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

Shy 131

Diagram 4

FIXING JIG

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

Pla 105c
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

Pla 116b

Diagram 5

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)

Boiler

Domestic water

Tundish (supplied)

Minimum 22 mm diameter Return Heating circuit Flow control valve Bypass valve Filling point

Diagram 6

Sch 173

Drain point

Cold supply
Pressure reducing valve (supplied)

BOILER LOCATION

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.

Diagram. 10

Diagram. 9
REAR OUTLET FLUE INSTALLATION
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. For top outlet flue connection, refer to 'Top outlet flue installation' Rear outlet flue - kit 86151 The rear outlet flue system consists of two parts, a white painted outer pipe and an aluminium inner, they are positively locked together when assembled. The flue kit 86151, see diagram 11, 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

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.

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.

Hab 210b

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.

SAFETY DEVICES

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.

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

Diagram 28

from boiler taking care to retain both fibre washers and seal on gas supply for use on reassembly. Unscrew and remove two injector bar retaining screws and separate injector bar from burner. Examine and clean injectors as necessary. Note: Do not use a wire or sharp instrument on the holes. Replace burner in reverse order to removal. Heat exchanger After removal of burner, examine heat exchanger for any blockages or build up of deposits. Clean using soft brush or vacuum cleaner. Important: Take care not to scratch or otherwise damage painted surface of heat exchanger. Reassembly of parts removed for servicing Replace all parts in reverse order to removal. Flue system Check externally to make sure flue is not blocked. Inspect flue system to make sure all fittings are secure. Operation of fan Switch on electrical supply and turn on gas. Switch boiler On/Off switch to 1 (On). Light burner by opening a hot tap. Without upper front panel in place, burner should be prevented from lighting by air flow detection system. Refit upper front panel. Check that fan runs when burner is lit and stops when it goes out. Cold water inlet filter (exept SB models) Drain down hot water circuit of boiler as follows: Close isolating valve on cold water inlet connection on fixing jig, see diagram 5. Open one or more hot water taps to drain boiler. Undo connecting nut from cold water inlet connection to gain access to filter. Remove white filter from inlet connection.

Des 047

Note: Connecting pipework is telescopic, it may be necessary to slide sleeve back for easier access to filter. Clean and inspect filter, replace if necessary. With both flow restrictor and filter in place, reconnect pipe to inlet connection and tighten. Fully open isolating cock on cold water inlet connection and check for leaks. Operation of water valve (exept SB models) With the Summer/Winter control in the 'Summer' position, slowly open a convenient tap until boiler lights. Measure water flow, it should not be greater than 3,5 litres/minute. If necessary, replace diaphragm. Replace all outer panels.

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.

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.

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

108198 B 06/98

Heating and hot water for the professionals

User Instructions

THEMA C
IN WARRANTY TECHNICAL HELPLINE

01773 828400

THIS IS A CAT II2H3+ APPLIANCE

01773 828100

USER INSTRUCTIONS THEMA C 23
Note! The boiler serial number is marked on the label attached to the front of these instructions. Refer to the 'Introduction' section for a description of the basic functions of the boiler.
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.. Page 2 - 3 Controls & lighting.. 3 Draining... 4 Servicing/maintenance.. 4

INTRODUCTION

The THEMA C 23 boiler is a wall mounted modulating combination boiler providing central heating and instantaneous 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. These instructions should be carefully followed for the safe and economical use of your boiler. 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. Bathroom fittings Any ancillary equipment such as mixing valves, showers etc. must be designed to operate at mains water pressure. Contact your local Water Authority for advice. Electrical supply WARNING: This boiler must be earthed. The boiler must be connected to a 230V 50Hz permanant supply. To connect a plug: The colours of three core flexible cable are: Brown - Live Blue - Neutral Green/yellow - Earth As the marking on your plug may not correspond with these colours, proceed as follows : The cable coloured blue must be connected to the terminal marked "N" or black. The cable coloured brown must be connected to the terminal marked "L" or red. The cable coloured green/yellow must be connected to the terminal marked "E", green or the earth symbol. Boiler location The boiler should have the following minimum clearances for maintenance purposes: 5mm on each side of boiler 300mm above boiler 250mm below boiler 450mm in front of boiler Mains failure In the event of failure of the electrical supply, the boiler will not operate. When the supply is restored, the boiler will return to normal operation.
Gas leak or fault If a gas leak or fault exists or is suspected, turn off the gas supply. Do not touch any electrical switches. Do not smoke. Consult the local gas supply company or your Installer/Service Provider. Air in the heating system Persistent air in the heating system may indicate leaks in the system or corrosion taking place. Call your Installer/Service Provider. Overheat safety In the event of a problem, the overheat safety devices cause safety shutdown of the boiler. If this happens, call your Installer/Service Provider. Boiler controls The control panel, located behind the pull down door at the lower front of the boiler casing, see diagram 1, allows the boiler to be started, shut down, controlled and monitored during use.
1 - On/Off switch 2 - Piezo ignition button 3 - Summer/Winter mode selector
4 - Hot water temperature adjuster 5 - Heating temperature adjuster

Diagram 1

CONTROLS AND LIGHTING

To light the boiler

Before starting the boiler check that: The gas meter tap is open. The boiler gas service cock is open. The boiler is connected to the electrical supply and turned on.
Setting to summer/Winter mode
Summer Domestic hot water only Winter Heating and hot water
1 - Push in and keep depressed
2 - Push in several times until the pilot has lit

Hab 257

Adjustment of domestic hot water temperature

Open a hot water tap. Turn the temperature adjuster until the desired hot water temperature is obtained. Hot water always has priority over central heating.
3 - Wait for 20 seconds after the pilot has lit
4 - Release button. The pilot should remain lit, if it doesn't, repeat operations 1 to 3
Adjustment of central heating temperature
Turn the temperature adjuster until the desired central heating temperature is obtained. Make sure that any external controls are calling for heat. The heating system will begin to heat up.
To stop the boiler Push OFF switch (0)

Hab 269

DRAINING
Protection against freezing The boiler has a built in frost protection device that protects the boiler from freezing. If the boiler is to be left for a short period and there is a risk of frost, ensure that the gas Diagram 2 and electrical supplies are left connected and that the Summer/ Winter switch is left in the position, see diag. 2. Note: This device works irrespective of any room thermostat setting and only protects the boiler. Always ensure that adequate frost protection is given to the entire system where necessary. If the boiler is to be out of use for any long periods during severe weather conditions, it is recommended that the whole system, including the boiler, be drained to avoid the risk of freezing. If in doubt, consult your Installer/Service Provider. 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. Note: If there is persistent loss of system pressure, indicated by the pressure gauge, you must consult your Installer/Service Provider. Heating safety valve CAUTION: A safety valve with a discharge pipe is fitted to this boiler. The valve MUST NOT BE TOUCHED except by a competent person. If the valve discharges at any time, switch the boiler off and isolate it from the electrical supply. Contact your Installer/Service Provider.

SERVICING/MAINTENANCE

To ensure the continued efficient and safe operation of the boiler, it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the installation conditions and usage but, in general, once a year should be enough. Cleaning The boiler casing can be cleaned with a damp cloth followed by a dry cloth to polish. Do not use abrasive or solvent cleaners. Boiler casing CAUTION. Do not remove or adjust the casing in any way, as incorrect fitting may result in faulty operation. If in doubt, contact your Installer/Service Provider.

109452 B 07/98