Saunier Duval SB30e Instructions For Use Installation And Servicing

[Page 1] Saunier Duval SB30e

221872B.07.01 Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT General/Sales enquiries: Tel: (01773) 824141 Fax: (01773) 820569 One Contact Local Service Customer Services: Tel: (01773) 828100 Fax: (01773) 828070 Instructions for...

[Page 2] Saunier Duval SB30e

2 221872B Testing and Certification This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not ...

[Page 3] Saunier Duval SB30e

3 221872B DAY HR MIN Introduction Please read these instructions and follow them carefully for the safe and economical use of your boiler. This boiler must have been installed by a competent person in accordance with the current rules in force in the...

[Page 4] Saunier Duval SB30e

4 221872B Setting Instructions for the 7 Day Digital Programmer This is a 24 hour programmer, that is 1pm is 13:00, and has two sets of 8 “ON” and 8 “OFF” daily switching actions (P1 and P2). It is fitted with a lithium battery back up which ...

[Page 5] Saunier Duval SB30e

5 221872B To Light the Boiler 1. Check the two isolating valves are open, the levers in line with the valve body, see diagram 3. 2. Open the controls cover door and familiarize yourself with the controls, see diagram 2. 3. Set “C”, programmer ...

[Page 6] Saunier Duval SB30e

6 221872B Instructions for Use Maintenance and Servicing To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depen...

[Page 7] Saunier Duval SB30e

7 221872B ■ Maximum Heating 60 litres system water (13.2 gallons) content using with a cold fitted expansion fill pressure vessel. of 0.7bar Electrical supply 230V~50Hz Electrical rating 150W fused 3A Internal Fuse rating 1) Type T2...

[Page 8] Saunier Duval SB30e

8 221872B 1.7 Gas Supply The gas installation shall be in accordance with the rules in force in the countries of destination. The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at...

[Page 9] Saunier Duval SB30e

9 221872B 25 ABOVE THE TOP OF THE BOILER CASE OR THE FLUE ELBOW IF FITTED 5 5 450 150 To achieve minimum "Installation" clearance of 5mm. The side panels will have to be fitted prior to boiler mounting. 7087 DIMENSIONS IN MILLIMETRES Diagra...

[Page 10] Saunier Duval SB30e

10 221872B 3 Flue and Ventilation A A F G E A G G G B,C B,C F F K K K C G L L UNDER CAR PORT etc. H,I J D F K MINIMUM SPACING 2816 Diagram 3.1 MINIMUM SITING DIMENSIONS FOR FANNED FLUE TERMINALS POSITION mm A DIRECTLY BELOW, ABOVE OR HORIZONTA...

[Page 11] Saunier Duval SB30e

11 221872B 4.1 General Notes The boiler is intended for use in a sealed system only. 4.2 Safety Valve The safety valve is an integral part of the boiler. It cannot be adjusted but has a manual test device. 4.3 Pressure Gauge A pressure gauge is incor...

[Page 12] Saunier Duval SB30e

12 221872B BOILER FILLING POINT DRAIN POINT ’A’ FLOW CONTROL VALVE HEATING CIRCUIT RETURN ADDITIONAL EXPANSION VESSEL (if required) Diagram 4.3 METHOD 1 METHOD 2 METHOD 3 SUPPLY STOP VALVE SUPPLY PIPE HOSE UNIONS SERVICING VALVE TEMPORARY HOSE H...

[Page 13] Saunier Duval SB30e

13 221872B 7.1 Flue Position and Length Determine flue application, length and terminal position before starting, refer to diagram 7.1. Note: The Easyfit Top Outlet Flue Pack and the Extended Top Outlet Flue Pack contains a flue duct extension piece ...

[Page 14] Saunier Duval SB30e

14 221872B 7 Flue Preparation Diagram 7.1 9360 TOP OUTLET/ REAR FLUE TOP OUTLET/ SIDE FLUE 15mm VIEW 'B' VIEW 'B' 15mm EASYFIT/EXTENDED TOP OUTLET FLUE PACK & 1 METRE EXTENSION KIT SCREW & TAPE SCREW & TAPE SCREW &...

[Page 15] Saunier Duval SB30e

15 221872B 7.3 Internal Access Flue If access to the outside wall is not practical, the flue system can be installed from inside. Use of the optional wall liner kit is required. 7.4 Rear Outlet Flue Fixing Fit the self adhesive foam seal provided in ...

[Page 16] Saunier Duval SB30e

16 221872B 8 Mounting the boiler 7011 Diagram 8.2 COMBUSTION CHAMBER PANEL RETAINING LUG (4) TRANSIT SCREW (2) 8.1 Boiler Mounting Remove the inner case front, secured by two clamps at the bottom lift up and unhook from the threaded lugs at the top, ...

[Page 17] Saunier Duval SB30e

17 221872B 8.2 Water and Gas Connections Locate the boiler water pipes and gas supply pipe making sure the washers are retained in the tubing nuts onto the isolation valves, fully push the boiler back, see diagram 8.8. Ensure the bottom boiler bracke...

[Page 18] Saunier Duval SB30e

18 221872B Diagram 8.10 AIR DUCT FLUE SPIGOT TAB (2) CUTOUT (2) 7305 7798 Diagram 8.9 UNION CONNECTION DISCHARGE PIPE 8 Mounting the boiler SAFETY VALVE DISCHARGE 8081 Diagram 8.8 CENTRAL HEATING RETURN ISOLATION VALVE GAS SUPPLY SEAL PRESSURE GAUGE ...

[Page 19] Saunier Duval SB30e

19 221872B 7308 Diagram 8.11 FAN FLUE DUCTING FLUE CONNECTING SLEEVE 8 Mounting the boiler 7307 Diagram 8.13 7901 Diagram 8.14 FAN FLUE DUCTING FLUE CONNECTING ELBOW SECURING SCREW RETAINING LIP FLUE DUCTING FLUE CONNECTING SLEEVE FLUE COLLECTOR RETA...

[Page 20] Saunier Duval SB30e

20 221872B 9 Electrical Connections 9.1 Supply Cable Connection CAUTION: To prevent an induced current from switching the appliance on, when not required, it is important that the system control cables are separated from the other mains supply cable...

[Page 21] Saunier Duval SB30e

21 221872B 9 Electrical Connections Diagram 9.2 7847 MAINS CABLE SCREW (2) CABLE CLAMP CONNECTION BLOCK SCREW (2) CONNECTION BLOCK PROGRAMMER PROGRAMMER BRACKET SCREW (2) PROGRAMMER PLUG MAINS SUPPLY ROUTING GROMMET MAIN TERMINAL BLOCK BRACKET MAIN T...

[Page 22] Saunier Duval SB30e

22 221872B Commissioning must only be carried out by a competent person in accordance with the current issue of BS6798. Please ensure the “Benchmark” logbook is completed and left with the user. 10.1 System Commissioning Check that the boiler is ...

[Page 23] Saunier Duval SB30e

23 221872B 10 Commissioning 6989 Diagram 10.1 BURNER PRESSURE TEST POINT GAS CONTROL VALVE MINIMUM RATE ADJUSTMENT SCREW MAXIMUM RATE ADJUSTMENT SCREW (Cap removed) 10.7 Instruct the User Instruct and demonstrate the lighting procedure, then advise t...

[Page 24] Saunier Duval SB30e

24 221872B 10 Commissioning 7020 Diagram 10.4 7021 SIDE PANEL SECURING SCREW (4) OUTER CASE FRONT SECURING NUT (6) SECURING SCREW (2) Diagram 10.3 7802 SECURING SCREWS CUTOUT CASE BASE Diagram 10.5 CUTOUT WRAP AROUND DATA LABEL ...

[Page 25] Saunier Duval SB30e

25 221872B SPARE PARTS REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been cle...

[Page 26] Saunier Duval SB30e

26 221872B 12 Servicing 12.4 Cleaning Main Burner Use a vacuum cleaner or suitable brush to clean the burner thoroughly, making sure that all burner ports are clear and unobstructed. Do not use a brush with metallic bristles. 12.5 Service Checks Insp...

[Page 27] Saunier Duval SB30e

27 221872B 12.6 Spark Gap Check that the spark and sensing gaps are as shown in diagram 12.6. 12.7 Operational Checks Light the boiler, carry out operational checks and any necessary adjustments as described in “Commissioning” in the Installation...

[Page 28] Saunier Duval SB30e

28 221872B F1 T2A yellow black brown blue red brown brown brown black N OVERHEAT CUTOFF PRESSURE DIFFERENTIAL CONTROL BOARD GAS VALVE PROGRAMMER SUPPLY PLUG ON/OFF SWITCH TERMINAL BLOCK SPARK ELECTRODES PERMANENT MAINS 230V-50HZ FAN PUMP X3 X3 X3 X3...

[Page 29] Saunier Duval SB30e

29 221872B 13 Fault Finding TO TEST FOR COMPONENT OPERATION / FAILURE Power to the appliance :- Test for 230V~ across live (brown) and earth (yellow and green), 230V~ across live and neutral (blue), and zero potential across neutral and earth. Therm...

[Page 30] Saunier Duval SB30e

30 221872B Check gas,water and electricity are available at the boiler. Before commencment of test, isolate the boiler electricity supply, ensure that the remote controls are not calling for duty. Check appliance installation and that it is mechanic...

[Page 31] Saunier Duval SB30e

31 221872B Is the air pressure switch functioning?. Change P.C.B. NO Replace air pressure switch. NO Replace P.C.B. Replace P.C.B. Replace P.C.B. Does the ignition electrode begin to spark? Does the gas control valve open to ignition rate between (5 ...

[Page 32] Saunier Duval SB30e

32 221872B 13 Fault Finding Diagram 13.5 7937 BROWN BLUE ORANGE RED BLACK LN 12 3 4 5 Diagram 13.4 7850 SECURING SCREW (3) PLUG PROGRAMMER ELECTRICAL CONNECTION (2) 13.2 Programmer If the programmer has failed it can be bypassed by disconnecting the ...

[Page 33] Saunier Duval SB30e

33 221872B 14.1 Fan Before starting refer to Section 11. Disconnect the two electrical connectors at the fan by pulling the boots not the wires, see diagram 14.1. Remove the two flexible tubes from the fan, noting their colour and positions, see diag...

[Page 34] Saunier Duval SB30e

34 221872B 14 Replacement of Parts SAFETY VALVE WASHER 7803 Diagram 14.4 UNION NUT Diagram 14.5 SECURING SCREW (2) RETAINING BRACKET (2) PRESSURE GAUGE 7026 FACSIA UNION NUT UNION NUT CLIP DISCHARGE PIPE EXPANSION VESSEL PIPE 14.8 Pressure Gauge Befo...

[Page 35] Saunier Duval SB30e

35 221872B Diagram 14.7 6982 CONTROL BOARD SENSING LEAD SUPPORT POSTS (4) Diagram 14.8 SECURING SCREWS (8) GAS SUPPLY PIPE) GAS CONTROL VALVE 7813 MANIFOLD MULTI PIN CONNECTOR Diagram 14.9 SPINDLE 7814 PUMP PLUG END SCREW TERMINAL COVER SCREW PUMP A...

[Page 36] Saunier Duval SB30e

36 221872B 14 Replacement of Parts Diagram 14.10 7815 LOW WATER PRESSURE SWITCH RETAINING CLIP LEFT HAND HYDRO BLOCK PLASTIC COVER Remove the clip to remove the water pressure switch, see diagram 14.10 Remove the plastic cover. Remove the electrical ...

[Page 37] Saunier Duval SB30e

37 221872B PRESSURE DIFFERENTIAL MICRO SWITCH Diagram 14.11 7830 SECURING CLIP 7831 PRESSURE DIFFERENTIAL MICRO SWITCH Diagram 14.12 HYDRO BLOCK ASSEMBLY SECURING PIN 1 SECURING PIN 4 SECURING PIN 5 SECURING PIN 2 LOW WATER PRESSURE SWITCH PUMP FILTE...

[Page 38] Saunier Duval SB30e

38 221872B 14 Replacement of Parts REAR OF THE BOILER SECURING PIN (2) BYPASS TUBE 7832 'O' RING (2) Diagram 14.17 BYPASS VALVE LEFT HAND SIDE HYDRO BLOCK 7833 SECURING PIN 'O' RING REAR OF THE BOILER Diagram 14.13 7895 Diagram 14...

[Page 39] Saunier Duval SB30e

39 221872B Diagram 14.19 7835 AUTOMATIC AIR VENT PUMP AIR VENT CAP Diagram 14.18 7834 EXPANSION VESSEL UNION NUT CONNECTION SECURING SCREW (2) Remove the two screws at the service cock bracket, see diagram 8.6. Ease the boiler from the isolating val...

[Page 40] Saunier Duval SB30e

40 221872B 14 Replacement of Parts Diagram 14.20 9376 PIPE SECURING CLIP (2) HEAT EXCHANGER BAFFLE SIDE INSULATION (2) FRONT RETAINING CLIP (2) COMBUSTION CHAMBER MAIN PANEL SECURING SCREW (4) 'O' RINGS BEADING 14.21 Heat Exchanger Before s...

[Page 41] Saunier Duval SB30e

41 221872B 7002 SELF ADHESIVE ALUMINIUM FOIL GASKET OPENING (BOILER INNER CASE FRONT) Diagram 14.22 PEEL OFF BACKING PAPER MICA WINDOW 14 Replacement of Parts FRONT INSULATION Diagram 14.21 COMBUSTION CHAMBER FRONT PANEL REAR INSULATION SIDE INSULATI...

[Page 42] Saunier Duval SB30e

42 221872B CONTROL BOARD MAINS SWITCH THERMISTOR N/O N/C C WATER PRESSURE SWITCH AIR PRESSURE SWITCH GAS VALVE SENSING ELECTRODE IGNITION ELECTRODE EARTH ELECTRODE PRESSURE DIFFERENTIAL MICRO SWITCH BOILER OVERHEAT CUT-OFF FAN w- WHITE b- BLUE bk- B...

[Page 43] Saunier Duval SB30e

43 221872B Diagram 15.1 7807 4 7 6 1 12 3 18 13 2 5 16 14 15 11 15 Spare Parts Key No Part No Description GC No 17 15.1 Part Identification The key number in diagram 15.1 and the first column of the list will help identify the spare part. 15.2 Order...

[Page 44] Saunier Duval SB30e

44 221872B Because of our constant endeavour for improvement, details may vary slightly from those shown in these instructions. ...