Heating and hot water for the professionals
Installation and Servicing Instructions

THEMA F

THIS IS A CAT II2H3+ APPLIANCE
IN WARRANTY TECHNICAL HELPLINE

01773 828400

01773 828100
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.

INSTALLATION SECTION

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

SERVICING SECTION

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.

INTRODUCTION

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.

Ins 020

A - Direct rear outlet flue Mark correct position of hole from template using hole between hook and connecting plate.

Pho 422

Diagram 11

Ins 021

B - Rear outlet side flue Mark the horizontal centre line on the rear wall. Extend the horizontal centre line to the side wall and mark the vertical centre line of the flue hole as shown in diagram 12. Important: When cutting the flue hole and when extending the flue centre line to a side wall, remember that the flue system must have a fall of about 35 mm 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 the hole for flues to the rear of boiler, always cover fixing jig to make sure it is not damaged. Calculation of flue cutting lengths Measure wall thickness e (mm). For side flues, measure distance from inside face of side wall to centre line of flue and subtract 176 mm for right hand flue or subtract 234 for left hand flue to get dimension a (mm), see diagram 13 or 14. 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 diagram 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. Refer to table 1 for the cutting lengths of both the inner and outer pipes for each of the flue options available.

Diagram 12

Diagram 13
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

Hab 209

Diagram 14

Hab 208

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.

ELECTRICAL CONNECTION
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.

When fitting room thermostat, remove wire link (E) and connect voltage free thermostat as shown
For no external controls leave wire link (E) in place

sch 228

The mains electrical cable is supplied with the boiler. It is coiled and tucked inside the boiler

Cylinder

THEMA F SB 18 E THEMA F SB 23 E

Diagram 19

sch 227

sch 229

COMMISSIONING
The commissioning and first firing of the boiler must only be done by a competent person. Gas installation It is recommended that any air is purged from the supply at the gas inlet test point on the left hand side of the gas valve, see diagram 20. Filling the system

Diagram 20

Open shut off valves (slot of screw corresponds to flow direction).
Undo, but do not remove, cap on automatic air vent on top of pump. Do not retighten cap.
Open the tap on the system filling loop and fill the system until the pressure indicated on the display is between 1 and 2 bar.

Ins 017a

Reg 007
Important: - If this procedure is not carried out properly, the boiler will go into safety lock-out until all of the air has been purged. - When venting air from boiler, do not touch the schrader valve on the expansion vessel, it is NOT a vent. - Before starting the boiler, turn the pump impellor to make sure it is free to move. Unscrew black cap on front of pump. Using screwdriver, push in pump spindle and turn pump impellor 3 to 4 times. DO NOT HIT SPINDLE. Replace black cap. Starting the boiler Before starting the boiler check that: - The gas meter tap is open. If using Butane or Propane, check that valve on storage cylinder or tank is open. - you have removed the two fan transist clips from fan.
- The boiler gas service cock is open. - The boiler is connected to the electrical supply and switched on. - The front casing is fitted. First starting up Following the instructions given in the 'User Instructions' set boiler to run in central heating mode. Set boiler thermostat for maximum temperature and check that any external controls, if fitted, are calling for heat. Allow the temperature to rise to the maximum value, with all radiator valves open. The temperature rise will cause release of the gases contained in the water of central heating system. - Gases driven towards the boiler will be automatically released through the automatic air vents. - Gases trapped at the highest point of the system must be released by bleeding the radiators.

Sec 055

Ins 061

Ins 062

Reg 056

Des 044

SETTINGS

Gas valve setting All boilers are tested and factory set during manufacture. Should it be necessary to reset a gas valve, for example after replacement, proceed as follows: Shut down boiler. 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

Diagram. 27

Reg 055 Mec 121

Diagram. 26

ON DIP

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

Reg 013

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

REPLACEMENT OF PARTS

To replace microswitch assembly exept SB models) Disconnect microswitch by pulling off plug. Unclip external controls connector from mounting bracket. Undo two screws securing microswitch assembly to reversing valve assembly, see diagram 29. Remove microswitch assembly from reversing valve. Fit replacement microswitch assembly in reverse order to removal. Reconnect plug and refit external controls connection to bracket. To replace fan Disconnect power supply and earth leads to fan. Unscrew and remove two fan retaining screws located at front edge of fan mounting plate. Remove fan with mounting plate attached by pulling forwards and out of boiler. Unscrew and remove three screws securing fan to fan mounting plate. Fit replacement fan to mounting plate and secure with screws. Fit replacement fan to boiler in reverse order to removal making sure that mounting plate retaining lugs are properly engaged into flue hood. Reconnect power supply and earth leads. Important: Make sure that fan outlet is correctly fitted into either the flue elbow for top outlet flue, or the rear connector for rear outlet flue. Before commissioning boiler, remove the two plastic transit clips from replacement fan. To replace air pressure switch Locate air pressure switch in upper left hand corner of sealed chamber. Pull off plastic tube from left hand connection. Grasp pressure switch and disengage it from bracket clips by pulling from the top. Remove electrical connections from switch. Fit electrical connections to terminals 1 and 3 of replacement switch. Fit replacement switch in reverse order to removal. Important: Refit plastic tube to LEFT hand connector (marked P1). To replace spark generator Locate spark generator on bracket to right hand side of gas valve. Undo and remove screw securing lower terminal cover to bracket and remove bracket. Disconnect four leads from spark generator.
microswitch on THEMA F 23 E

Diagram 29

Diagram 30
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.

Hab 286

Sch 228
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.

Diagram 31

Diagram 32
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.

Des 054

Cla 007
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.

Diagram 33

Diagram 34
To replace loss of water switch Drain down heating circuit of boiler only as described in 'To replace pump'. Note: It is not necessary to drain entire heating circuit to carry out this work. Pinch plastic cover to release retaing clips and remove cover from switch. Pull plug lead from switch terminals. Remove clip holding switch into left side of reversing valve assembly. Pull switch out of reversing valve assembly, see diagram 33. Fit replacement switch in reverse order to removal, using new 'O' ring provided and applying silicone grease to 'O' ring before fitting. Reconnect plug to switch terminals. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. To replace water valve or diaphragm (except SB models) Drain down hot water circuit of boiler only as described in 'Routine Cleaning and Inspection'. Remove microswitch assembly as described previously. Unscrew connecting nut from cold water inlet connection, second from left on fixing jig. Keep filter and flow regulator. Remove clip holding connecting pipe in rear of water valve. From below boiler, grip clip with long nosed pliers and pull down. Note: This connecting pipe is telescopic, it may be necessary to slide back brass sleeve to facilitate removal.

Sec 059

Remove clip holding pipe to heat exchanger in rear of water valve. From front of boiler, grip clip with long nosed pliers and pull upwards. Unscrew and remove large screw holding water valve to back plate of reversing valve assembly, see diagram 32. Disengage water valve from reversing valve and remove from boiler. Note: When disengaging water valve from heat exchanger pipe, check that non-return valve is not held on end of pipe. If so, carefully separate pipe from valve to ensure that small spring and plunger do not fly out and are lost. To replace diaphragm, undo five screws and separate main components of water valve. If white diaphragm cover is to be replaced, separate original from water valve end casting and fit replacement cover. Fit replacement diaphragm , making sure that metal disc FACES diaphragm cover and beaded edge of diaphragm is correctly fitted in corresponding groove in both cover and plastic housing, see diagram 35. Reassemble water valve, evenly tightening five screws. Fit water valve actuating pin into hole in diaphragm cover, through nose end of valve and and push in until flush, or slightly below, nose end of valve. Note: Apply silicone grease to pin before fitting. Refit water valve to boiler, locating nose end into rear of reversing valve assembly, 'springing' heat exchanger pipe to gain clearance as necessary. Fit large water valve retaining screw but do not tighten fully at this stage. Apply silicone grease to 'O' ring and fit onto end of heat exchanger pipe. Fit pipe into water valve by pulling it forward. Make sure that 'O' ring is correctly located. Whilst holding pipe in rear of water valve, fit retaining clip. This should easily clip over pipe and should NOT have to be forced. If resistance is experienced, either pipe is not correctly fitted in rear of water valve or clip is not being fitted properly through slot between back plate and plastic housing of water valve. When clip is fitted, check connection by pushing pipe back away from water valve. Refit telescopic connecting pipe to inlet of water valve after applying silicone grease to 'O' ring. Fit retaining clip into groove on connecting pipe, through slot between back plate and water valve plastic housing. Check connection by pulling pipe. Make sure that clip is not loose and likely to fall out at a later date. If in doubt, fit a new clip. With both flow regulator and and plastic filter washer in place, refit connecting nut to inlet connection and tighten. Open isolating valve on cold water inlet connection and check for leaks. Replace microswitch assembly. To replace gas valve Ensure gas supply is off. Disconnect two black electrical leads from gas valve modulating coil.

Diagram 35

Diagram 36
Disconnect two white and one red lead from gas valve main solenoid. Pull off clear plastic tube from gas valve to sealed chamber tapping point. Unscrew main gas supply pipe nut on top of gas valve, releasing spark ignition unit bracket, see diagram 36. From below boiler, unscrew gas valve connection between gas valve and fixing jig isolating cock. Unscrew and remove two screws securing gas valve to bottom plate of boiler. Remove gas valve from boiler. Refit replacement gas valve in reverse order to removal. Note: Use new 'O' ring provided between gas valve and burner supply pipe. Refit electrical connections to replacement gas valve as follows: - BLACK leads to modulating coil. - WHITE leads to EV1 and EV2 terminals of main solenoid - RED lead to COM terminal of main solenoid. To replace modulating coil Ensure gas supply is off. Disconnect two black electrical leads from gas valve modulating coil. Unscrew and remove two screws holding modulating coil to gas valve and remove coil from gas valve. Fit replacement modulating coil in recerse order to removal. Reconnect electrical leads to replacement coil. Note: All boilers are tested and factory set during manufacture. Should it be necessary to reset a gas valve, for example after replacement, refer to 'Settings'.

Mec 117

Des 058
To replace safety valve Drain down entire heating system. From below boiler, disconnect heating flow pipe from rear of fixing jig. Undo heating flow connection on front of fixing jig. Remove clip from heating flow pipe connection on right of front section of reversing valve. Pull pipe towards right and out of reversing valve. Remove pipe from boiler and keep. From below boiler, disconnect safety valve discharge pipe. Working through boiler from the front using a long screwdriver, undo and remove screw holding safety valve assembly to fixing jig. Remove complete safety valve assembly from fixing jig and remove from boiler. Fit replacement safety valve in reverse order to removal. Note: Apply silicone grease to 'O' ring before fixing pipe into right hand side of reversing valve. Refill heating system and boiler, vent and pressurise as described previously. To replace heat exchanger Drain down both heating and hot water circuits of boiler only as described previously. Note: It is not necessary to drain entire heating system to carry out this work. Remove combustion chamber cover as described in 'Routine Cleaning and Inspection'. Remove two clips from heating connections to left side of heat exchanger. Remove clip holding pump outlet connection into pump and slide connection up pump outlet pipe. Pull complete pipe down to disengage from heat exchanger. Remove retaining clip from LHS pipe connection on front section of valve and disengage pipe. Disengage pipe downwards from heat exchanger. Unscrew and disconnect two hot water connections to right side of heat exchanger. Grasp both sides of heat exchanger and slide forwards and out of boiler. Fit replacement heat exchanger in reverse order to removal. Note: Use new sealing washers and 'O' rings provided. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. To replace expansion vessel 1 Boiler in place Note: The expansion vessel can be replaced with the boiler in place provided that there is a minimum clearance of 400mm on one side of the boiler and that no vertical pipework passes between boiler and wall on that side. Drain down the heating circuit of the boiler only as described in 'To replace pump'. Note: It is not necessary to drain entire heating system to carry out this work. Remove pump from boiler as described previously. Unscrew pipe connection nut from expansion vessel and disengage pipe from connection. Keep sealing washer. Whilst supporting weight of vessel, push bottom of vessel away from boiler, disengaging threaded connection from hole in rear of boiler. Allow vessel to drop out of its two upper retaining brackets. Remove vessel to side of boiler. Fit replacement expansion vessel in reverse order to removal ensuring that sealing washer is fitted to vessel pipe connection. Check that vessel charge pressure is 1bar. Correct if necessary. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. 2 Boiler removed from wall Drain down the heating circuit of the boiler only as described in 'To replace pump'. Note: It is not necessary to drain entire heating system to carry out this work. Ensure that gas and electrical supplies to boiler are turned off. Disconnect flue from either rear or top of boiler as applicable. Disconnect external controls connections, if applicable. Unscrew and disconnect five connections between fixing jig and boiler. Disengage pipe connections. Lift boiler off hanging bracket and place on a convenient working surface. Remove expansion vessel from boiler as described in previous section. Fit replacement vessel in reverse order to removal and check charge pressure. Replace boiler on wall, tighten all connections, gas connection first, ensuring that all sealing washers, filters and the cold water flow regulator are fitted before tightening. Reconnect flue system. Open isolating valves on flow and return connections, refill, vent and pressurise boiler. Check for leaks. Reconnect external controls connections, if applicable. Reconnect gas and electrical supplies to boiler. Check for gas soundness. To replace boiler thermistor Locate boiler thermistor on heating flow pipe on left hand side of boiler, see diagram 37.

SCHEMATIC WIRING DIAGRAM

IG P SW3 K4 K5 EV1 TA CTN EV AL FA FL TRA Pr EX ON/OFF switch Pump Microswitch Hight limit thermostat Loss of water switch Gas valve modulating coil Room thermostat (if fitted) Boiler thermistor Gas valve Ignition unit Ignition electrode Flame sense electrode Transformer Air pressure switch Fan

THEMA F 23 E PCB

6.13 6.14

6.15 6.11

6.12 6.9

6.8 6.6 6.4 6.2

2.2 14.6 2.1 9.1 9.2 8.4 8.3 8.2 8.1 14.4 14.3 14.7 14.2 14.1 14.5
13.4 13.1 12.2 13.3 12.1 13.2
THEMA F SB 18 E and THEMA F SB 23 E PCB

Ra TH K5

6.12 6.9 6.8 6.6 6.4 6.2
IG P K4 K5 EV1 TA CTN EV AL FA FL TRA Pr EX TH
ON/OFF switch Pump Hight limit thermostat Loss of water switch Gas valve modulating coil Room thermostat (if fitted) Boiler thermistor Gas valve Ignition unit Ignition electrode Flame sense electrode Transformer Air pressure switch Fan Cylinder thermostat

3.3 3.2 3.1

13.4 13.1 12.2 12.1 13.2 13.3

Diagram 39

Sch 240

Sch 242

Diagram 38

FAULT FINDING

Prior to fault finding, check : Inlet gas pressure = 20 mbar Electrical supply = 240 V - 50 Hz Central heating system is pressurised at 1 - 1,5 bar. Overheat thermostat on RHS of heat exchanger has not tripped reset if necessary. Carry out electrical system checks i.e. earth continuity, resistance to earth, short circuit and polarity with a suitable meter. Note : these must be repeated after any servicing or fault finding. Ensure that all external controls are correctly wired and calling for heat. The fault finding charts will enable the majority of faults to be diagnosed. To use the charts effectively, it is necessary to determine exactly which aspects of the boiler are working correctly and which are not. For example: If the domestic hot water works but the heating doesnt, refer to chart No. 1. If heating works correctly but the hot water doesnt, refer to chart No. 2. IMPORTANT: Always adopt a logical, step by step procedure starting at the beginning of the appropriate fault finding chart. WARNING. Always isolate the boiler from the electrical supply before carrying out any electrical replacement work. Always check for gas soundness after any service work.

NO CENTRAL HEATING

Turn ch temp. control to max. does burner fire ?

Does pump run ?

Refer to chart n3

Does fan run ?

Refer to chart n4
Is short selector lever on front of reversing valve in right hand position ?
Does burner fire when a hot tap is opened ?

NO YES

Refer to chart n2
External controls (if fitted)

Internal control (clock)

Short out external controls connection on top of reversing valve. Does burner fire ?
Rectify wiring operation faults on external controls
Is there continuity across terminals 3 and 4 of clock ?
Remove leaos from boiler thermistor. Check its resistance according to thermistor value table. is thermistor ok ?
Is clock calling for heat ? Replace thermistor
Is wiring between clock and pcb connection cn7 ok ?

Replace clock

Replace main pcb

CHART 1

Open hot tap fully. Does burner fire ?

NO HOT WATER

(except SB models)

PUMP NOT RUNNING

Is there 240 v at pump ?

YES YES

With selector switch/thermostat NO in position and turner to maximum. Does burner fire for CH ? Refer to chart n2

Is pump jammed ?

Is there 240 v at terminal cn2 of PCB ?

Replace pump motor

Free pump
Is there at least 3 litres/min water flow at tap ?
Check mains water supply, water filter

Replace main PCB

Check operation of water valve diaphragm. Does reversing valve mechanism move when hot tap is opened ?

Replace diaphragm

CHART 3
Is there continuity across DHW microswitch and PCB connections cn 6.4 and cn 6.9 ?

Replace dhw microswitch

FAN NOT RUNNING
Is there 240 v at fan ? Is fan jammed ?
Remove leads from boiler thermistor. Check its resistance in accordance with thermistor value table. Is thermistor ok ?

Replace thermistor

Replace fan

CHART 4

CHART 2

Termistor Values

Temperature (C) nominal resistance () for NTC Temperature (C) nominal resistance () for NTC 50 3605

SPARE PARTS

When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge. Short parts list No. Description Fan Pump Spark generator Air pressure switch Main PCB (SB models) Main PCB (THEMA F 23 E) Part No. No. Description Part No. Control PCB (all models) 57277 Water valve diaphragm kit 52519 Microswitch assembly (THEMA F 23 E)51590 Temperature/pressure gauge 57278 Boiler Thermistor 57060 Overheat thermostat 51199

4000124050-2 10.03
Instructions for Use Installation and Servicing
To b e l e f t w i t h t h e u s e r

Themaclassic F24E

Fanned Flue Combination Boiler G.C.No. 47-047-35

Themaclassic F18E SB

Fanned Flue System Boiler G.C. No.41-920-35

F24E shown

Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

Guarantee Registration

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

4000124050-2

Contents

CONTENTS

DESCRIPTION

SECTION

PAGE No.

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
INSTALLATION INSTRUCTIONS
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

SERVICING INSTRUCTIONS
Routine Cleaning and Inspection Fault Finding Wiring Diagram F24E Wiring Diagram F18E SB Replacement of Parts Spare Parts

Important Information

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.
Testing and Certification
This boiler is tested and certificated for safety and performance. It is therefore important that no alteration is made to the boiler, without permission, in writing, from Hepworth Heating Ltd. Any alteration not approved by Hepworth Heating Ltd., could invalidate the certification, boiler warranty and may also infringe the current issue of the Statutory Requirements. The requirements are: The installation of this boiler must be carried out by a competent person in accordance with the current rules in force in the countries of destination at the time of installation, for Ireland, install in accordance with I.S.813 "Domestic Gas Installation". Manufacture's instructions supplied must not be taken as overriding statutory requirements.

CE Mark

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels. Type test for purposes of Regulation 5 certified by: Notified body 0049. Product/production certified by: Notified body 0049. The CE mark on this appliance shows compliance with: 1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels. 2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits. 3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.
Control of Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured and give no known hazard in this state. Insulation pads / ceramic fibre These can cause irritation to skin, eyes and the respiratory tract. If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material is broken. Normal handling should not cause discomfort, but follow normal good hygiene and wash your hands before eating, drinking or going to the lavatory. If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention. The insulation is composed of non-combustible material.

Draining and Filling

Caution: The boiler is installed as part of a sealed system which must only be drained and filled by a competent person. If the 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.

F24E Only

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

3.2.1.0.45 35

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

Diagram 1

organisation or Saunier Duval Service using the telephone number on the inside front cover of this literature.

Appliance Introduction

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.

Manual GMT/BST Time Changeover
Each year, in the Spring, press 1h to advance the time an hour. In the Autumn, press 1h to set back an hour.

Event Review

To review the programs at any time, press Prog. key. Events will appear in the order they were entered with repeated presses of the Prog. key. After all events have been reviewed, the blank display will appear to allow entering another event. Another press of the Prog. key will display the number of free events available, such as Fr 16 if 4 events have been entered.

Troubleshooting

PROBLEM: Days are flashing, pressing any key does nothing except key turns output ON and OFF.
SOLUTION: Time of Day and Day of Week have not been set. See "SETTING THE TIME" This is the condition after a reset. If the timer is found in this condition after it has been installed, programmed and operating for a while, it may indicate that interference has disrupted the microprocessor causing a loss of programme information. A second, but very unlikely cause of loss of programme is a power failure with the backup capacitor low or dead. Check by disconnecting power and monitoring how long the capacitor keeps the time of day in the display. Typically, the capacitor will maintain the time and programmes for 4 days, but not more than 5 days. PROBLEM: Time of day was set while holding the down, but days are still flashing. key

Manual Override

While in the Run Mode, pressing the key once will reverse the current mode; ON to OFF or OFF to ON. The symbol appears in the display to indicate a temporary override. At the next scheduled switching time, automatic control resumes, eliminating the override. CONTINUOUS OPERATION: While in the Run Mode, press the key twice to turn the output to permanently ON. symbol appears in display. key three times will turn the output OFF symbol appears in display. key until
Pressing the permanently.
To terminate a continuous override, press the appears in the display.
SOLUTION: Current day of week was not set while holding the key. See "SETTING THE TIME" down PROBLEM: It is 10AM and an ON event for 8AM was entered, but the output is not ON. Display shows the and symbols. SOLUTION: After programming, the timer does not "look back" key (temporary to determine if it should be ON. Press the override) to turn the output ON; appears in display. The timer will assume automatic operation at the next programmed event. PROBLEM: An event for 8AM Monday through Friday was entered, but it will not accept it and is flashing.

Changing an Event

Select the event to be changed with the Prog. key. A new set of days may be selected with the Day key just as in initial programming. Hours and minutes can be changed with the h and m keys. Press Prog. or key to store the new programme.

2.3 Gas Supply The gas installation must be 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". The supply from the governed meter must be of adequate size to provide a steady inlet working pressure of 20mbar (8in wg) at the boiler. Important Notice If your boiler has been converted to use L.P.G. Propane the following note applies: Propane cylinders are under pressure and should never be stored or used indoors residentially. They should only be kept outside. Under no circumstances should L.P.G. Propane cylinders be fitted or stored in basement areas or boiler houses. On completion, test the gas installation for soundness using the pressure drop method and suitable leak detection fluid, purge in accordance with the above standard.

3 Heating System Design

Bypass fully shut

Available pressure (kPa)

Open 1/4 turn Open 1/2 turn Open 1 turn Open 2 turns

(10 kPa = 1 m WG)

Flow rate through heating system (I/h)

Diagram 3.1

The installation of the boiler must comply with the requirements of the current issue of BS6798, in Ireland, refer also to the current edition of I.S.813"Domestic Gas Installations". In GB it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (for Scotland, the Water Byelaws 2000, Scotland). To comply with the Water Regulations your attention is drawn to: The Water Regulations guide published by the Water Regulation Advisory Service (WRAS) which gives full details of the requirements. In IE the requirements given in the current edition of I.S.813 "Domestic Gas Installations" and the current Building Regulations must be followed. The F24E and F18E SB are for use with sealed central heating systems. Heating surfaces may consist of radiators, convectors or fan assisted convectors. The safety valve is an integral part of the boiler and it cannot be adjusted. The circulation pump is integral with the boiler. Pipe sectional areas shall be determined in accordance with normal practices, using the output/pressure curve (diagram 3.1). 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 rate is shown in table 1. 13

Instruct the User

Instruct and demonstrate the lighting procedure and advise the user on the safe and efficient operation of the boiler. Instruct on and demonstrate the operation of any heating system controls. Advise the user on the use and maintenance of any scale reducer and pass on any relevant instructional documents. Advise that to ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the installation conditions and usage, but in general, once a year should be enough. Draw attention, if applicable, to the current issue of the Gas Safety (Installation and Use) Regulations, Section 35, which imposes a duty of care on all persons who let out any property containing a gas appliance in the UK. It is the Law that any servicing is carried out by a competent person. Advise the user of the precautions necessary to prevent damage to the system, boiler and the building, in the event of the heating system being out of use during frost or freezing conditions. Advise the user that the permanent mains electrical supply SHOULD NOT be switched off, as the built in frost protection and pump saver program would not be operable. Reminder, leave these instructions and the Benchmark logbook with the user.

Completion

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.

To Drain the Domestic hot water circuit (F24E Only)
Close boiler isolating valve (b). Turn on one or more hot water taps.

To Drain the boiler

Close isolating valves (a) and (c). Open the boiler drain valve (f).
COLD WATER INLET (F24E Only)

(c) (f)

BOILER DRAIN VALVE HEATING FLOW
DOMESTIC HOT WATER OUTLET (F24E Only)
GAS SERVICE COCK Diagram 15.2
Note: Isolating cocks water and gas are shown in the: OFF position

15.3 Front panel

Unscrew and remove the two retaining screws from the bottom of the front panel. Remove front panel by lifting up and forward.

15.4 Control panel

Lower forwards to gain access to lower part of boiler.
15.5 Sealed chamber cover
Unscrew and remove the two retaining screws from the sealed chamber cover, see diagram. 15.3. Lift cover up and off pins on top of boiler.
15.6 Side panels (for ease of access if available), refer to diagram 15.4
Unscrew and remove the two retaining screws from front of each side panel. Left hand side panel only disconnect the control panel retaining strap at the control panel. Unhook each panel from the front retaining tabs. Pull each panel forward from the rear retaining tabs to remove.
15.7 Combustion chamber cover
Unscrew and remove the two screws securing combustion chamber cover to combustion chamber, see diagram 15.5. Remove combustion chamber cover from boiler.

Diagram 15.3

15.8 Ignition and Flame Sensing Gaps
Check that the ignition and flame sensing gaps as shown in diagram 15.6. Note: To gain access to ignition and sense electrodes for removal, refer to Section, 18.11 and 18.12 in Replacement of Parts.
15.9 Burner, refer to diagram 15.7
Unscrew and remove the two burner retaining screws. Remove burner from boiler by easing it forward off the two burner guides, taking care not to damage the insulation. Clean burner by washing in soapy water. Dry thoroughly before refitting. Note: To gain access to injectors for removal and cleaning, refer to Section, 18.8.

When heating is on: 230V ac between 1 and 2 of the motor. About 25V ac to 35V ac between 2 and 3. When hot water is on: 230V ac between 2 and 3 of the motor. About 25V ac to 35V ac between 1 and 2.
If voltages are different: Connections. Control board (PCB). Three way valve lead. 1
Unfasten the clip (YES, no risk of water leak), pull out the motor and leave it plugged in. When hot water is on: the spindle should pull in. When heating is on : the spindle should push out.
If electrical supply is OK. but the motor axle does not move Replace the motor, or replace the control board (PCB).
(F24E Only) Domestic water flow
To test: Use a new detector and connect it electrically in place of the faulty one. Blow through to simulate a demand for water.
FAULT: NO HEATING Are the external heating controls calling for heat? YES Is the polarity correct? YES Connect 1 and 2 on J10, does boiler fire in central heating? YES Faulty 230V controls board. NO Faulty main PCB. NO Rectify, check the 230V controls board. NO Rectify fault on external controls.

F24E ONLY

FAULT: NO HOT WATER, BUT THE HEATING IS WORKING Is the water flow rate greater NO than 1.7l/min. (threshold figure). YES Is flow detector operating ? YES Check the connectors on the flow sensor and the control board (PCB). If the fault persists, fit a relplacement control board (PCB). NO Change or clean it. Check the cold water inlet filter for dirt. Is the cold water tap fully open ? Check the heat exchanger for scaling.
F1 FAULT DISPLAYED FAULT: THE BURNER LIGHTS BUT THEN GOES OUT. THERE IS NO FLAME DETECTED. The flame is not spreading across the whole burner and is not reaching the sensing electrode. Is the gas pressure correct?
Check that the gas taps are fully open Check the gas pressure.
YES Is the boiler actually designed for the gas being used. NO Change the gas type for the boiler (gas conversion kit).
YES Clean the gas filter. Clean the burner.
F1 or F4 FAULT DISPLAYED FAULT: THE BURNER LIGHTS, THEN GOES OUT. The flame is spreading across the whole burner, but not being detected. CHECK THE CHECK PROBE THE MAINS With the power turned off, check the continuity between the flame sense electrode and terminal H2. 4 on the control board (PCB). Check the connector on the end of the wire. Check that the spark electrode is pointing towards the flame. Check the spark electrode. Change it.

FAULT NOT FOUND If the problem persists, change the control board (PCB). (flame detection module faulty).
F1 FAULT DISPLAYED FAULT: THE BURNER DOES NOT LIGHT AT ALL, BUT THERE IS AN IGNITION SPARK. Are the gas taps on? YES Is there 24Vdc at the gas control valve? for testing see component testing data. YES Test the gas control valve. Check resistance of safety valve coil. NO Check the wiring. If the problem persists, change the control board (PCB). NO Turn on the gas taps.
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.

Electrical contacts.

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

SENSE ELECTRODE

MAINS VOLTAGE HEATING CONTROLS PLUG
230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS.
REMOVE VOLTAGE FREE LINK FLOW SENSOR

CONTROLS INTERFACE

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

CHASSIS EARTH

INSULATION

18.14 Combustion chamber insulation, refer to diagram 18.8.
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. Remove the heat exchanger, refer to Section 18.13. Pull out side insulation panels from combustion chamber. Tilt rear insulation panel forwards and out. Fit replacement insulation.

Diagram 18.8

PCB (CONTROL BOARD)

10021 10001

CONTROL BOARD COVER

Diagram 18.9

Lift to remove the heat exchanger taking, care not to damage the insulation.

230V CONTROLS BOARD

CONTROL PANEL F24E shown

USER INTERFACE BOARD

MAINS SWITCH Diagram 18.10 HEX HEAD SCREW (4 OFF) PUMP HEAD
18.16 User interface board, refer to diagram 18.10.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Unclip control panel user interface and hinge forward. Do not strain the cables. Disconnect the electrical connections from the user inter face board. Remove the two user inter face board retaining screws. Remove the user inter face board.
PUMP ELECTRICAL CONNECTION BOX
18.17 Mains switch, refer to diagram 18.10.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Unclip control panel user interface and hinge forward. Do not strain the cables. Disconnect the electrical connections from mains switch. Remove the mains switch.

Diagram 18.11

Unclip control panel user interface and hinge forward. Do not strain the cables. Disconnect the electrical connection from the programmer. Undo the two securing screws and remove the programmer.
18.18 230V Controls board, refer to diagram 18.10.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Unclip control panel user interface and hinge forward. Do not strain the cables. Disconnect the electrical connection from the 230V controls board and the electrical connection from printed circuit board (PCB). Remove the 230V controls board retaining screw. Remove the 230V controls board.

F24E shown Diagram 18.15

18.24 (F24E Only) Water flow sensor, refer to diagram 18.14.
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. Drain down the hotwater circuit, refer to relevant part of Section 18.1. Undo the union nut on the cold water inlet isolating valve. Pull out slotted metal clip securing filling system tap into housing, swing the tap forwards. Pull out the two slotted metal clips retaining the domestic water inlet filter housing. Remove domestic water inlet filter housing. Remove electrical connections from water flow sensor. Pull off slotted metal clip and remove water flow sensor.
AIR VENT F24E shown Diagram 18.16
18.23 Boiler drain point, refer to diagram 18.13.
18.25 System water pressure sensor, refer to diagram 18.15.

GAS CONTROL VALVE

Drain down the boiler, refer to relevant part of Section 18.1. Remove electrical connections from water pressure sensor. Pull off slotted metal clip and remove water pressure sensor. Please ensure that the new "O" ring and clip supplied are fitted.
18.26 Bypass valve, refer to diagram 14.1.
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. Drain down the boiler, refer to relevant part of Section 18.1. Remove the ignition unit, refer to Section 18.33. Pull out slotted metal clip, ease out bypass valve from bypass valve housing.

Diagram 18.17

18.27 Automatic air vent, refer to diagram 18.16.
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. Drain down the boiler only, refer to relevant part of diagram 18.1. Unscrew to remove automatic air vent. After fitting replacement automatic air vent ensure the cap is open.

THREE WAY VALVE ACTUATOR

Diagram 18.21

IGNITION UNIT

Diagram 18.22
THREE WAY VALVE HEAD Diagram 18.20 THREE WAY VALVE/ BYPASS HOUSING
Before starting refer to the front of Section 18 Important information.
18.32 (F24E Only) Three-way valve actuator, refer to diagram 18.21.
Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Drain down the boiler only, refer to relevant part of diagram 18.1. Remove the gas control valve, refer to Section 18.28. Remove 3-way valve head, refer to Section 18.31. Remove the three way valve actuator.
18.33 Ignition unit, refer to diagram 18.22.
Remove ignition unit securing screw. Pull upwards to release and remove the ignition unit from the retaining slot.
18.34 (F24E Only) Domestic hot water plate to plate heat exchanger
Disconnect electrical connections.

Diagram 18.23

EXPANSION VESSEL

9772 9773

For ease of access remove the left hand side panel, refer to Section 15.6.
Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Drain down the boiler and hotwater circuit ,refer to relevant parts of diagram 18.1. Unclip the central heating thermistor. Unscrew the heating flow pipe union nut, swing pipe forwards. Remove the gas supply pipe between the gas control valve and injector bar, see diagram 18.23. Disconnect the union connection from the expansion vessel. Supporting domestic hot water plate to plate heat exchanger, unscrew and remove two screws securing it onto pump mounting and 3-way valve/bypass housing. Remove plate to plate heat exchanger from boiler. Fit replacement plate to plate heat exchanger. Note: Plate to plate heat exchanger mounting screws are offset to ensure correct fitting.

Diagram 18.24

DOMESTIC HOT WATER PLATE TO PLATE HEAT EXCHANGER
Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position, refer to the installation instructions. Replacing the expansion vessel Before starting refer to the front of Section 18 Important information.

IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Drain down the boiler only ,refer to relevant parts of diagram 18.1. Disconnect the flue system.
Disconnect the pressure relief valve discharge pipe. Disconnect the mains cable and any external controls cables. Lift up to remove the boiler from the wall. Remove sealed chamber cover, refer to Section 15.4. Remove the right hand side panel, refer to Section 15.6. From the rear of the boiler, unclip wiring harness retaining wire. Undo pipe coupling on expansion vessel. Unscrew and remove expansion vessel bracket retaining screw.
Note: Check that expansion vessel pressure is correct, see Section 1 Technical Data.
18.36 Sealed chamber cover seal, refer to diagram 18.25
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 old seal, thoroughly clean the casing. Fit the new seal, it is supplied to the correct length. Note: Ensure the seal is fitted correctly giving an air tight seal.
SEAL SEALED CHAMBER COVER Diagram 18.25
Slide expansion vessel to the left and forward to remove.

FRONT PANEL

Disconnect the fixing jig connection pipes at the boiler.
For this operation the boiler must be removed from the wall.

18.35 Expansion vessel

19 Spare parts
When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge.
Short parts list No. Description Central heating thermistor Fan Air pressure switch F24E only Domestic water flow sensor Printed circuit board - Main Pump head System water pressure sensor Gas control valve (G20) Gas control valve (G30) Discharge safety valve Overheat thermostat Ignition electrode Flame sense electrode 230V controls board User interface PCB Stepper motor (G20) Stepper motor (G30) Ignition unit F24E only Three way valve head Three way valve actuator Heat exchanger Burner Part No. S57398 S10088 S10089 S57202 S10082 S10052 S57205 S10045 S10046 S10067 S10080 S10038 S10037 S10091 S10081 S57434 S57435 S57427 S57206 S10064 S10030 S10042 G.C. No.
Because of our constant endeavour for improvement details may vary slightly from those in the instructions.