Heatline SARGON 18S Installation, Servicing And User Instructions Manual Download

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SARGON 18S / 24S / 30S

PRE-MIX

CONDENSING

SYSTEM BOILER

Installation, Servicing
and User Instructions

Summary of Contents for SARGON 18S

Page 1: ...SARGON 18S 24S 30S PRE MIX CONDENSING SYSTEM BOILER Installation Servicing and User Instructions ...

Page 2: ...condensate outlet to the bottom left hand corner of the boiler as shown in the diagram 2 Cut the plastic hose to desired length and fit a plastic coupling to connect to your plastic waste pipe NOTE Removal of the condensate trap for cleaning purposes 1 Pull off the plastic hose from the condensate trap 2 Unscrew the bottom of the trap in an anti clockwise direction by hand The accessory for the co...

Page 3: ...ment of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings Benchmark Log Book Boiler Registration SEDBUK As part of the industry wide initiative the boiler comes complete with an Installation Commissioning and Service Record Log Book Please read the Log book carefully and in accordance with current legislation complete all sectio...

Page 4: ...ctrical Connections 13 Wiring Diagram 14 10 Boiler Installation 15 11 Gas Supply 19 12 Filling the System 19 13 Control Panel Functions 20 14 Commissioning 23 15 Onboard Adjustments 24 16 Safety Devices 26 17 Routine Servicing 27 18 Component Replacement 30 19 Gas Type Conversion 37 20 Fault Finding Chart 38 Appendices Appendix 1 Spare Parts List 41 Appendix 2 User Instructions 42 Appendix 3 Bench...

Page 5: ...s currently in force Read these instructions carefully before installing or using the appliance Manual Handling When manoeuvring the boiler always use safe techniques keep your back straight bend your knees don t twist move your feet Avoid bending forwards or sideways and keep the load as close to your body as possible Where possible transport the boiler using a suitable trolley sack truck or get ...

Page 6: ...ied to these terminals For mains powered thermostat connection see section 9 5 Warning High Voltage This sign is located on the back of the control box housing warning of high voltages within the control box Turn off and isolate the appliance before removing this cover NOTE Take care as there may be residual voltage within some components LOW VOLTAGE ROOM THERMOSTAT This picture shows the terminal...

Page 7: ...oilers of rated input not exceeding 70kW BS 5449 Central heating for Domestic Premises BS 5546 Installation of gas hot water supplies for domestic purposes BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding 70kW Part 1 Flues BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding 70kW Part 2 Air Supply BS 6891 Installation of low pressure gas pipe w...

Page 8: ...Diaphragm LPG colour Red Max power consumption Watts 175 Level of protection IPX4D Maximum heating temperature ºC 84 85 Max domestic hot water temperature ºC 60 Operating pressure PMS Min Bar 8 0 5 Expansion Vessel Capacity litres 7 Expansion Vessel Pre charge bar 0 5 Air Intake Pipe Diameter mm 100 Flue Pipe Diameter mm 60 100 concentric 80 80Twin CO2 at nom 0 1 NG 9 8 9 5 9 9 CO2 at nom 0 1 Prop...

Page 9: ...sor Flow 11 Pressure Relief Valve 12 Gas Valve 13 Pressure Sensor 14 Pump 15 Return Hydroblock 16 Central Heating Temperature Sensor Return 17 Condensing Trap 18 Burner 19 Plastic Flue Channel 20 Automatic Air Vent 21 Pressure Relief Valve Figure 1 Valves A Heating Flow 22mm Red B Gas Inlet 22mm Yellow C Heating Return 22mm Blue with filter Figure 1a C D E F G H BOTTOM VIEW C 39mm D 65mm E 86mm F ...

Page 10: ...an automatic system by pass should be fitted as far away from the boiler as possible Note It is no longer permissible to utilise a non thermostatic controlled radiator as a by pass 3 6 Room temperature can be controlled by the use of an external room thermostat and thermostatic radiator valves Note connection of the room thermostat is dependant on the operating voltage of the thermostat See sectio...

Page 11: ...of time to dissipate any excess heat from within the boiler s heat exchanger If during the heating period there is a call for hot water this will take preference over heating When satisfied the boiler will then supply the heating demand as required Note there will be a delay of 45sec delay depending on how the boilers dipswitches are set See section 15 3 for details 4 4 DOMESTIC HOT WATER MODE Whe...

Page 12: ...20 C temperature rise across the boiler flow and return 5 5 When fitting a new boiler to an existing system the system must be thoroughly flushed in accordance with the recommendations of BS7593 2006 prior to installation NOTE Also that the gas supply pipe to the boiler from the meter should be in 22 mm copper 5 6 It is recommended that the system should be protected by a proprietry anticorrosion ...

Page 13: ...f the temperature falls too low However if the electrical supply is to be turned off the boiler the heating system and domestic hot water circuit must be drained 9 6 Appliance Sitting 6 1 If the boiler is to be installed in any room or compartment it does not require any purpose made ventilation for combustion air If sited in a room containing a bath or shower then particular reference is drawn to...

Page 14: ... All wall mounted terminals sited within 2m of the level which people have normal access should be adequately protected with a suitably sited guard 7 3 Where the flue terminates within 1m of a plastic or painted gutter or within 500mm of painted eaves then protection should be provided in the form of an aluminium shield at least 1m in length fitted to the underside of the gutter or painted surface...

Page 15: ...iler and the vertical extension pipes and roof terminal are connected by clips 8 5 The 80 80mm twin flue pipe system may be extended up to a maximum of 20m in any combination of horizontal or vertical configuration using additional spare components available from your boiler supplier or Heatline stockist NOTE When such a system is used it is necessary to have all joints accessible for inspection 8...

Page 16: ...all 300 P From a structure on the roof or another roof terminal 600 Q From a vertical flue terminal to an adjacent wall 300 R From a vertical flue terminal to an adjacent wall which includes an open ing window See Note 3 1000 Notes 1 An opening here means an opening element such as an openable window or a fixed opening such as a air vent However in addition the outlet should not be nearer than 150...

Page 17: ...ge room thermostat terminal block is located behind the plastic cover on the left hand side figure 7 On connection of a voltage free room thermostat to the boiler the factory fitted bridge across the room thermostat terminal connectors must be removed If a mains voltage thermostat is to be used then please refer to 9 5 below and the electric wiring diagram in figure 8 9 5 Mains powered thermostats...

Page 18: ...safety checks for earth continuity earth resistance polarity and short circuit are carried out prior to making the final connection A diagram of the boiler s electrical circuit is given as figure 8 Fuse ratings 2AT Figure 8 Open Therm On Off Low Voltage Room Thermostat Mains powered thermostat connections ...

Page 19: ...nd 7 of these instructions 10 3 Position the supplied template on the wall ensuring it is level both vertically and horizontally figure 10 Mark the boiler wall bracket fixing positions and flue outlet position rear flue only For flue side exit from the boiler Mark the horizontal flue centre line on the rear wall Extend the horizontal line to the side wall allowing a 3 decline back if required see ...

Page 20: ...bracket via the boiler mounting slots figure 12 10 7 Connect isolation valves to the boiler ensuring the washers are fitted correctly NOTE Refer to Figure 1 which shows the correct location of each valve 10 8 Condensing type boilers must be connected to an appropriate drainage system either a A corrosion resistant or plastic drain must be fitted to allow discharge of condensate to a drain see figu...

Page 21: ...d free from burrs Figure 14 10 13 Measuring from the back of the terminal connection mark distance L 10mm figure 15 onto the inner flue duct and cut the duct to size ensuring that the cut is square and free from burrs Figure 15 10 14 Pass the flue assembly through the wall and connect the assembly to the boiler ensuring that both the air and flue duct joints are fully pushed home into the connecti...

Page 22: ...an be found for future reference NOTE Please instruct the user how to top up the pressure if required 10 18 Connect the cold water inlet heating system flow return and pressure relief valve pipework to the supplied boiler fittings ensuring that the pipework has been correctly flushed before final connection 10 19 The electrical connections to the boiler must be in accordance with Section 9 of thes...

Page 23: ...e correctly made the boiler may be filled with water via the filling loop not supplied with the boiler Ensure that two manual feed valves and boiler isolation valves are open 12 3 Release the cover cap on the boiler s automatic air vent which is located on top of the internal pump figure 17 and the manual vent on top of the heat exchanger when filling the system Figure 17 12 4 The manual feed valv...

Page 24: ...er operates the resistance measured is compared to the manually set reference value The differential determines the modulation of the gas valve adjusting the useful heat output generated and stabilising the temperature to within 1ºC 13 2 Re set Function Should the boiler lock out at any time please check the water pressure which should be between 0 8 and 2 0bar the gas supply and ionisation probe ...

Page 25: ... H Indicator 3 Reset Indicator 6 Water Temperature Indicator Failure Codes F0 The Water Pressure is TOO LOW or TOO HIGH F1 Lockout due to overheating This may be the overheat thermostat or thermal fuse NOTE If the Thermal Fuse has blown the boiler will not re set until the heat exchanger has been replaced F3 Primary temperature probe damage F4 Lockout due to ignition problem or Condensate Trap Blo...

Page 26: ...cond pipe on the right to either one of the outer pipes see figure 2 DO NOT CLOSE ANY OF THE THREE SERVICE VALVES CONNECTED DIRECTLY TO THE BOILER If the boiler frequently loses pressure then your installer should be consulted Failure to have leakage repaired may cause corrosion within your heating system Figure 20 The operational time periods may be set as follows Rotate the clock actuator mechan...

Page 27: ... it s on board controls to suit the demand of the system 14 2 Prior to firing the condensate trap must be filled with water and plastic discharge pipe connected to drain before operating the boiler see section 10 9 for details check that the electrical supply to the boiler is On Indication is shown on the LCD display and the gas service cock is in the open position Set the boiler s central heating...

Page 28: ...switch settings The potentiometer settings are the same for NG and LPG Potentiometers on the back of the board SARGON 18S SARGON 24S SARGON 30S No Function Factory Settings Factory Settings Factory Settings 1 R31 Maximum fan speed 2 o clock 10 o clock 10 o clock 2 R29 Maximum CH power 6 o clock 6 o clock 7 o clock 3 R30 Ignition power 6 o clock 6 o clock 6 o clock 4 R28 Anti cycling time 9 o clock...

Page 29: ... The boiler is capable of up to 255 seconds ignition delay anti cycling time before re ignition following burner shut down on the primary hydraulic water reaching its set temperature This delay can be increased up to a maximum of 255 seconds by turning potentiometer R28 Figure 22 clockwise 15 4 Pump working mode setting The boiler has a factory set to operate the pump for pre purge and post purge ...

Page 30: ...ure of the system is 1 5bar when cold 16 2 The temperature of the water flowing from the primary heat exchanger is monitored by an overheat thermostat located on the outlet pipe If the water temperature gets too hot the switch opens cutting off the electrical supply to the gas valve and causing the boiler to Lock out fault code F1 Once activated the boiler has to be cooled and manually re set by s...

Page 31: ...ce a year following the procedures set out below 17 2 Prior to servicing a check of the flue operation and terminal guard if fitted along with a preliminary check of the boilers operation must be undertaken 17 3 Ensure that both the electrical and gas supplies to the boiler are isolated before commencing any work on the boiler 17 5 Remove the boiler casing as follows Open the front panel by removi...

Page 32: ...of the gas valve figure 28 and release the pipe from the fan assembly Be careful not to damage or dislodge the restrictor located in the gas valve outlet Remove the nuts from around the heat exchanger and after disconnecting the electrodes figure 29 pull the fan and burner assembly forward giving access to the fan connections Release the electrical leads and remove the burner fan assembly Figure 3...

Page 33: ...ing the service reassemble the boiler components in reverse order Take care not to damage or dislodge the gas restrictor and ensure that all component joints gaskets are sound Any damaged gaskets must be replaced 17 11 Reinstate the boiler s electrical and gas supplies and check for gas tightness and correct boiler operation 17 12 Due to the construction of the heat exchanger the condensate trap s...

Page 34: ...arts of the boiler insulation pads gaskets and rope seals are manufactured from man made fibres When damaged or broken these fibres may cause a temporary irritation High dust levels may irritate eyes and upper respiratory system It is important therefore that sensible precautions are applied when exchanging components NOTE 1 Ensure that both the electrical and gas supplies to the boiler are isolat...

Page 35: ...the pipe from the fan assembly Be careful not to damage or dislodge the restrictor located in the gas valve outlet Remove the nuts securing the fan assembly to the front of the heat exchanger and pull the fan assembly forward giving access to the fan connections Release the electrical leads and remove the burner fan assembly Fit the replacement fan unit in reverse order and reconnect all electrica...

Page 36: ...e PCB to the control panel and lift out the PCB Fit the replacement PCB in reverse order of removal ensuring that the PCB electrical connections are correctly located and fully pushed home 18 6 Pump Read the notes at the head of this section before commencing any work on the appliance The order of removal is dependant on whether it is the motor or body that has failed In case of motor failure Disc...

Page 37: ...mp body assembly Detach the pump body from the hydraulic block by removing the clip Fit the replacement body in reverse order ensuring that the pump washers are fitted and the correct polarity of the electrical connections is maintained Open the isolating valves on the flow and return connections refill vent and re pressurise the system ensuring the pump union joints are sound 18 7 Primary Heat Ex...

Page 38: ...the silicone tube and electrical connections from the gas valve Undo the nut on top of the gas valve figure 40 and release the pipe from the fan assembly Be careful not to damage or dislodge the restrictor located in the gas valve outlet Figure 40 Release the main gas connection below the gas valve Remove the gas valve s two securing screws and washers from the bottom side of boiler Figure 41 Rota...

Page 39: ...Heating Mode three times each within a two second interval A wrench symbol will be displayed in the LCD window and the boiler will ignite at minimum rate In this mode of operation the gas rate will be controlled by the CH control for 15min after which time normal operation will take over and the wrench symbol will disappear With the CH control knob at minimum gas rate using a 4mm allen key adjust ...

Page 40: ...pressurise the boiler ensuring all joints are sound Figure 43 Figure 44 18 11 Overheat Safety Thermostat Read the notes at the head of this section before commencing any work on the appliance Locate the overheat safety thermostat upstream of the three way valve see figure 1 Disconnect the electrical connections from the thermostat Remove the thermostat from the pipe being careful not to damage the...

Page 41: ...e boiler this includes converting to a different gas type Change the diaphragm which is located in the outlet of the gas valve See section 2 technical data table for gas valve diaphragm details Once re assembled check for gas tightness Set the CO2 as described in section 18 11 Gas Conversion Setting noting the correct CO2 value for the type of gas that will be used Check for correct boiler operati...

Page 42: ...e following carefully before starting Gas supply is on adequate and purged Electric supply is on Polarity is correct Pump spins freely Winter mode is selected by function knob on front panel CH system pressure is must be between 1 and 2 bar Check low water pressure switch cable connections Check and if necessary replace low water pressure switch Check suppy lead F1 F2 fuse and replace if necessary...

Page 43: ...repl ace Main PCB NO Check External CH control inputs and wiring Check and if necessary replace main PCB Check cable connections of fan and if necessary replace fan or repl ace main PCB Check cleaning of fan and if necessary replace fan Chart III Fan Operation Is 24 V dc present on X4 1 3 terminals NO YES Check an d if necessary replace main PCB Go to Chart I YES Re set control if neccesary Does f...

Page 44: ...on of the hydroblock from the pump by releasing the clip Figure 49 Release the heat exchanger outlet pipe nut and rotate the pipe for ease of removal from the remaining section of the hydroblock as described in 18 2 Disconnect the three way valve stepper motor electrical connection and remove the stepper motor by releasing the clip as described in 18 17 Release the nut connecting the CH outlet con...

Page 45: ...8 CIRCUIT BOARD 3003201368 9 INTERFACE BOARD 3003201933 10 WIRING HARNESS WITH TIMER 3003201954 11 IGNITION ELECTRODE CABLE 3003201985 12 IONASITON ELECTRODE CABLE 3003201986 13 FLUE SENSOR 3003201949 14 CH SENSOR NTC 3003200152 15 FAN 3003201367 16 LIMIT THERMOSTAT 3003200397 17 FRONT PANEL 3003201988 18 SPARK GENERATOR 3003201369 19 RETURN GROUP 3003200018 20 CONDENSATE TRAP 3003201775 APPENDICE...

Page 46: ...42 SARGON 18S 24S 30S PRE MIX CONDENSING SYSTEM BOILER User Instructions ...

Page 47: ...pment of their appliances to ensure their customers benefit from the latest advances in combustion technology and energy savings Benchmark Log Book Boiler Registration SEDBUK As part of the industry wide initiative the boiler comes complete with an Installation Commissioning and Service Record Log Book Please read the Log book carefully and in accordance with current legislation complete all secti...

Page 48: ...1minute Go to Cha rt 4 Check supply lead Check CH sensor cab le connections Is F3 failure code shown on lcd YES Check pump connection cables and 230 V ac supplying of pump Does pump run NO Does burner work YES NO Go to Char t 5 Winter mode is sele cted by function selector knob on front panel Ch heat demand present Chart I Check electrical supply D C H s ensor and frost prot ection Chart II Check ...

Page 49: ...excess heat within the boiler ACCESS TO THE BOILER CONTROLS The boiler controls are sited at the bottom of the boiler s front case See figure 2 Figure 2 BOILER CONTROLS The function and operation of the main controls located on the control panel fascia figure 3 is as follows Figure 3 1 Analogue Timer 4 C H Pressure Gauge 2 C H Temperature Control 5 LCD Display 3 Function Switch 1 Pressure Gauge Sh...

Page 50: ... 6 0 Down position The boiler is off independent of the function switch 4 LCD Display Screen While giving the operational status of the boiler and water temperature to aid in fault diagnostics the control unit has a built in facility that automatically indicates a fault status If more than one fault simultaneously occurs then only the highest priority fault is displayed Figure 4 Figure 4 4 1 Flame...

Page 51: ... pipes see figure 11 DO NOT CLOSE ANY OF THE THREE SERVICE VALVES DIRECTLY CONNECTING TO THE BOILER If the boiler frequently loses pressure then your installer should be consulted Failure to have leakage repaired may cause corrosion within your heating system OPERATING THE BOILER Prior to operating the boiler check that the pressure reading on the LCD panel lies between 1 and 2bar Set the boiler s...

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Page 54: ...NOTES 3003202113 01 ...

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