h
0,99 kg/h
Propane Gas (G31)
230 V
235 W
IP44
Available pressure (kPa) between
heating supply and return lines
Electrical supply
Maximum absorbed power
Level of protection
1,20 mm
20 mbar
13,8 mbar
2,16 mbar
3,20 m3/h
1,32 m3/h
Open 1/4 turn
3
Open 1/2 turn
600
800
1000
1200
Flow rate through heating system (I/h)
4
Open 1 turn
5
Open 2 turns
SCHEMATIC WIRING DIAGRAM
B8.1
B8.2
B6.1
B6.3
B6.4
B6.2
Pr
P
B3.3
B1.2
B2.9
Opt.
H6.1
H6.2
B1.13
B2.4
L
Db
+
B2.8
B2.11
M/A
h8.1
N
Cp
B1.15
h8.2
B1.7
h4.1
B1.8
h4.3
B1.10
h3.1
B3.1
V1
Ps
h3.3
Ex
h1.1
P
K4
TA
Ra
CTN 3
B1.6
CTN 2
B1.4
B1.3
h5.2
CTN 1
h5.3
h5.1
b5.1
1
B2.8
b5.2
2
B2.7
b5.4
HL
B2.2
B2.1
B2.4
B7.3
B7.2
B7.1
B3.5
B3.6
b5.5
B4.1
Flam
8
5
B1.5
B4.4
ACF
9
Ph
B2.6
B2.5
B4.3
N
1
2
3
4
h2.4
B4.2
10 11
DA
V CH
3 COM
V
SAN
B3.2
B3.3
B3.4
h1.2
h2.2
h2.3
h2.5
h2.1
J1
GND
S
Ve
FL
INTERFACE
M/A
Ps
P
ACF
-
on/ off
domestic water pump
heating pump
ignition card and flame control
DA
- ignition demand
⊗
- safety engaged
Flam
- ionisation contact
V3V
- three-way valve
CH
- heating
COM
- common
SAN
- hot water
INTERFACE - User interface
Db
- output detector
Cp
- water pressure sensor
V1
- gas mechanism modulating valve
J1
- connector for room temp. thermostat
TA
- room temperature thermostat
Diagram 14
CD
Vitesse
Extracteur
(option)
+
SE
Ra
- room temp. thermostat anticipation resistor
FA
- ignition electrodes
FL
- ionisation electrode
CTN1 - hot water thermistor
CTN2 - heating thermistor
CTN3 - accumulator thermistor
K4
- overheating safety
Pr
- air pressure switch
Ex
- fan
accessories
Opt
- option card
CD
- remote control
SE
- external sensor
HL
- clock
sch292
FA
29
FAULT FINDING
Before trying to operate the boiler make sure that :
• All gas supply cocks are open and that the gas
supply has been purged of air.
• The heating system pressure is at least 1 bar.
• There is a permanent mains supply to the boiler.
• The fuse on the PCB is intact.
WARNING. Always isolate the boiler from the electrical supply before carrying out any electrical replacement work.
Always check for gas soundness after any service
work.
Should there be any doubt about the voltage supply to any of the components, it is possible to carry
out a simple electrical test to ensure all is operational in that area.
To carry out the electrical test, gain access to the
main Printed Circuit Board (PCB), as described previously, and measure the voltages according to
table 1.
Table 1
Voltage
Measured value
Measuring point
230 Volt
230 V AC
Between terminals H8.1 and H8.2
24 Volt
maximum 33V DC
minimum 20V DC
Between terminals B2.4 and B2.7
15 Volt
15V + 0.5V
Between terminals B2.4 and B2.2
Display
5V + 0.5V
Between terminals B2.4 and B4.2
The ISOFAST has an on-board fault diagnostic system. Should a fault occur on the boiler, the warning LED at
the top of the user display
will illuminate and the LCD display will indicate the precise area where the
fault has occured.
09
FF
Sec 052
A fault code is displayed on the left hand side of the LCD display, whilst at the same time, the letters FF
appear with a telephone symbol.
30
FAULT FINDING
List of fault codes
Code
Fault
00
No fault
02
Air flow fault
04
Ignition fault -flame detection
05
Overheating
06
Central heating thermistor/wiring fault
07
Domestic hot water thermistor/wiring fault
08
Storage vessel thermistor/wiring fault
09
System pressure sensor fault
10
Fan fault
11
Pump blockage
12
User interface fault
13
Main PCB fault
14
CTN2 > 97°C - pump will run
15
Gas mechanism fault
20
Communication fault
Additional display
information
31
FAULT FINDING
Thermistor values
The following table applies to the central heating,
domestic hot water and storage vessel thermistors:
Temperature (°C)
Resistance (Ω)
0 ...................................... 32565
5 ...................................... 25345
10 ..................................... 19875
15 ..................................... 15700
20 ..................................... 12500
25 ..................................... 10000
30 ...................................... 8060
35 ...................................... 6535
40 ...................................... 5330
45 ...................................... 4370
50 ...................................... 3605
55 ...................................... 2989
60 ...................................... 2490
65 ...................................... 2085
70 ...................................... 1755
75 ...................................... 1480
80 ...................................... 1260
85 ...................................... 1070
90 ....................................... 920
95 ....................................... 785
100 ...................................... 680
System pressure sensor
The resistance of the sensor at various pressures is
as follows :
0 bar ...................... between 280 Ω and 320 Ω
1 bar ...................... between 195 Ω and 220 Ω
3 bar ...................... between 93 Ω and 143 Ω
SPARE PARTS
When ordering spare parts, quote the part number and description, stating the appliance model number
and serial number from the data badge.
Short parts list
No. ...... Description ...................................... Part No.
1 .......... Domestic hot water thermistor .......... 57213
2 .......... Central heating thermistor ................. 57215
3 .......... Storage vessel thermistor ................... 57250
4 .......... Fan ........................................................ 57238
5 .......... Air pressure switch ............................... 57237
6 .......... Domestic water flow sensor ............... 57202
7 .......... Printed circuit board ........................... 57248
8 .......... Pump .................................................... 57207
9 .......... 3-way valve head ............................... 57206
10 ........ System pressure sensor ....................... 57205
11 ........ Gas valve module .............................. 57079
12 ........ Central heating safety valve ............. 57228
13 ........ Storage vessel safety valve ............... 57229
14 ........ High limit thermostat ........................... 57212
15 ........ Ignition electrode ................................ 57194
16 ........ Flame sense electrode ....................... 57195
32
116277 B 07/00
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