Saunier Duval Thema F 23
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Heating and hot water for the professionals
Installation and Servicing Instructions
THIS IS A CAT II2H3+ APPLIANCE
IN WARRANTY TECHNICAL HELPLINE
INSTALLATION AND SERVICING INSTRUCTIONS
THEMA F 23 E - THEMA F SB 18 E - THEMA F SB 23 E
Note! The boiler serial number is marked on the label attached to the inside of the boiler. Refer to the 'Introduction' section page 3 for a description of the basic functions of the boiler. To safely operate the boiler, refer to the Users Instructions.
Introduction.. Page 3 Dimensions... 3 Technical data.. 4 - 5 Boiler schematic.. 6 Fixing jig... 7 Domestic hot water system design. 7 Heating system design... 8 Piping system installation.. 8 Boiler location... 9 Boiler installation.. 10 Rear outlet flue installation.. 11 - 12 Top outlet flue installation.. 13 Electrical connection... 14 Commissioning.. 15 - 16 Safety devices... 16 Settings... 17 Changing gas type.. 17
Routine cleaning and inspection. Page 18 - 19 Replacement of parts.. 19 - 24 Microswitch assembly... 19 Fan... 19 Air pressure switch.. 19 Spark generator... 19 Main printed circuit board.. 19 Ignition printed circuit board.. 20 Pump... 20 Temperature/Pressure gauge.. 20 Reversing valve assembly.. 20 Reversing valve front section.. 21 Loss of water switch.. 21 Water valve or diaphragm.. 21 Gas valve... 22 Modulating coil... 22 Central heating safety valve.. 23 Heat exchanger.. 23 Expansion vessel.. 23 Boiler thermistor... 23 Overheat thermostat.. 24 Combustion chamber insulation.. 24 Ignition electrode.. 24 Flame sense electrode.. 24 Burner... 24 Burner injectors.. 24 Timeclock... 24 Schematic wiring diagram.. 25 Fault finding... 26 - 27 Spare parts... 27
Mandatory warning notice 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 you assistance.
The THEMA F 23 E boiler is a wall mounted modulating combination boiler with electronic ignition providing central heating and instantaneous domestic hot water. 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 THEMA F SB 18 E and SB 23 E boilers are wall mounted modulating boilers with electronic ignition providing central heating only. The central heating temperature is user adjustable from the boiler control panel. The boilers are of the II2H3+ category for use with Natural Gas (G20) as distributed in the United Kingdom, or with Butane or Propane gas (G30/G31) with the appropriate conversion kit. Conversion kits: Conversion Part No. Natural Gas (G20) to G30/GBoilers burning LPG or similar gases MUST NOT be fitted in basements or below ground level. The boiler has a fan assisted balanced flue which both discharges the products of combustion to and draws the combustion air from the outside air.
The boiler is supplied for rear outlet flue connection. Alternatively, the boiler is designed to allow the flue system to be connected to the top of the boiler, top outlet flue connection. Refer to the flue fitting instructions. Electrical components have been tested to meet the equivalent requirements of BEAB. 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. 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. The installation must be carried out by a competent person in accordance with the relevant requirements of The Building Regulations, The Water Byelaws, The Building Standards (Scotland) Regulations and any applicable local regulations. Ancillary equipment A range of flue accessories are available including vertical flues, twin-pipe flues, bends etc. For further information contact your supplier.
1 Bypass fully shut 2 Open 1/4 turn 3 Open 1/2 turn 4 Open 1 turn 5 Open 2 turns
Flow rate through heating system (I/h)
24 Ignition module Heating temperature adjuster Hot water temperature adjuster Temperature/ressure gauge Expansion vessel Pump Automatic air vent Burner Heat exchanger bleed pipe Heatexchanger Gas valve Heating and hot water thermistor Ignition electrode Overheat thermostat Flame sense electrode Loss of water pressure switch Fan Air pressure switch Gas cock
A B C D E
Heating return Cold water inlet Heating flow Domestic hot water flow Gas supply
THEMA F SB 18 E - THEMA F SB 23 E
Ignition module Heating temperature adjuster Temperature/pressure gauge Expansion vessel Pump Automatic air vent Burner Heat exchanger bleed pipe Heatexchanger Gas valve Heating and hot water thermistor Ignition electrode Overheat thermostat Flame sense electrode Loss of water pressure switch Fan Air pressure switch Gas cock
From left to right, the fixing jig comprises: A - Heating return with isolating valve (m). B - Cold water inlet with isolating valve (p). C - Heating flow with isolating valve (q), drain screw (r) and safety valve (s). D - Domestic hot water out. E - Gas service cock.
3 A B C
Filters and washers : 1 - Washer 2 - Metal filter 3 - Flow regulator 4 - Plastic filter 5, 6 & 7 - Washers
p r q s
THEMA F SB 18 THEMA F SB 23 E
From left to right, the fixing jig comprises: A - Heating return with isolating valve (m). C - Heating flow with isolating valve (q), drain screw (r) and safety valve (s). 3 E - Gas service cock. 11
m p r q s 7 E
DOMESTIC HOT WATER SYSTEM DESIGN
Copper tubing or plastic Hep2 O may be used for the domestic hot water system. Unnecessary pressure losses should be avoided. The boiler may operate with a minimum supply pressure of 0,3 bar but under a reduced flow rate. Optimum performance will be obtained from a supply pressure of 1 bar. The flow restrictor must be fitted in the cold water inlet during installation. This limits the flow through the boiler to a maximum of 12 l/min.
HEATING SYSTEM DESIGN
The THEMA F boiler is compatible with any type of installation. Heating surfaces may consist of radiators, convectors or fan assisted convectors. Pipe sectional areas shall be determined in accordance with normal practices, using the output/pressure curve (diagram 3). 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 20C. The minimum flow is 500 l/h. The piping system shall be routed so as to avoid any air pockets and facilitate permanent venting of the installation. Bleed fittings shall 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 1 bar (corresponding to a static head of 5 m w.g.) and allows a maximum system volume of 140 litres for an average temperature of 75C 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 6. 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 using a proprietary product such as Fernox or Sentinel. Contact the product manufacturers for specific details. Filling the system Provision must be made for filling the system at low level. The use of a WRC approved filling loop is strongly recommended, connected as shown in diagram 6.
PIPING SYSTEM INSTALLATION
Heating system connections - Pipe diam 22 mm Hot water system connections - Pipe diam 15 mm Gas connection - Pipe diam 22 mm Safety valve discharge - Pipe diam 15 mm Safety valve discharge WARNING. It must not discharge above an entrance or window or any type of public access area. Connect the safety valve discharge pipe to the boiler, the discharge must be extended using not less than 15 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 competent person in accordance with the above regulations.
Water connection Connect the water pipes to the fixing jig using the copper tails supplied, see diagram 5. Warning: To prevent damage to the isolating cocks, do not solder joints or fittings with the copper tails connected. Connect the system pipework to the boiler observing the correct flow and return format as shown in diagram 6.
Additional expansion vessel (if required)
Minimum 22 mm diameter Return Heating circuit Flow control valve Bypass valve Filling point
Pressure reducing valve (supplied)
Clearances The position of the boiler must be such that there is adequate space for servicing. The recommended clearances are: 40 mm either side of the boiler. 600 mm at the front of the boiler. 300 mm below the boiler. Fixing jig The fixing jig comprises three parts: 1) The connecting plate which allows the connection and soundness testing of all the pipework before the boiler is fitted and helps support the weight of the boiler. 2) The hook which supports the weight of the boiler. 3) The template which ensures the hook and connecting plate are correctly fitted relative to one another. Place template on wall in required position, making allowances for the necessary clearances etc., see diagram 7. Note: It is permissible to install the boiler with reduced clearances at the bottom and sides of the boiler 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. Mark the position of the holes for the hook and connecting plate. Drill, plug and fix the connecting plate and hook to the wall using suitable screws. Check that both the hook and connecting plate are level. If the boiler is not installed immediately, protect the various couplings to prevent any ingress of foreign materials e.g. plaster, paint etc. Terminal position The minimum acceptable spacings from the terminal to obstructions and ventilation openings are shown in diagram 8.
The boiler must be installed so that the terminal is exposed to the external air. Note: Under certain weather conditions the flue may produce a plume of condensation, this is quite normal. If the terminal is fitted within 850mm of a plastic or painted gutter or 450m of painted eaves, an aluminium shield of a minimum length of 750mm should be fitted to the underside of the gutter or painted surface. Should any doubt exist as to the permissible position of the terminal, contact the Saunier Duval Technical Helpline 01773 828400. Cupboard or compartment ventilation The boiler can be fitted in a cupboard or compartment without need for permanent ventilation.
Minimum dimensions (in mm) for the positioning of flue terminals
A - Under a window.. 300 B - Under an air vent.. 300 C - Under a gutter.. 75 D - Under a balcony.. 300 E - From an adjacent window.. 300 F - From an adjacent air vent.. 300 G - From vertical drain pipes or soil pipes. 75 H - From an external corner of the building.. 300 I - From an internal corner of the building. 300 L - From the ground or from another floor. 300 M - Between two terminals vertically.. 1500 N - Between two terminals horizontally. 300
G C E F M
A B D I H L
Statutory requirements The installation of this boiler must be carried out by a competent 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 so as to eliminate any foreign bodies and contaminants such as filings, solder particles, oil, grease etc. Note. Solvent products could cause damage to the system. Note. If using a rear outlet flue system, follow the instructions in 'Rear outlet flue installation' section prior to hanging the boiler. Engage boiler upper part onto the hook, see diagram 9. Allow the boiler to seat down onto support plate, see diagram 10. Fit filter and washers, strictly adhering to the sequential order and directions shown on diagram 5. Connect the various couplings between the boiler and the connection plate.
Table 1 Flue cutting lengths
Cutting length (mm) Flue option Rear outlet Side flue to left (Diagram 13) Rear outlet Side flue to right (Diagram 14) outer pipe e + a + 96 inner pipe e + a + 173 Comments maximum distance 'X' without extension 1080 mm maximum distance 'x' without extension 1080 mm
e + a + 154
e + a +231
Extended flue The horizontal flue is extended by using one or more of the 1000 mm extension pipes, Saunier Duval part number 85091. These are connected together by push fit type joints, clamps and seals. Calculation of flue cutting lengths for extended flue Using the correct number of extension kits as table 2, measure dimensions a and e, see diagram 13 or 14. Cut both the inner and outer pipe to the dimensions given in table 3. Important: All cutting lengths should be measured from the push fit end of the extension pipe. Do not leave any burrs or sharp edges on the cut ends of the pipes. Installation of flue assembly-direct rear flue Fit rubber sealing collar (C) into groove at the outer end of pipe (A), see diagram 16. 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 diagram16. Fit internal plastic flange (F) onto outer pipe. Push along the pipe until engaged against internal wall. From inside, insert inner pipe (B) into outer pipe turning anti-clockwise to allow inner to fully enter outer pipe. Fit rubber sleeve (H) onto outer pipe. Take hold of inner flue,twist clockwise and push gently onto fan outlet. Pull rubber sleeve onto boiler spigot ensuring a good seal. Installation of flue assembly-side flue Fit rubber sealing collar (C) into groove at the outer end of pipe (A), see diagram 16. 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 diagram16. Fit internal plastic flange (F) onto outer pipe. Push along the pipe until engaged against internal wall. From inside, push inner pipe (B) into outer pipe turning anti-clockwise to allow inner to fully enter outer pipe. Fit rubber sleeve (H) onto outer pipe. Fit both 'O' rings (F) into flue elbow (D), 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. Important: If the flue has been cut, ensure that there are no burrs that could damage the 'O' ring. Remove the backing from the self adhesive gasket (J) and carefully fit gasket to base of flue elbow. Fit elbow onto boiler and secure with the four screws (G). Take hold of inner flue, twist clockwise and push gently onto the elbow outlet taking care not to tear the 'O' ring. Pull rubber sleeve onto elbow ensuring a good seal.
Table 2 Number of extension kits required
Flue option Side flue (left or right) Dimension 'X' 1081 to 1811mm 1812 to 2542 mm No. of extension kits 1 2
Table 3 Extended flue cutting lengths
Cutting length (mm) Flue option Rear outlet Side flue to left (Diagram 13) outer pipe e + a - 906 inner pipe e + a + 829 Comments maximum distance 'X' without extension 1080 mm maximum distance 'x' without extension 1080 mm
Rear outlet Side flue to right (Diagram 14)
e + a - 848
e + a + 771
TOP OUTLET FLUE INSTALLATION
Top outlet flue - kit 86151 see diagram 18, is 1000 mm long and comprises: - Outer pipe... A - Inner pipe.. B - External rubber sealing collar.. C - Flue elbow... D - Internal flange... E - 'O' rings.... F - Screws... G - Rubber collar... H - Clamp and seal... I - Gasket... J A - Flue to rear of boiler Mark correct position of hole from template. B - Flue to side of boiler Mark horizontal centre line for hole on rear wall. Extend horizontal centre line to side wall and mark vertical centre line of flue hole as shown in diag. 12. Under normal circumstances, it will be possible to gain access to the outside of the building to fit the flue terminal assembly. Where outside access is not possible e.g. high rise buildings, the flue terminal can be fitted from inside the building only if required. Note : When cutting flue hole and when extending flue centre line to a side wall, remember that the flue system must have a fall of about 35 mm per metre of flue DOWNWARD AWAY FROM the boiler. There must NEVER be a downward incline towards the boiler. 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 105 mm diameter core drill. For installations with internal access only - Use a 125 mm diameter core drill. Important: Before cutting hole for flues to rear of boiler, always cover fixing jig to make sure it is not damaged.
Table 1 :
Flue Cutting length (mm) Flue option outer pipe inner pipe e + a + 202 Comments maximum distance 'X' without extension 1080 mm Flue option outer pipe inner pipe e + a + 800 Comments maximum distance 'X' without extension 1080 mm Top outlet e + a + 877 Side flue to (left or right)
Table 2 : Number of extension kits required Flue option Dimension 'X'
Side flue (left or right) 1081 to 1811 mm 1812 to 2542 mm No. of extension kits 1 2
Table 3 :
Extended Flue Cutting length (mm)
Top outlet e + a + 125 Side flue to (left or right)
Calculation of flue cutting lengths Measure wall thickness e (mm), see diagram 17. For side flues, measure distance from inside face of side wall to centre line of flue and subtract 205 mm for both right and left hand flues to get dimension a (mm). Refer to table 1 for cutting lengths of both inner and outer flue pipes for each of the various flue options available. Important: All flue cutting lengths must be measured from the terminal end of the flue pipes, see diag. 15. When the dimension X measured on site is greater than that given in table 1, a flue extension kit will be required, refer to table 2 for details. Extended flue The horizontal flue is extended by using one or more of the 1000 mm extension pipes, Saunier Duval part number 85091. These are connected together by push fit type joints, clamps and seals. Calculation of flue cutting lengths for extended flue Using the correct number of extension kits as table 3, measure dimensions a and e, see diagram 17. Important: All cutting lengths should be measured from the push fit end of the extension pipe. Do not leave any burrs or sharp edges on the cut ends of the pipes.
Installation of flue assembly Fit rubber sealing collar (C) into groove at the outer end of pipe (A), see diagram 18. Fit outer pipe (A) into wall with the groove to the outside. Pull pipe inwards to bring rubber sealing collar hard up against external wall, see diagram16. Fit internal plastic flange (E) 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 (F) into the flue elbow (D), 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. Important: If the flue has been cut, ensure that there are no burrs that could damage the 'O' ring. Remove the backing from the self adhesive gasket (J) and carefully fit gasket to base of flue elbow. Fit elbow onto boiler and secure with the four screws (G). Take hold of inner flue, twist clockwise and push gently onto the elbow outlet taking care not to tear the 'O' ring. Fit clamp and seal (I) onto outer pipe ensuring a good seal.
Warning. This boiler must be earthed All system components must be of an approved type. The mains electrical cable is supplied with the boiler. It is coiled ans tucked inside the boiler 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. WARNING: ON NO ACCOUNT MUST ANY EXTERNAL VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE HEATING CONTROLS CONNECTION PLUG. 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. Time clock A mechanical or digital time clock is available as an accessory, Saunier Duval part N 86148 (mechanical) or 86149 (digital). External controls The THEMA boiler is designed to operate at maximum efficiency at all times. The of a programmable electronic room thermostat is recommended for optimum performance, Saunier Duval part number 40010. Please contact your supplier. The boiler will work for heating without a room thermostat and/or timeswitch being connected provided that the wire link fitted between the two terminals of the connector (E) is left in place, see diagram 19. A 230V room thermostat can be used but do not make any connection to the compensating resistor, see diagram 19. ON NO ACCOUNT must any electrical voltage be applied to any of the terminals of the external controls plug.
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 1 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 1 bar is indicated on the pressure gauge when system is COLD. Gas pressures The main burner pressure should be checked during commissioning to make sure the correct input is obtained. Proceed as follows: Shut down boiler. Undo screw on burner pressure test point below sealed combustion chamber, see diagram 23. Connect a suitable pressure gauge. Gain access to the rear of the control panel and locate the range rating adjuster screw, see diagram 24. Start boiler as described in 'User Instructions'. Set boiler thermostat to maximum and check that any external controls are calling for heat. Check that the reading on the gauge matches that given in 'Technical Data' for the type of gas being used. Adjust the range rating adjuster screw as necessary to obtain the desired input. Shut down boiler. Remove pressure gauge, tighten up test point screws and check for gas soundness. Using a ball point pen, clearly indicate on the data label the input the boiler is set to. Note: This adjustment does not affect the domestic hot water output. If measured burner pressure differs greatly from the given figure, check the gas inlet pressure as follows: Shut down boiler.
Remove screw from inlet test point on the side of the gas valve, see diagram 23. Connect a suitable pressure gauge. Start boiler as described in 'User Instructions'. Check that the inlet pressure reading matches that given in 'Technical Data' for the type of gas being used. Shut down boiler. Remove pressure gauge, tighten up test point screws and check for gas soundness. If the gas pressure is incorrect, refer to the Fault Finding section in 'Servicing Instructions'. If the inlet pressure is below that given, the gas supply pipework/meter must be checked and any fault corrected. In the case of an LPG installation, check the storage tank or cylinder, regulator and pipework.
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. In case of power supply failure The boiler no longer operates. As soon as power supply is restored, the boiler will be automatically restarted. Overheat safety In the event of a problem, the overheat thermostat causes safety shutdown of the boiler. Should this occur, reset the thermostat by pressing in the red button. The overheat thermostat is located on the RHS of the heat exchanger. Important notice: A central heating system cannot operate satisfactorily unless it is properly filled with water and unless the air initially contained in the piping systems has been properly bled off. If these conditions are not satisfied, air noise will occur within the system. The THEMA F 23 E boiler 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 and the summer/winter switch is in the position. The frost protection device will light the boiler when the temperature of the boiler water falls below 6C. When the temperature reaches 16C, the boiler stops. Note: This device works irrespective of any room thermostat setting and only protects the boiler.
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. Connect a suitable pressure gauge as described in 'Commissioning'. Maximum setting Remove one electrical connector from the modulating gas valve coil. Turn the domestic hot water temperature adjuster to maximum setting. Remove the protective cover B A from the gas valve adjuster. Using a 2 mm rod, press in the spindle in the middle of screw M, see diagram 25. Turn nut 'B' to obtain the desired pressure, see technical data. Minimum setting This must be done AFTER the maximum setting. Hold not B to prevent from turning, turn nut 'A' to obtain the desired pressure, see technical data. After adjustment, refit the cover to the gas valve adjuster and refit electrical connector. Bypass The THEMA F 23 E has a built-in bypass. This must be adjusted according to the requirements of the system, refer to the flow rate pressure curve (diagram 3). 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 26. Turn the screw clockwise to close the bypass. When using thermostatic radiator valves (TRV's), it is recommended that an additional, adjustable bypass of 15 mm minimum diameter is fitted between the flow and return of the heating circuit, see diagram 6. Any bypass must be fitted before system controls. PCB Settings The PCB on the Thema F 23 E can be set to operate in different ways to suit individual installations. The dip switch SW1, see diagram 27, should be set as follows: 1 - OFF 2 - ON 3 - OFF 4 - OFF 5 - OFF 6 - OFF
Reg 055 Mec 121
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. 86161
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. It is the law that any servicing is carried out by a competent person. 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. The maximum domestic hot water flow rate is 12 litres/minute. Remove boiler casing as follows: Upper front panel Hinge down control cover to gain access to control panel. Disengage the two 'quarter turn' fasteners by turning the heads of the screws a quarter of a turn towards the centre of the boiler. Carefully lower the panel down on its hinge until it is horizontal. Turn both plastic catches to release upper front panel. Remove upper front panel by pulling forward at the bottom and lifting off. Note: The upper front panel is retained by a plastic safety strap, disengage this before removal. Side panels From below boiler, unscrew and remove black plastic screws securing side panels to the boiler. Prise out black plastic inserts and lift panel off boiler. Combustion chamber Loosen two wing nuts on combustion chamber cover. Disengage retaining lugs from holes in either side of combustion chamber and move rods away to clear combustion chamber sides, see diagram 28. Unclip two toggle clips holding upper part of combustion chamber in place. Holding both sides, pull chamber forward to release it from underside of heat exchanger and out of boiler. Take care not to damage insulation material on inside faces of combustion chamber. Cleaning the burner Pull off leads to ignition electrode. Pull off lead to flame sense electrode. Unscrew and remove screw holding earth lead to flame sense electrode. Undo main gas supply nut from main burner. Unscrew and remove locking nut from both main gas connection and burner pressure tapping point. Lift front edge of burner until tapping point and gas supply connection are free. Remove burner
microswitch on THEMA F 23 E
Undo and remove screw securing spark generator to bracket and remove spark generator. Fit replacement spark generator in reverse order to removal. Reconnect two grey power supply leads and two clear ignition leads to spark generator, the polarity is not important. Refit lower terminal cover. To replace main printed circuit board (PCB) With lower front panel down as described previously, undo and remove screw holding pump connection cover to PCB cover, see diagram 30. Open cover and unclip plastic clip securing pump cable to lower front panel. Pull off pump connector and earth lead. Undo and remove four screws securing PCB cover to lower front panel. Lift off PCB cover. Pull off connectors CN6, CN7, CN8 and CN9 on PCB. Undo and remove screw holding PCB to lower front panel. Lifting PCB up slightly on LHS, pull PCB out of electrical connector on ignition PCB. Leave ignition PCB in place.
Fit replacement PCB in reverse order to removal. Important: When fitting replacement PCB, ensure that control knob spindles correctly locate into PCB adjuster slots. Refit connectors and covers in reverse order to removal. To replace ignition PCB Gain access to PCB's as described in previous section. Remove main PCB securing screw as described in previous section. Pull off three electrical connectors on PCB. Lift up ignition PCB, separate from main PCB and remove from boiler. Fit replacement PCB in reverse order to removal. Refit connectors and covers in reverse order to removal. To replace pump Drain down heating circuit of boiler only as follows: Close isolating valves on flow and return connections on fixing jig, see diagram 5. Note: These valves are closed when slots are at right angles to direction of flow. It is not necessary to drain entire heating circuit to carry out this work. Drain boiler by attaching a plastic tube to drain outlet and opening drain valve knob anticlockwise, see diagram 5. Gain access to pump connection as described in 'To replace main PCB'. Pull off pump connector and earth lead. Pull out retaining clip from telescopic pump outlet connection and slide connection upwards to release from pump. Undo and remove two fixing screws and remove pump retaining bracket from front of pump. Grasp pump body, lift upward to disengage from reversing valve and turn pump to right. Remove pump by pulling forward and over reversing valve assembly. Discard old pump inlet 'O' ring. Apply silicone grease to new 'O' ring supplied, and fit onto inlet connection on replacement pump. Fit replacement pump in reverse order to removal. Note: Apply silicone grease to pump outlet connection 'O' ring before assembly. Refit pump electrical connection. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. To replace temperature/pressure gauge Drain down heating circuit of boiler only as described in 'To replace pump'. Undo and remove screw securing pressure gauge capillary to front section, see diagram 31. Carefully pull capillary from front section. Undo and remove two screws securing temperature/pressure gauge to lower front panel and remove gauge. Fit replacement gauge in reverse order to removal.
Fit capillary of new gauge to front section using new 'O' ring supplied. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. To replace reversing valve assembly Remove temperature/pressure gauge capillary as described previously. Remove pump as described previously. Remove microswitch assembly as described previously. Remove retaining clip from LHS pipe connection on front section of valve and disengage pipe. Unscrew and disconnect heating flow (centre) connection at fixing jig. Remove retaining clip from heating flow pipe connection on right of front section. Remove flow pipe from boiler. Unscrew and disconnect heating return (left hand) connection at fixing jig. Remove retaining clip from expansion vessel pipe connection at rear of reversing valve assembly and disengage pipe, pushing pipe back and out of reversing valve. Undo and remove large screw holding water valve to back plate of reversing valve assembly, see diagram 32.
Push water valve back to disengage it from reversing valve. Unclip and remove loss of water pressure switch from left of reversing valve assembly, see diagram 33. From below boiler, undo and remove three screws holding reversing valve to bottom plate of boiler. Remove complete reversing valve assembly from boiler. Undo and remove heating return connecting pipe and hose from rear of reversing valve assembly. Fit hose to replacement reversing valve assembly. Fit replacement reversing valve into boiler in reverse order to removal. Note: Use new 'O' rings, retaining clip, filter and washer provided. Unscrew and remove microswitch assembly from top of replacement reversing valve assembly to allow refitting of water valve. Note: fit expansion vessel pipe and loss of water switch to reversing valve assembly before pump, to ensure that it is correctly located. Apply silicone grease to all 'O' rings and hoses prior to assembly. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. To replace reversing valve front section Remove pressure gauge capillary as described previously. Remove pipe connections from either side of reversing valve front section, refer to previous section. Move short selector lever on front of valve to left hand position. From below boiler, undo and remove single screw holding reversing valve front plate to bottom plate of boiler. Undo and remove six screws holding front section to rear section of reversing valve, see diagram 34. Remove front plate complete with pump bracket and then front section from reversing valve, along with rubber sealing gasket. Assemble bypass valve provided and fit into hole in underside of replacement front section. Fit 'U' shaped retaining clip. Note: Use bypass valve fitted to original front section for guidance. Fit replacement front section, with gasket, to rear section. Locate front plate and replace six fixing screws. Take care to evenly tighten screws ensuring they are not cross threaded. Refit pipe connections to either side of front section using new 'O' rings provided. Apply silicone grease to 'O' rings before fitting. Refit pressure gauge capillary in reverse order to removal. Ensure short selector lever on front of valve is set to right hand position. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks.
Instructions for Use Installation and Servicing
To b e l e f t w i t h t h e u s e r
Fanned Flue Combination Boiler G.C.No. 47-047-35
Themaclassic F18E SB
Fanned Flue System Boiler G.C. No.41-920-35
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT
Thank you for installing a new Saunier Duval appliance in your home. Saunier Duval appliances' are manufactured to the very highest standard so we are pleased to offer our customers a Comprehensive Guarantee. This product is guaranteed for 24 months from the date of installation or 30 months from the date of manufacture, whichever is the shorter, for parts. In addition this product is guaranteed for 12 months from the date of installation or 18 months from the date of manufacture, whichever is the shorter, for labour. The second year of the parts guarantee, from the beginning of the 13th month onwards after installation, is conditional upon the boiler having been serviced by a CORGI registered gas installer, in accordance with the manufacturer's recommendations. We strongly recommend regular servicing of your gas appliance, but where the condition is not met, any chargeable spare parts or components issued within the applicable guarantee period still benefit from a 12 month warranty from the date of issue by the manufacturer. We recommend you complete and return as soon as possible your guarantee registration return literature, supplied in the document envelope. If your guarantee registration return literature is missing you can obtain a copy by telephoning Saunier Duval Service on (0)1773 828100.
RECORD YOUR SAUNIER DUVAL APPLIANCE DIRECT BY CALLING
Customer Service: Saunier Duval GB GREAT BRITAIN: Tel. (0)Fax. (0)Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT Saunier Duval IE IRELAND: Tel. (0)14191919 Fax. (0)14584806 Hevac, Muirfield Drive Naas Road Dublin 12 Technical Advice Line: Tel. (0)General and Sales enquiries : Tel. (0)Fax. (0)(0)
INSTRUCTION FOR USE
Important Information Draining and Filling Appliance Introduction Appliance Safety Devices Maintenance and Servicing User Controls and Lighting Analogue Programmer F24E only Digital Programmer Kit F24E only
Technical Data General Information Heating System Design Domestic Hot Water System Design F24E only Boiler Schematic F24E Boiler Schematic F18E SB Boiler Location, flue and ventilation Fixing Jig Piping System Installation Boiler installation Horizontal Telescopic Top Flue Installation Horizontal Top Flue Installation Electrical Connection Commissioning Changing Gas Type Bypass Settings
5 5a 10 10a 13 14
Routine Cleaning and Inspection Fault Finding Wiring Diagram F24E Wiring Diagram F18E SB Replacement of Parts Spare Parts
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 competent person in accordance with the regulations.
Electrical Supply WARNING: This boiler must be earthed. All system components shall be of an approved type and shall be connected in accordance with the current issue of BS7671 and any applicable local regulations. External wiring must be correctly earthed, polarised and in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S.813 "Domestic gas installation". Connection of the boiler and system controls to the mains supply must be through a common isolator and must be fused at 3A, maximum. This method of connection must be by a fused double pole isolating switch, with a minimum contact separation of 3mm on both poles. The switch should be readily accessible and preferably adjacent to the appliance. It should supply the appliance only and be easily identifiable as so doing. Alternatively, an unswitched shuttered socket outlet and 3A fused 3 pin plug, both to the current issue of BS1363 may be used provided that they are not used in a room containing a bath or shower. Wiring to the boiler must be PVC 85oC insulated cable, not less than 0.75mm2 (24/0.20mm). Manual Handling Guidance During the appliance installation it will be necessary to employ caution and assistance whilst lifting as the appliance exceeds the recommended weight for a one man lift. In certain situations it may be required to use a mechanical handling aid. Take care to avoid trip hazards, slippery or wet surfaces. Heating System Controls The heating system must be controlled as described in the relevant part of the current issue of : Building Regulations, approved document L1, and the references: 1) GIL 59, 2000: Central heating system specification (CheSS) and 2) GPG 302, 2001: Controls for domestic central heating system and hot water. BRECSU. 3) The domestic heating and hot water guide to the building regulations 2001. Thermostatic radiator valves may be installed, however they must not be fitted in a room where the room thermostat is located. 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. Protection Against Freezing The appliance has a built in frost protection programme as long as the electricity and gas are left switched on. This device operates the burner and system pump when the temperature inside the boiler falls below 60C. Any other exposed areas of the system should be protected by a separate frost thermostat.
Gas leak or fault
WARNING: 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.
Caution: The boiler is installed as part of a sealed system which must only be drained and filled by a competent person. If the mains electricity and gas are to be turned off for any long periods during severe weather, it is recommended that the whole system, including the boiler, refer to diagram 1, should be drained to avoid the risk of freezing. Make sure that, if fitted, the immersion heater in the cylinder is switched off. If in doubt, consult your servicing company.
If the boiler loses water: the pressure will be indicated, see diagram 1 (a) and the boiler ON indicator (b) will flash red indicating a fault. Fill the system by the filling device (c) at the bottom of the boiler until the pressure gauge reads 1.0 bar. A mains inlet pressure of 2.0 bar is required to reach a fill pressure of 1.0 bar. Reset boiler: refer to diagram 2, turn the On/Off switch to (0), wait for five seconds. Turn the On/Off switch to ( I ) to reset the appliance.
BOILER DRAIN VALVE
F18E SB Only
If the boiler loses water: the pressure will be indicated, see diagram 1 (a) and the running lamp (b) will flash red indicating a fault. Fill the system with the external filling device until the pressure gauge reads 1.0 bar. Reset boiler: refer to diagram 2, turn the On/Off switch to (0), wait for five seconds. Turn the On/Off switch to ( I ) to reset the appliance. Warning: Take care not to overfill the boiler. At a pressure of 2.5 bar or above indicating over pressure, the boiler ON indicator (b) will flash red indicating a fault. The pressure must be reduced to 1.0 bar by opening the drain valve, refer to diagram 1. If the fault continues call the relevant Servicing
organisation or Saunier Duval Service using the telephone number on the inside front cover of this literature.
The F24E and F18E SB boilers are wall mounted modulating boilers with electronic ignition providing central heating and hot water. The boiler is of the II2H3+ category and is for use with natural Gas (G20) as distributed in the United Kingdom, but can be converted to use Butane (G30), Propane (G31) with the appropriate kit. Thema Classic F24E LPG boilers are factory set for use on Butane (G30) and Propane (G31) without requirement for any additional adjustments. 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. This boiler is not suitable for outdoor installation. This boiler may be installed in any room, although particular attention is drawn to the installation of a boiler in a room containing a bath or shower where reference must be made to the relevant requirements. Any electrical switch or boiler control utilising mains electricity should be placed so that it cannot be touched by a person using the bath or shower. In GB this is the current I.E.E. WIRING REGULATIONS and BUILDING REGULATIONS. In IE reference should be made to the current edition of I.S.813 "Domestic Gas Installations" and the current ETCI rules. The central heating and domestic hot water (F24E only) temperatures are user adjustable. F24E Only. 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. 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. These instructions should be carefully followed for the safe and economical use of your boiler. The 'User Controls and Lighting' section describes how to safely use the boiler. Note: The boiler serial number is marked on the data label attached to the rear of the control box.
A range of accessories are available. For further information contact your supplier.
Appliance Safety Devices
Air flow rate safety device
If the flue is obstructed, the built in safety system will turn the boiler OFF, the fan will continue to run. The boiler will be ready to operate when the fault has been cleared.
The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will light the boiler when the temperature of the boiler water falls below 6C. When the temperature reaches 16C, the boiler stops. Any other exposed areas of the system should be protected by a separate frost thermostat.
In the event of the boiler overheating the safety devices will cause a safety shutdown. If this happens, call your Installation/ Servicing company.
Electrical supply failure
The boiler will not operate without an electrical supply. Normal operation of the boiler should resume when the electrical supply is restored. Reset any central heating system controls, to resume normal operation. If the boiler does not resume normal operation turn the mains reset switch off and on. If the boiler does not resume normal operation it is advisable to consult your installation / servicing company.
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 competant person. If the valve discharges at any time, switch the boiler off and isolate it from the electrical supply. Contact your installation/ service company.
Maintenance and Servicing
WARNING: This appliance contains metal parts (components) and care should be taken when handling and cleaning with particular regard to edges of sheet metal parts to avoid any possibility of personal injury. The boiler casing can be cleaned with a damp cloth, followed by a dry cloth to polish. Do not use abrasive or solvent cleaners. Please be advised that the Benchmark logbook should be completed by the engineer on completion of commissioning and servicing. All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your benchmark Logbook. You can check your installer is CORGI registered by calling CORGI direct on: (0) 1256 372300.
Pressure gauge: 4 The boiler pressure gauge will show a reading between 1.0 and 1.5 bar. Refer to Section Draining and Filling if required.
Programmer Instructions for Use
Analogue Programmer (F24E Only) Part No. A20086. Fitted as standard.
Setting the time, see diagram 3 Rotate the dial clockwise, by hand, until the indicator arrow is pointing to the current time. Note: The time is set in 24 hour format. Setting the programme on and off times, see diagram 3 Select the on times by pushing the black tappets to the outside. Select the off times by pushing the black tappets to the inside. To override or advance the programmer The clock has a manual on/off switch which operates as follows: Upper position I : Heating on continuously Middle position Lower position 0 : : Heating on timed Heating off
Digital Programmer Kit. (F24E Only) Part No. A20087. Not fitted as standard.
KEYPAD DESCRIPTION See diagram 4 for position of keypads as described below, Time/Automatic Run Mode selection Prog. Programme selection Res.* Reset clears all settings ON/OFF selector in Prog. Mode, Manual Override selector in Run Mode 1h* Summer/Winter time setting h Sets the Hour (12: - - AM) m Sets the Minute (- -: 01 AM) Day Sets Day(s) for time and programmes *Recessed keys; use a pen point to press
To override or advance the programmer
INDICATOR ARROW Diagram 4 OFF TIMES ON TIMES BLACK TAPPETS Diagram 3
The LCD incorporates a number of different elements to display various data and information.
The Digital Programmer will accept up to 20 events Each event consists of: 1. An ON or OFF command 2. Time of day (Hour and Minute) 3. Single day or multiple days An event is required for each ON and OFF.
NOTE: MULTIPLE ON OR OFF EVENTS MAY BE PROGRAMMED, SEE EXAMPLE. BEFORE PROCEEDING WITH SETTING THE TIME AND PROGRAMMING THE UNIT, PRESS THE RESET KEY TO CLEAR ALL DATA FROM THE MEMORY.
Programming 24 Hour or 7 Day Schedules
It may be helpful to write out the programme schedules before beginning. THE CURRENT TIME OF DAY AND DAY OF WEEK MUST BE SET PRIOR TO PROGRAMMING. SEE "SETTING THE TIME" Example Event 1: ON at 7:00AM Monday through Saturday Event 2: OFF at 5:00PM Monday through Friday Event 3: OFF at 7:00PM Saturday Three events need to be entered. Press Prog. key only once. Display shows:
Selecting AM/PM or 24 Hour Time
After pressing reset, the display may show AM (below). The numbered day symbols will be flashing on and off. If the display does not show AM, it is in 24 hour time. To change to AM/PM mode, press and hold the h key and press the 1h key once. AM will appear in display. If display is in AM/PM mode and 24 hour time mode is desired, press and hold the h key, press the 1h key once.
1 Technical Data
The F24E and F18E SB are delivered in two separate packages: The boiler including hanging bracket complete with isolating valves and fittings. The flue system.
Net lift weight (boiler only) F24E 34 kg F18E SB 32 kg Gross lift weight (boiler, hanging bracket isolation valves and packaging) F24E 35 kg F18E SB 33 kg
2 General Information
IMPORTANT NOTICE. Where no British Standards exists, materials and equipment should be fit for their purpose and of suitable quality and workmanship. Refer to Manual Handling Operations, 1992 regulations. The installation of this boiler must be carried out by a competent person in accordance with the rules in force in the countries of destination. Manufacturers instructions must not be taken as overriding statutory requirements. 2.1 Sheet Metal Parts WARNING: When installing the appliance, care should be taken to avoid any possibility of personal injury when handling sheet metal parts. 2.2 Statutory Requirements The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force. In GB the installation of the boiler MUST be carried out by a competent person as discribed in the following regulations: Manufacturers instructions, supplied. The Gas Safety (Installation and Use) Regulations. The appropriate Building Regulations, either The Building Regulations, The Building Regulations (Scotland), The building Regulations (Nothern Ireland). The Water Fittings Regulations or Water Bylaws in Scotland. The Health and Safety at Work Act, Control of Substances Hazardous to Health (COSHH). The Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. In I.E the installation must be carried out by a competent person and installed in accordance with the current edition of I.S. 813 "Domestic Gas Installations", the current Building Regulations and reference should be made to the current ETCI rules for electrical installation. In GB the following Codes of Practice apply: BS4814, BS5440 Part 1 and 2, BS5449, BS5546 Part 1, BS6700, BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593, BS7671. In IE: I.S.813, BS5546, BS5449, BS7074, BS7593. Manufacturers notes must not be taken as overriding statutory requirements. BSI Certification This boiler certificated to the current issue of EN 483 for performance and safety. It is important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration that is not approved by Hepworth Heating Ltd., could invalidate the warranty and could also infringe the current issue of the Statutory Requirements.
Drain point Control valve Drain point
Additional Bypass valve (if required)
TEMPORARY CONTROL HOSE CONNECTION VALVE UNION DRAIN POINT
TYPE CA BACKFLOW PREVENTION DEVICE FLOW RETURN CONTROL VALVE CONTROL VALVE SUPPLY PIPE AIR GAP
Bypass valve Control valve Drain point
DRAIN POINT Method 2
4 Domestic Hot Water System Design. F24E Only
General - All domestic hot water circuits, connections, fittings must be in accordance with the relevant standards and water supply regulations. For GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulation Guide. For IE: The current edition of I.S.813 "Domestic Gas Installations". Copper tubing or plastic Hep20 may be used for the domestic hot water system. Unnecessary pressure losses should be avoided. Provision shall be made for a drain valve at the lowest points of the system. The flow restrictor, supplied in the document envelope, must be fitted as diagram 7.1, limiting the flow through the boiler to a maximum of 10 litres/min. The boiler will operate with a minimum supply pressure of 0.5 bar, at a reduced flow rate. Best operating performance will be obtained from a supply pressure of 1 bar or greater.
4.1 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.
5 Boiler Schematic F24E
1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas control valve. 15 - Loss of water sensor. 16 - Domestic heat exchanger 17 - 3 way valve 18 - Domestic water flow sensor 19 - Filter cold water inlet 20 - Filling system 21 - Discharge safety valve (3bar) 22 - Drain valve 23 - Heating filter
A - Heating return B - Cold water inlet C - Heating flow D - Domestic hot water outlet E - Gas
FITTED TO REAR OF APPLIANCE
5a Boiler Schematic F18E SB
1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas control valve. 15 - Loss of water sensor. 16 - Heating filter. 17 - Discharge safety valve (3bar).
A - Heating return. B - Heating flow. C - Gas.
6 Boiler Location, Flue and Ventilation
6.1 Boiler Location
9.5 Filling loop extension knob F18E SB
KNURLED UNION NUT finger tighten only
The filling loop extension is not required for this boiler, it can be discarded.
DISCHARGE SAFETY VALVE PIPE Diagram 9.1
FILLING LOOP EXTENSION
10 Horizontal Telescopic Top Flue Installation
L 70mm 65mm
Suitable for installations that require a flue length "L" from 430 minimum to 660 maximum. If longer flueing is required extensions and bends are available, see note below. If the flue length, see diagram 10.2. is less than 430 'L' Do Not cut this flue but use the horizontal top flue 86285. Note: Additional 1 metre extensions, 90 and 45 bends are available. The maximum extended flue is 3.5m. The use of flue bends requires the max extended flue lengths to be reduced by 1m. for 90 and 0.5m. for 45.
10.1 Horizontal Telescopic Top Flue Kit of parts, refer to diagram 10.1. 10.2 Horizontal telescopic flue system Rear and side flue lengths and dimensions, see diagram 10.2.
Note : Top of boiler casing not front panel
20mm * refer to diagram 6.1 Min. Clearance
Drill, Screw and Tape (not supplied)
D G* H* F* C
70mm 184mm 65mm
The flue kit A2004500 is 660 mm long and comprises: - Telescopic flue assembly.. A - Fixing collar seal... B - Fixing collar... C - Elbow... D - External rubber sealing collar. E - *Gasket... F - *Screws 6 off... G - *'O' rings... H - *Screws 4 off.. J
* supplied in plastic bag
Telescopic Top flue kit
The Horizontal Telescopic Top Flue, Kit No. A2004500
For flue lengths up to 0.5m fit the restrictor (supplied in the document envelope) inside the fan outlet, see diagram 10.3. Remove the elbow (D) and the telescopic flue assembly (A) from the flue kit. Refer to Step 1. diagram 10.4. Fit the telescopic flue assembly (A) into the prepared hole in the wall. Position the elbow (D) on the boiler, do not secure. Position the telescopic flue assembly (A) as it would be fitted. Refer to Step 2. diagram 10.4. Remove the telescopic flue assembly (A) from the prepared hole in the wall, make sure the air duct is extended to its required length. The flue duct at the elbow end must protrude 25mm. Drill ,secure with two screws and tape to secure the air duct, take care not to drill the inner flue pipe. Fit the fixing collar seal (B) to the telescopic flue assembly (A). Refer to Step 3. diagram 10.4. Fit the telescopic flue assembly (A) with the fitted fixing collar seal into the prepared hole in the wall. Remove the backing from the self adhesive gasket (F) and carefully fit gasket to base of flue elbow. Fit the O rings (H) into the grooves in the flue ducts within the elbow (D). Lubricate the O rings with silicone. Fit flue elbow (D) onto boiler and secure with the four screws (G). Refer to Step 4. diagram 10.4. Fit rubber sealing collar (E), into groove at the outer end of the air duct pipe (A). Carefully pull flue duct pipe into the elbow (D). (If the telescopic flue has been pulled apart care must be taken not to damage the O ring on the flue duct when re-assembling). Secure with two screws (G). Pull telescopic flue assembly (A) inwards to bring rubber sealing collar hard up against external wall. Refer to Step 5. diagram 10.4. Fit the fixing collar (C) using the two screws (G).
17mm Air duct cutting length L minus 90mm plus 17mm = cutting length Flue duct Air duct
Flue duct cutting length Air duct cutting length + 95mm = cutting length
25mm check dimension (cut end)
Horizontal Top flue system
The maximum permissible length (L) is 3.5 m. For flue systems up to 0.5 m length, the flue restrictor must be fitted (a) inside the fan outlet. For longer flue systems, the restrictor must not be fitted. For each 90 flue elbow used, (or two 45 elbows) the maximum permissible length (L) must be reduced by 1 metre.
11 Electrical Connection
WARNING: This appliance must be earthed. 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. All system components must be of an approved type. Electrical components have been tested to meet the equivalent requirements of the BEAB. Do not interrupt the mains supply with a time switch or programmer. 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 3mm 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.
11.1 Mains Cable
Important: If a replacement supply cable is required it must be purchased. Part No. S1008600.
11.2 Voltage Free External Controls
WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION TERMINAL. This boiler will operate continuously on heating, as supplied, if the wire link (E), fitted between the two terminals of the heating controls connection, is left in place, see diagram 11.1. External heating controls e.g. Room thermostat, should be fitted in accordance with the rules in force and as shown in the example, diagram 11.2.
Adjust the boiler temperature control and any system controls to their required settings. For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813.
13 Changing Gas Type
Should it be necessary to change the gas type, a conversion kit with instructions will be required. This modification must only be carried out by a competent person. Conversion natural gas (G20) to G30/G31 Part No. A20027. Unclip the control box, see diagram 11.1. Run the appliance in heating mode. Read the burner pressure setting in heating mode, before the boiler modulates. Adjust the central heating output to the minimum setting by adjusting potentiometer P3, refer to commissioning section. Adjust the potentiometer P6 burner pressure to the desired value, by inserting a small flat edge screw driver into the arrowed slot, turn to adjust to the desired setting, see diagram 12.2. Return the potentiometer P3 to its initial value.
Setting the step pressure.
Adjusting the step pressure may be a necessary operation after gas conversion or after changing the gas control valve when a new replacement part is required. Proceed as follows: Gain access to the gas control valve, connect a pressure gauge.
14 Bypass Setting
The boiler has a built-in bypass, refer to diagram 14.1. The boiler is supplied with the bypass open half a turn. It should not be necessary to adjust the bypass, but if required ensure that under no circumstances does the flow rate fall below the figures specified, refer to table 1. in section 3 (turn clockwise 'A' to close the valve ).
15 Routine Cleaning and Inspection
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 clearly authorised by Hepworth Heating. 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. It is the law that any servicing is carried out by a competant person.
PRODUCTS SAMPLING POINT Diagram 15.1
15.1 Products of combustion check
Note: To obtain a products of combustion reading, unscrew the left hand sampling point cap on the flue elbow, located on top of boiler, see diagram 15.1. Connect the analyser tube onto sampling point. Refer to the combustion product values in Section 1 Technical Data. Switch on the electrical supply and gas supply, then operate the boiler. On completion of the test switch off the electrical supply and the gas supply, remove analyser tube and replace sampling point cap.
15.10 Fan, refer to diagram 15.8
Disconnect power supply leads and earth lead from fan. Unscrew and remove the two fan retaining bolts. Ease the fan down and forwards to remove.
15.11 Heat exchanger, refer to diagram 15.9
Remove air pressure switch sensing tube from the side of the flue hood. Unscrew and remove the two retaining screws from front of each side panel. Unhook each panel from the front retaining tabs and ease outwards. Remove the flue hood. When refitting ensure the rear of the flue hood locates in the tabs. Use a soft brush or vacuum clean the heat exchanger.
DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER.
3.5mm 3.5mm IGNITION GAP
FAN RETAINING SCREWS
FLAME SENSING GAP
POWER SUPPLY LEADS Diagram 15.6 Diagram 15.8
BURNER RETAINING SCREWS BURNER GUIDE
AIR PRESSURE SWITCH SENSING TUBE
DOMESTIC WATER INLET FILTER HOUSING
If the water flow rate through the appliance has reduced it may be necessary to clean or replace the domestic water inlet filter. Close isolating valve (b) on cold water inlet. Pull out slotted clip securing the filter in its housing, remove the filter to clean or renew if necessary. Push the filter fully into its housing and replace the securing clip. Open isolating valve, (b) diagram 15.2, on cold water inlet and test the Domestic Hot Water circuit for soundness.
15.13 Central Heating Filter, refer to diagram 15.11
Remove the filter retaining clip and filter clean or renew if necessary. Push the filter fully into its housing, ensuring the correct orientation. The flat and hole in the filter as shown. Secure with retaining clip.
15.14 Sealed chamber cover seal check
Check the condition of the seal, replace as required. To replace remove the old seal, thoroughly clean the casing surfaces. Fit new seal, it is supplied to the correct length, see diagram 18.25.
15.15 Combustion chamber insulation
FAULT: THE ROOM TEMPERATURE IS INADEQUATE AND RADIATORS ARE LUKE-WARM. Is the room thermostat and or radiator set high enough and calling for duty? NO Turn up settings YES Is the heating temperature on the boiler set high enough? YES Is the heating power adequate? - Check set point P3. (Refer to Commissioning) - Check dip switch setting. (Refer to Commissioning) - Check the adjustment of the by-pass internal and external (If fitted). - F24E Only Check the 3-way valve is not passing into the domestic hot water heat exchanger.
16 Fault Finding F24E ONLY
FAULT: THE WATER AT THE TAPS IS LUKE-WARM. Is the temperature higher if you reduce the flow through the taps? NO Check the 3-way valve is not passing into the radiators. (The radiators should stay cold in Summer setting)
YES Check that the cold water inlet restrictor is fitted. Check the rate of flow. Check burner pressure is correct.
FAULT: THE FAN DOES NOT START. Is there is 230V ac at fan during demand? YES Faulty fan, replace. NO
Check continuity of fan harness. YES
Faulty PCB, replace.
FAULT: THE FAN RUNS BUT THERE ARE NO SPARKS. CHECK CONTINUITY OF IGNITION (ELECTRODES AND LEADS) CHECK POWER SUPPLY FROM PCB TO IGNITION UNIT CONNECTIONS TO THE AIR PRESSURE SWITCH Pr
Air flow switch take-off.
17 Wiring Diagram F24E
FAN g/y br b w OVERHEAT THERMOSTAT or w THERMISTOR CH WATER PRESSURE SENSOR b b w g THREE-WAY VALVE bk bk w p y g or gn CHASSIS EARTH w GAS CONTROL VALVE PUMP g/y AIR PRESSURE SWITCH bk IGNITION PLUG ELECTRODES IGNITOR UNIT
MAINS VOLTAGE HEATING CONTROLS PLUG
230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS.
REMOVE VOLTAGE FREE LINK FLOW SENSOR
VOLTAGE FREE HEATING CONTROLS PLUG
b r gn
REMOVE THE LINK IF FITTING VOLTAGE FREE OR 230V EXTERNAL CONTROLS. IF THE LINK IS NOT REMOVED THE BOILER WILL RUN CONTINUOUSLY.
J10 J1 S1 J12
J13 H2 H5 H1
g/y br br b g/y b b br g/y
J2 FUSE 125mAT
g/y w r b br ON/OFF SWITCH 230V~50Hz PERMANENT MAINS SUPPLY FUSED AT 3A
bk- BLACK w- WHITE g/y- GREEN/ YELLOW br bpgBROWN BLUE PINK GREY rorgnyRED ORANGE GREEN YELLOW
17a Wiring Diagram F18E SB
FAN g/y br b w w GAS CONTROL VALVE bk WATER PRESSURE SENSOR THERMISTOR CH b b w g bk w p y g or gn IGNITOR UNIT PUMP CH g/y CHASSIS EARTH
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Remove burner from boiler, refer to Section 15.9. Remove the left hand side panel, refer to Section 15.6. Undo and remove screw securing electrode assembly to the burner injector assembly, see diagram 18.6. Disconnect the electrical connections at the ignition unit, see diagram 18.22. Note the routing of the cables.
18.12 Flame sense electrode
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Remove burner, refer to Section 15.9. Remove the right hand side panel, refer to Section 15.6. Undo and remove screw securing sense assembly to the burner injector assembly, see diagram 18.6. Disconnect the electrical connection from the inline connector, Note the routing of the cable.
SENSE ELECTRODE ASSEMBLY
18.9 Burner injector assembly, refer to diagram 18.6.
18.13 Heat exchanger, refer to diagram 18.7.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 18.1. Remove the fan, refer to Section 15.10. Remove air pressure switch sensing tube from the side of the flue hood, see diagram 15.9. Release both side panels, refer to section 15.6. Remove the flue hood, lift up and off. When refitting ensure the rear of the flue hood locates in the tabs. Disconnect the electrical leads from the overheat thermostat. Remove the two pipe securing clips.
18.15 Printed circuit board (PCB), refer to diagram 18.9.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Undo and remove the two front retaining screws. Hinge up the control panel cover and ease forwards from the rear retaining lugs to gain access to PCB. Do not strain the cables attached to the PCB. Note the routing of the cables. Carefully pull off electrical connections to PCB. Unclip and lift out PCB. Fit replacement PCB. Be careful not trap any of the cables. Make sure that PCB connections are fully pushed onto replacement PCB.
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