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.

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.

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. If the boiler loses water: the pressure will be indicated (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. Reset boiler: refer to diagram 2, switch On/Off to ( 0 ), wait for five seconds. Switch On/Off to ( I ) to reset the appliance.

BOILER DRAIN VALVE

(b) (a)

Appliance Introduction

The Themaclassic plus boiler is a wall mounted modulating combination boiler with electronic ignition providing central heating and instantaneous hot water. The boilers are equipped with a litre domestic hot water storage vessel that ensures maximum hot water temperature stability during domestic demand. The boiler is of the II2H3+ category for use with Natural Gas (G20) as distributed in the United Kingdom, or Butane (G30), Propane (G31) with the appropriate conversion kit. 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. Both the central heating and domestic hot water temperature are user adjustable. 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. 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. 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.

Flue options

There are various flue systems to choose from, for detailed information refer to flue options guide, which is available from your nearest stockist.

Accessories

A range of accessories are available. For further information contact your supplier.

Diagram 1

Appliance Safety Devices
Air flow rate safety device
If the flue is obstructed, even partially, the built in safety system will turn the boiler OFF, the fan will continue to run. The boiler will be ready to operate when the fault has been cleared.

Frost protection

The appliance has a built in frost protection device that protects the boiler from freezing. With the gas and electric supplies ON and irrespective of any room thermostat setting, the frost protection device will light the boiler when the temperature of the boiler water falls below 6C. When the temperature reaches 16C, the boiler stops. Any other exposed areas of the system should be protected by a separate frost thermostat.

Overheating safety

In the event of the boiler overheating the safety devices will cause a safety shutdown. If this happens, call your Installation/ Servicing company.
Electrical supply failure
The boiler will not operate without an electrical supply. Normal operation of the boiler should resume when the electrical supply is restored. Reset any central heating system controls, to resume normal operation. If the boiler does not resume normal operation turn the mains reset switch off and on. If the boiler does not resume normal operation it is advisable to consult your installation / servicing company.

Heating safety valve

CAUTION: A heating safety valve with a discharge pipe is fitted to this boiler. The valve MUST NOT BE TOUCHED except by a competent person. If the valve discharges at any time, switch the boiler off and isolate it from the electrical supply. Contact your installation/ service company.
Domestic Hot Water safety valve
CAUTION: A domestic hot water 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 installation/ service company.

Maintenance and Servicing

Cleaning

WARNING: This appliance contains metal parts (components) and care should be taken when handling and cleaning with particular regard to edges of sheet metal parts to avoid any possibility of personal injury. The boiler casing can be cleaned with a damp cloth, followed by a dry cloth to polish. Do not use abrasive or solvent cleaners.

Spare Parts

REMEMBER, When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating Ltd. If a part is required contact Heatcall (Saunier Duvals own service organisation) using the telephone number on the inside front cover of this booklet. Please quote the name of the appliance, this infomation will be on the name badge on the front of the appliance. If in doubt seek advice from the local gas company or Heatcall (Saunier Duvals own service organisation) using the telephone number on the inside front cover of this booklet.
To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals but in general once a year should be enough, refer to guarantee registration on the inside front cover of this literature. If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35. Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination. To obtain service, please call your installer or Heatcall (Saunier Duvals own service organisation) using the telephone number on the inside front cover of this literature. Please be advised that the Benchmark logbook should be completed by the engineer on completion of commissioning and servicing. All CORGI Registered Installers carry a CORGI ID card, and have a registration number. Both should be recorded in your benchmark Logbook. You can check your installer is CORGI registered by calling CORGI direct on: 01256 372300.

Controls and lighting

Central heating adjustment
The temperature of the water in the central heating circuit can be set between, approx. 38OC and 87OC. It is supplied, factory set to 38OC - 73OC

Domestic hot water

The temperature can be adjusted from approx. 38C up to 65C.
- OFF/ON switch - Display - Programing buttons - Running lamp illuminated green when boiler is ON (flashing red when fault indicated)

Timed central heating and instantaneous domestic hot water Central heating and domestic hot water Domestic hot water only Central heating only Long absence / Holiday mode and Appliance frost protection Diagram 2
Make sure that: The boiler is connected to the electrical supply. The gas service cock is open. Switch ON (I) The running lamp will illuminate green.

1. Lighting the boiler:

3. Domestic hot water temperature adjustment:
Press button once, is displayed and the current temperature setting flashes. Press - or + to set a temperature between 38c to 65c. The display will default to normal after 5 seconds if no buttons are pressed.
Switch to OFF (0) the electrical supply is OFF.

2. Stop the boiler:

4. Central heating temperature adjustment:
Press button twice, is displayed and the current temperature setting flashes. Press - or + to set a temperature between 38c to 87c. The display will default to normal after 5 seconds if no buttons are pressed.

7. If a fault occurs:

The green running light will change to a red flashing light and the display will flash the letter F with the type of fault. Reset the boiler: Switch the boiler OFF ( 0 ), wait for five seconds. Switch the boiler ON ( I ), the boiler is reset. If the fault continues call your Installation/Servicing company or Heatcall using the telephone number on the inside front cover of this literature.

(Ignition fault shown)

5. Heating Mode select:
Press button and three times, is displayed

8. Installation filling:

If the boiler loses water: The green running light will change to a red flashing light and the display will flash the letter F with the low system water pressure fault and the current system pressure. Fill the system by the filling device at the bottom of the boiler until the pressure gauge reads 1.0 bar.
will flash along side the current mode setting.
Press - or + to set as required. The display will default to normal after 5 seconds if no buttons are pressed.
6. Long absence / Holiday mode:
This mode protects the boiler against frost
Warning: Take care not to overfill the boiler. At a pressure of 2.5 bar or above the high system water pressure fault will be displayed. The pressure must be reduced to 1.0 bar by opening the drain valve, see diagram 1. If the fault continues call your Installation/Servicing company or Heatcall using the telephone number on the inside front cover of this literature.

Programmer instructions for use

Setting the time.

Make sure there is an electrical supply to the boiler and the boiler is switched ON ( I ). four times, is displayed and the time Press button will flash, press - or + to set the correct time (24hr clock). press "+" and , and the will be displayed along with 0 to 24 hour ON / OFF settings and 1 to 7 days of the week. Set ON / OFF times at 30min intervals for each day 1 to 7 of the week. A flashing square is displayed below the current day of the

Setting the day.

Press button five times, is displayed and the current day setting will flash, press - or + to set the correct day. 1=MON, 2=TUE, 3=WED, 4=THU, 5=FRI, 6=SAT, 7=SUN
week selected, Press - or + to select the day 1 to 7 to be set. Press to set ON / OFF times, and are displayed, a flashing square will now be displayed below the 0 along the top of the display along with the corresponding time 00:00OFF to the right of the display, this indicates that 00:00 to 00:30 is set to OFF, to set this to ON press + , or to set

Setting the programmer.

Press button six times, is displayed.
to OFF press , continue setting the ON / OFF times for the remainder of that day / 24hr period in 30min intervals. Press , and is displayed, press + to select the next day or - to select the previous day to be set, continue setting the remaining days as required. The display will default to normal after 60 seconds if no buttons are pressed.

1 Technical Data

Heating
Heat input (max) NET Q Heat input (min) NET Q Heat output (max) GROSS P Heat output (min) GROSS P Efficiency - Sedbuk D Maximum heating temperature Expansion vessel effective capacity Expansion vessel charge pressure Maximum system capacity at 75C RED Safety valve,

F24E PLUS F30E PLUS

25,9 kW 88,370 BTU/H 12,3 kW 41,967 BTU/H 23,6 kW 80,523 BTU/H 10,6 kW 31,731 BTU/H 78,3% 87 C 6,5 l 0,5 bar 125 l 32,6 kW 111,231 BTU/H 12,5 kW 42,650 BTU/H 29,6 kW 100,995 BTU/H 10,3 kW 35,144 BTU/H 79,6% 87 C 8l 0,5 bar 156 l 3 bar
Net lift weight (boiler only) 39 kg (F24E) 41 kg (F30E) Gross lift weight (boiler and packaging) 41 kg (F24E) 43 kg (F30E) 365 232

11564a

maximum service pressure 3 bar

Hot water

Heat input (max) NET Q Heat input (min) NET Q Heat output (max) GROSS P Heat output (min) GROSS P Maximum hot water temperature Minimum hot water temperature Specific flow rate (for 30 C temp rise) Threshold flow rate Maximum supply pressure Minimum supply pressure BLUE Safety valve,
25,9 kW 32,6 kW 88,370 BTU/H 111,231 BTU/H 12,3 kW 12,5 kW 41,967 BTU/H 42,650 BTU/H 23,6 kW 29,6 kW 80,523 BTU/H 100,995 BTU/H 10,6 kW 10,3 kW 31,731 BTU/H 35,144 BTU/H 65 C 38 C 11,3 l/min. 1,7 l/min. 10 bar 0,5 bar 10 bar 65 C 38 C 14,1 l/min. 1,7 l/min. 10 bar 0,5 bar 10 bar

Combustion

Products outlet diameter Fresh air inlet diameter Combustion products values

(10 kPa = 1 m WG)

Bypass fully shut Open 1/4 turn Open 1/2 turn Open 1 turn Open 2 turns

Diagram 3.1

the product manufacturers for specific details.
Additional expansion vessel (if required)

Boiler

Filling device Domestic water

3.1 Bypass

The boiler is fitted with an adjustable automatic bypass.

Cold supply in

Hot water out

TABLE 1. FLOW RATE

Model Minimum flow rate F 24 E plus ? F 30 E plus 21.26 litres per minute This is equal to 20C differential at maximum heat input
Ensure that under no circumstances does the flow rate drop below the figure specified, see Table 1. A bypass is not required on the central heating circuit unless the system controls could allow the boiler to operate when there is no flow. Where a bypass has to be fitted, the bypass must be placed at least 1.5 metres from the appliance, see diagram 3.2.

* Bypass (If required)

Bypass valve
Drain point Control valve Drain point

Return

Heating circuit

3.2 Filling the system

Diagram 3.2
A filling device is fitted to the boiler to initially fill the system and replace water lost during servicing, see the relevant parts of diagram 2 controls and lighting and diagram 3.2.
4 Domestic Hot Water System Design
Copper tubing or plastic Hep20 may be used for the domestic hot water system. Unecessary pressure losses should be avoided. Provision shall be made for a drain valve at the lowest points of the system. The flow restrictor must be fitted limiting the flow through the boiler to a maximum of 12 l/min (F30E Plus) 10 l/min (F24E Plus). The boiler will operate with a minimum supply pressure of 0,5 bar, at reduced flow rate. Best operating comfort will be obtained from a supply pressure of 1 bar.

4.1 Hard Water Areas

In areas where the water is 'hard', more than 200mg/litre, it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler.

5 Boiler Schematic

1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas valve. 15 - Loss of water sensor. A - Heating return 16 - Domestic heat exchanger B - Cold water inlet 17 - 3 way valve C - Heating flow D - Domestic hot water outlet 18 - Domestic water flow sensor E - Gas 19 - Filter cold water inlet 20 - Filling system 21 - Discharge safety valve (3bar) 22 - Drain valve 23 - Heating filter 24 - Domestic safety valve 10 bar 25 - Micro accumulation vessel thermistor 26 - Micro accumulation vessel 27 - Heating element

Flue centre line BOILER

STEP 2.
25mm minimum Air Duct over lap

(B) FIXING

COLLAR 25mm SEAL

(G) Drill, screw 2 off

and tape the Air Duct

STEP 3.

(D) ELBOW

(G) (A) (E)

EXTERNAL RUBBER SEALING COLLAR 'O' RING

GASKET

BOILER

STEP 4.

(D) (A) (E) (G) 2 off (G) (A) (E)

FIXING (C) COLLAR

Diagram 11.3

STEP 5.

11.3 Installation of telescopic flue assembly
12 Horizontal Top Flue Installation
Suitable for installations that require a max. flue length "L" of 740mm. If a shorter flue length is required, the flue can be cut to a min. length"L" of 260mm rear or 300mm side. See diagram 12a.2 for min. flue lengths.
12a.2 Flue systems rear and side, refer to diagram 12a.1. 12a.3 Flue cutting, refer to diagram 12a.3.
Important: Do not leave any burrs or sharp edges on the cut ends of the pipes.

D A J H I C

The flue kit 86285 is 810 mm long and comprises: - Air duct pipe... A - Flue duct pipe... B - Elbow... C - Fixing collar seal.. D - Fixing collar.. E - External rubber sealing collar. F - Internal flange.. G - Gasket... H - Screws... I - 'O' rings... J

70mm 184mm 65mm

Horizontal Top flue kit

Diagram 12a.1

Diagram 12a.2
12a.1 The Horizontal Top flue - kit 86285
Outside wall face L Flue centre line C L 90mm
12a.4 Installation of horizontal top flue assembly
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 (H) and carefully fit gasket to base of elbow (C). Fit both O rings (J) into the flue elbow (C), one at the inlet, one at the outlet. By necessity, they are a loose fit, apply a small amount of suitable lubricant to each O ring when fitting. Fit rubber sealing collar (F), into groove at the outer end of pipe (A). Insert flue duct pipe (B) into inner end of air duct pipe (A), rotate flue duct pipe to locate into groove inside air duct pipe. Fit air/flue duct pipe assembly through the wall with rubber sealing collar to the outside. Fit internal plastic flange (G) onto air duct pipe (A). Fit the fixing collar seal (D) onto the flue duct pipe (B) ensuring it is the correct way round (the larger diameter onto the pipe). Pull air/flue duct pipe assembly inwards to bring rubber sealing collar (F) hard up against external wall. Fit elbow onto boiler and secure with the four screws (I). Carefully push the fixing collar seal onto the elbow ensuring that the flue duct pipe locates into the flue elbow outlet while taking care not to tear the O ring. Fit the fixing collar (E) around the fixing collar seal (D) and secure with 2 screws provided. Push the internal plastic flange (G) along the air duct pipe (A) until engaged against internal wall.

Adjusting the step pressure.
This setting is used to adjust step pressure which may be necessary after gas conversion or after changing the gas control valve. Settings:2.9 mbar Natural gas G20 4.41 mbar Butane G30 5.4 mbar Propane G31 Lock the boiler at minimum power as follows. Press the mode button for about 10 seconds, Use + or - to display code 96, Press the mode button to confirm, The display idicates line 1 in the data menu, The figure on the left is the data, the one on the right is the setting for the data. Scroll through the data using + or - until you reach 8, Press the mode button the figure on the right begins to flash, Change it to 1 using + or -. Press the mode button to confirm. This mode will time out after 15 minutes. Adjust the step pressure. The factory set value is noted on the data label.
Adjust the maximum burner pressure setting.
Press the mode button for about 10 seconds, Use + or - to display code 35, Press the mode button to confirm, The display idicates line 23 in the data menu, The figure on the left is the data, the one on the right is the setting for the data. Scroll through the data using + or - until you reach 25, Press the mode button the figure on the right begins to flash, Change it to the required setting 0 to 199 using + or -. Press the mode button to confirm.
17 Routine Cleaning and Inspection
REMEMBER, when replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Hepworth Heating. To ensure the continued efficient and safe operation of the boiler it is recommended that it is checked and serviced at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage, but in general once a year should be enough. It is the law that any servicing is carried out by a competent person.

PRODUCTS SAMPLING POINT

SAMPLING POINT CAP
17.1 Products of combustion check
Top Flue: To obtain a products of combustion reading, unscrew the left hand sampling point cap on the flue elbow, located on top of boiler, see diagram 17.1. Rear Flue: To obtain a products of combustion reading, remove the sampling point cap on the flue spigot, located between the boiler and the wall, see diagram 17.1. Connect the analyser tube onto sampling point. Refer to the combustion product values in Section 1 Technical Data. Switch on the electrical supply and gas supply, then operate the boiler. On completion of the test switch off the electrical supply and the gas supply, remove analyser tube and replace sampling point cap.

Diagram 17.1

17.4 Control panel
Lower forwards to gain access to lower part of boiler.

Diagram 17.11

18 Fault Finding

Before trying to operate the boiler make sure that : All gas supply cocks are open and that the gas supply has been purged of air. The heating system pressure is at least 1 bar. There is a permanent mains supply to the boiler and that the polarity is correct. The fuse on the PCB is intact. 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. Should there be any doubt about the voltage supply to any of the components, it is possible to carry out a simple electrical test to ensure all is operational in that area. IMPORTANT: On completion of the fault finding task which has required the breaking or remaking of the electrical connections, the continuity, polarity, short circuit and resistance to earth checks must be repeated using a suitable multimeter.
Overheat thermostat reset button
Refer to Section 20.10 to locate the overheat thermostat reset button. Depress the button to reset.

OVERHEAT THERMOSTAT

RESET BUTTON

Diagram 18.1

'01' '02' '03' '04' '05' '06' '07' '08' '09' '10' '11' '12' '13' '14' '15' '16' '17' '18' '19' '20' '0.5bar' '2.7bar'
Ignition fault (lockout) caused by no gas, no detection Air fault, pressure switch, no power to fan Air fault lock Ignition fault (lockout) caused by no gas, no detection Overheat fault Central heating flow NTC fault Domestic hot water NTC fault Micro accumulation vessel NTC fault Water pressure sensor fault Central heating return NTC fault No reception by the main board (MMI Lead) User interface or distant control panel fault Main board fault Over temperature on primary water circuit Stepper motor fault (gas valve) Gas safety valve failure Power supply <170V Local user interface fault Central heating NTC not connected to pipe User interface not compatible with boiler Lack of water fault (<0.5b) Upper water pressure (>2.7b)

9961 11797

FAULT: NO HOT WATER, BUT THE HEATING IS WORKING Is the water pressure greater than 0.5 bar ? YES 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. NO Insufficient water pressure. The appliance will not operate. Find out why the pressure is so low.
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? YES Is the boiler actually designed for the gas being used. YES Clean the gas filter. Clean the burner. NO Change the gas type for the boiler (gas conversion kit).
Check that the gas taps are fully open Check the gas pressure.
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 spark electrode and terminal H24 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).
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

11899p

Is the heating temperature on the boiler set high enough? YES
Is the heating power adequate? - Check the adjustment of the by-pass internal and external (If fitted). - Check the 3-way valve is not passing into the domestic hot water heat exchanger.

PUMP ELECTRICAL CONNECTION BOX Diagram 20.11
For ease of access if required remove the right hand side panel, refer to Section 17.6. Undo four head fixing screws and remove pump head. Gain access to the pump electrical connection box and remove cover. Disconnect pump cable from pump (avoid straining cables). Connect electrical connection to replacement pump head. Fit replacement pump head.
20.19 Mains switch, refer to diagram 20.10.
Before starting refer to the front of Section 20 Important information. Unclip control panel user interface and hinge forward. Do not strain the cables. Remove the mains switch. Disconnect the electrical connections from the mains switch.
20.21 Filling system tap, refer to diagram 20.12.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Drain down the hot water circuit only, refer to relevant part of diagram 20.1. Pull of the filling loop tap extension. Pull out slotted metal clip securing tap into housing, remove tap. Pull out slotted metal clip and remove pipe from tap. 48
20.20 Central heating pump head, refer to diagram 20.11.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 20.1. Note: it is not necessary to drain down the entire heating system to carry out this work.
MAINS SWITCH Diagram 20.10
20.22 Reduced pressure zone valve (RPZ), refer to diagram 20.12.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3.
REDUCED PRESSURE ZONE VALVE (RPZ)
Drain down the boiler only, refer to relevant part of diagram 20.1. Pull out slotted metal clip securing pipe to RPZ. Pull out slotted metal clip securing RPZ into housing, remove RPZ.
20.23 Boiler drain point, refer to diagram 20.13.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4.

FILLING TAP

Diagram 20.12
Pull out slotted metal clip securing boiler drain valve into housing, remove boiler drain valve.

20.24 Water flow sensor, refer to diagram 20.14.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Drain down the hot water circuit, refer to relevant part of Section 20.1. 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.
BOILER DRAIN VALVE Diagram 20.13
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Drain down the boiler, refer to relevant part of Section 20.1. Remove electrical connections from water pressure sensor. Pull off slotted metal clip and remove water pressure sensor.
20.25 System water pressure sensor, refer to diagram 20.15.
WATER FLOW SENSOR Diagram 20.14
Drain down the boiler only, refer to relevant part of diagram 20.1.
Lower the control panel, refer to Section 17.4.
20.26 Bypass valve, refer to diagram 20.15.
SYSTEM WATER PRESSURE SENSOR

BYPASS VALVE

Pull out slotted metal clip, ease out bypass valve from bypass valve housing.
20.27 Automatic air vent, refer to diagram 20.16.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Drain down the boiler only, refer to relevant part of diagram 20.1. Unscrew to remove automatic air vent. After fitting replacement automatic air vent ensure the cap is open.

Diagram 20.15

CAP AIR VENT Diagram 20.16 GAS CONTROL VALVE
Drain down the boiler, refer to relevant part of Section 20.1.
20.28 Gas Control valve, refer to diagram 20.17.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Disconnect gas supply pipes and union nuts at the gas control valve. Disconnect supply pipe union nut at the burner injector bar. Remove gas control valve retaining clip from the underside of gas control valve.

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.

To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals, but in general once a year should be enough, refer to guarantee registration on the inside front cover of this literature. If this appliance is installed in a rented property there is a duty of care imposed on the owner of the property by the current issue of the Gas Safety (Installation and Use) Regulations, Section 35. Servicing/maintenance should be carried out by a competent person in accordance with the rules in force in the countries of destination. To obtain service, please call the relevant service organisation or Saunier Duval Service using the telephone number on the inside front cover of this literature.
User Controls and Lighting
Central heating temperature selector minimum setting (approx. 38C) up to maximum setting (approx. 73C). Boiler ON indicator (fault indicated by light flashing red) On/Off switch
4 Pressure gauge (bar) and temperature gauge (C)
Domestic hot water temperature selector (F24E Only) minimum setting approx. 38C up to maximum setting 60C.

Programmer (F24E Only).

The ECO setting is ideally suited for all the requirements of normal family use (showers, washing up etc.). The maximum setting should be reserved for occasional use when very hot water is required.

Lighting the boiler :

Heating temperature adjustment : 2

Make sure that:

The boiler is connected to the electrical supply. The gas service cock is open. The room thermostat is calling for heat (if fitted). Turn the On/Off switch 1 The boiler ON indicator 5 to ON ( I ) will illuminate green.
Winter: Set the control knob between 1 and 5 (Heating ON) Summer: Set the control knob to (Heating OFF)

Stop the boiler :

to OFF ( 0 ) the Turn the On/Off switch 1 electrical supply is OFF.
If a fault occurs (indicated by

red flashing light) : 5

Reset boiler: Turn the On/Off switch to ( 0 ), wait for five seconds. Turn the On/Off switch to (I) the boiler is reset. If the fault continues call your Installation/Servicing company or Saunier Duval Service using the telephone number on the inside front cover of this literature.
Domestic hot water adjustment (F24E Only) : 3
Position ( 0 ): Domestic hot water OFF Position ( I ) and ECO: Domestic hot water between approx. 38C and 50C ECO: Maximum recommended for constant use Between ECO and maxi: Occasional use for water above approx. 50C
Pressure gauge: 4 The boiler pressure gauge will show a reading between 1.0 and 1.5 bar. Refer to Section Draining and Filling if required.

IF THE h AND m KEYS ARE HELD DOWN LONGER THAN 2 SECONDS, THE NUMBERS WILL ADVANCE RAPIDLY. Press and hold the key during the following:
Event 1 (ON at 7:00AM Monday through Saturday) Press key once. ON symbol appears
Press h key to 07AM Press m key once to 00 Press Day key once is displayed Press Prog. key to enter
(If British Summer Time is in effect, press 1h first) 1. Press h to advance to the current hour (while holding down the key) 2. Press m to advance to the current minute (while holding down the key) 3. Press Day repeatedly to advance to current day key) (while holding down the
Event 2 (OFF at 5:00PM Monday through Friday) Press key twice. OFF symbol appears
Press h key to 05PM Press m key once to 00

Day Key Selections

Press Day Key 0 times 1 time 2 times 3 times 4 times 5 times 6 times 7 times 8 times 9 times 10 times 7 Display Shows Days Every Day Mon.Sat. Mon.Fri. Sat. & Sun. Monday Tuesday Wed. Thursday Friday Saturday Sunday
Press Day key two times 5 is displayed Press Prog. key to enter
Event 3 (OFF at 7:00PM Saturday) Press key twice. OFF symbol appears
Press h key to 07PM Press m key once to 00 Press Day key 9 times until only 6 is displayed Press Prog. key to enter Press key to enter Run Mode
NOTE: If the days are flashing, it indicates the day of the week was not set when setting the time. The timer cannot be programmed unless the day of the week is entered.
IF AN "ON" TIME WAS PROGRAMMED THAT IS EARLIER IN THE DAY THAN THE CURRENT TIME, PRESS ONCE TO TURN THE TIMER "ON". (IT DOES NOT "LOOK BACK" TO DETERMINE IF IT SHOULD BE ON OR OFF AFTER PROGRAMMING). IF 24 HOUR TIME CONTROL (SAME SCHEDULE EVERY DAY OF THE WEEK) IS DESIRED, IGNORE Day KEY. If an ON or OFF symbol is not entered, the ON symbol will flash, and programme will not be accepted.
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.

4.1 Hard Water Areas

In areas where the water is 'hard', more than 200mg/litre, it is recommended that a proprietary scale reducer is fitted in the cold water supply to the boiler.

5 Boiler Schematic F24E

1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas control valve. 15 - Loss of water sensor. 16 - Domestic heat exchanger 17 - 3 way valve 18 - Domestic water flow sensor 19 - Filter cold water inlet 20 - Filling system 21 - Discharge safety valve (3bar) 22 - Drain valve 23 - Heating filter
A - Heating return B - Cold water inlet C - Heating flow D - Domestic hot water outlet E - Gas
FITTED TO REAR OF APPLIANCE

Diagram 5.1

5a Boiler Schematic F18E SB
1 - Fan. 2 - Air pressure switch. 3 - Heat exchanger. 4 - Overheat thermostat. 5 - Combustion chamber. 6 - Expansion vessel. 7 - Flame sense electrode. 8 - Burner. 9 - Ignition electrode. 10 - Pump. 11 - Heating thermistor. 12 - Ignition unit. 13 - By-pass. 14 - Gas control valve. 15 - Loss of water sensor. 16 - Heating filter. 17 - Discharge safety valve (3bar).
A - Heating return. B - Heating flow. C - Gas.

Diagram 5a.1

6 Boiler Location, Flue and Ventilation

6.1 Boiler Location

The recommended clearances are shown in diagram 6.1. Note: The boiler must be mounted on a flat wall which is sufficiently robust to take its weight when full. If in doubt, expert advice should be obtained, in the event of the wall being found not suitable. The minimum acceptable spacings from the terminal to obstructions, other terminals and ventilation openings are shown in diagram 6.2. For Ireland the minimum distances for the flue terminal positionning must be those detailed in I.S.813 "Domestic Gas Installations".
The boiler must be installed so that the terminal is exposed to the external air.
6.2 Terminal guard, see diagram 6.3.
A terminal guard is required if persons could come into contact with the terminal or the terminal could be subject to damage. If a terminal guard is required, it must be positioned to provide a minimum of 50mm clearance from any part of the terminal and to be central over the terminal. A suitable terminal guard type K3 can be supplied by: Tower flue components Ltd. Morley road Tonbridge Kent TN9 1RA

8.1 Cutting the flue hole
Remove the wall template, follow the instructions given on the wall template. Position the wall template, taking due regard of the minimum clearances for the selected flue application, see diagram 8.1. Rear hole cutting Mark correct position of Top Rear flue outlet hole from template, then remove template, before cutting, for use, later. Side hole cutting Mark the horizontal centre line for the hole on the rear wall. Extend the horizontal centre line to the side wall and mark the vertical centre line of flue hole as shown in diagram 8.1. IMPORTANT NOTE: 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 35mm per metre of flue downward towards the terminal. There MUST never be a downward incline towards the boiler. 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 105mm diameter core drill. For installations with internal access only use a 125 mm diameter core drill.
8.2 Fixing jig, refer to diagram 7.1
IMPORTANT NOTE: Ensure that the hanging bracket is fitted to a flat and true wall area for correct alignment with the boiler. Side Flue - Check the horizontal centre line and reposition the template if necessary. Rear Flue - Reposition the wall template over the hole in wall. Mark the securing position holes. Check that the hanging bracket is level. Drill, plug and secure the bracket to the wall, using suitable screws (not supplied) for the wall type and capable of supporting the total weight of the appliance (refer to wall template for fixing points).

Diagram 8.1

8.3 Water connection
IMPORTANT NOTE: Do not subject the isolating valves to heat from blowlamp, when making connection. Connect the system pipework to the fixing jig connection pipes and the fixing jig isolating valves, observing the correct flow and return as shown in diagram 8.1.
8.4 Gas connection 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. The whole of the gas installation, including the meter, should be inpected, tested for soundness and purged in accordance with the current issue of BS6891 and in IE the current edition of I.S.813 "Domestic Gas Installations".

9 Boiler Installation

9.1 Sheet metal parts
WARNING: When installing or servicing this boiler, care should be taken when handling the edges of sheet metal parts to avoid the possibility of personal injury. If fitted ensure the plastic plugs are removed from water and gas pipes. NOTE: There will be some spillage of water. (F24E Only) Fit the cold water inlet restrictor (supplied in the document envelope) into cold water inlet isolating valve, see diagram 7.1. Important Note. With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift. Lift the boiler up and engage boiler onto the hanging bracket, refer to diagram 7.1. Fit the boiler connection pipes and washers between the boiler and isolating valves, see diagram 7.1.

STEP 1.

Outside wall face FLUE LENGTH 90mm

(D) (A)

17mm IMPORTANT "BUTT FIT"

Flue centre line BOILER

STEP 2.
25mm minimum Air Duct over lap

(B) FIXING

COLLAR 25mm SEAL

(G) Drill, screw 2 off

and tape the Air Duct

STEP 3.

(D) ELBOW

(G) (A) (E)

EXTERNAL RUBBER SEALING COLLAR 'O' RING

GASKET

STEP 4.
RESTRICTOR fitted for flue lengths less than 0.5m

(G) 2 off (G) (A) (E)

FIXING (C) COLLAR

STEP 5.

The restrictor must be fitted to the inside of the fan outlet.

Diagram 10.3

Diagram 10.4
10.3 Installation of telescopic flue assembly
10a Horizontal Top Flue Installation
Is suitable for installations that require a max. flue length "L" of 740mm. If a shorter flue length is required, the flue can be cut to a min. length"L" of 260mm rear or 300mm side. See diagram 10a.2 for min. flue lengths. Note: Additional 1 metre extensions, 90 and 45 bends are available. The maximum extended flue is 3.5m. The use of flue bends requires the maximum extended flue lengths to be reduced by 1m. for 90 and 0.5m. for 45.
10a.2 Flue systems rear and side, refer to diagram 10a.1. 10a.3 Flue cutting, refer to diagram 10a.2.
Important: Do not leave any burrs or sharp edges on the cut ends of the pipes.

D A J H I C

The flue kit 86285 comprises: - Air duct pipe... A - Flue duct pipe... B - Elbow... C - Fixing collar seal.. D - Fixing collar.. E - External rubber sealing collar. F - Internal flange.. G - Gasket... H - Screws... I - 'O' rings... J

Horizontal Top flue kit

Diagram 10a.1

Diagram 10a.2

10a.1 The Horizontal Top flue - kit 86285H
Outside wall face L Flue centre line C L 90mm

11643 10092

10a.4 Installation of horizontal top flue assembly
Important: If the flue has been cut, ensure that there are no burrs that could damage the O ring. For flue systems less than 0,5 m long, fit the flue restrictor (a) into the fan outlet, see diagram 10a.4. Remove the backing from the self adhesive gasket (H) and carefully fit gasket to base of elbow (C). Fit both O rings (J) into the flue elbow (C), one at the inlet, one at the outlet. By necessity, they are a loose fit, apply a small amount of suitable lubricant to each O ring when fitting. Fit rubber sealing collar (F), into groove at the outer end of pipe (A). Insert flue duct pipe (B) into inner end of air duct pipe (A), rotate flue duct pipe to locate into groove inside air duct pipe. Fit air/flue duct pipe assembly through the wall with rubber sealing collar to the outside. Fit internal plastic flange (G) onto air duct pipe (A). Fit the fixing collar seal (D) onto the flue duct pipe (B) ensuring it is the correct way round (the larger diameter onto the pipe). Pull air/flue duct pipe assembly inwards to bring rubber sealing collar (F) hard up against external wall. Fit elbow onto boiler and secure with the four screws (I). Carefully push the fixing collar seal onto the elbow ensuring that the flue duct pipe locates into the flue elbow outlet while taking care not to tear the O ring. Fit the fixing collar (E) around the fixing collar seal (D) and secure with 2 screws provided. Push the internal plastic flange (G) along the air duct pipe (A) until engaged against internal wall.

If conversion from G20 to 30 or 31 is required, refer to section 13. It is recommended that any air is purged from the supply at the gas purge point on the gas valve, see diagram 12.1.

Filling the system

The following steps 1 - 8, show how to fill the system.
BURNER PRESSURE POINT GAS PURGE POINT
The boiler is connected to the electrical supply. The gas service cock is open. Turn the switch OFF ( 0 )
F24E shown 2. Open the three water isolating valves.

Diagram 12.1

Note: Isolating valves are shown in the: OFF position
HEATING RETURN F24E shown
COLD WATER IN (F24E Only)

HEATING FLOW

DOMESTIC HOT WATER OUT (F24E Only)

GAS SERVICE COCK

3. Undo cap on automatic air vent on top of pump and leave undone.
4. Turn the switch ON ( I ) F24E Only Open the tap on the filling device Fill the system until the pressure indicated on the display is 1 bar. Close filling device.
NOTE: On initial fill there may be a small discharge of water from the Reduced Pressure Zone valve
5. Bleed each radiator to remove air, ensure all bleed screws are re-tightened. If necessary repressurise the system, refer to procedure 4

Ins 061a

Adjusting the Central heating output.
The central heating output is factory preset to approx. 15kW. If a different central heating output is required, proceed as follows: To gain access to potentiometer P3, unclip the control box, see diagram 11.1.
The potentiometer P3, is shown in diagram 12.2,to adjust to the required heating output, insert a small flat edge screw driver into the arrowed slot in potentiometer P3, turn clockwise to adjust to the desired setting. Use a manometer to monitor the burner pressure.

MANOMETER

P. max.

POTENTIOMETER P3

POTENTIOMETER P6

SW1 DIP SWITCH

Factory set in "OFF" position
USER INTERFACE BOARD Diagram 12.2

Dip Switches

The position of the SW1Dip Switch(s), see diagram 12.2, and the table below can be used to change the operation of the PUMP OPERATION WITH BURNER WITH HEATING DEMAND FACTORY SETTING

pump and maximum heating temperature of your boiler.

DIP SWITCH 1 ON OFF*

* GB/IE PREFFERED SETTING 28

Ins 062a

7. Ensure the display indicates a system pressure of 1.0 bar adjust if necessary.
8. Open various hot water taps to bleed system
Leave cap open on automatic air vent.
When all adjustments are completed. Adjust heating temperature to maximum. Check that any external controls, if fitted, are calling for heat (set room thermostat to maximum). Allow the temperature to rise to the maximum value, with all radiator valves open. The temperature rise will cause release of the air contained in the water of the central heating system. Air driven towards the boiler will be automatically released through the automatic air vent. The air trapped at the highest point of the system must be released by bleeding the radiators. Check the burner gas rate required, ten minutes after lighting. Refer to Data Label on electrical controls box. Should there be any doubt about the gas rate it should be checked at the meter, refer to technical data. On reaching maximum temperature, the boiler should be turned off and the system drained as rapidly as possible whilst still hot. Refill system to a pressure of between 1 and 2 bar and vent as before. Restart boiler and operate until a maximum temperature is reached. If necessary, refer to section 14 to adjust the bypass. Shut down boiler and vent heating system. If necessary, top up heating system and make sure that a pressure of at least 1 bar is indicated when system is COLD. F24E Only Flush the domestic hot water system by opening the hot water taps for several minutes. Please ensure the Benchmark logbook is completed and left with the user and the magnetic lighting instruction label is placed on the surface of the boiler casing.

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.

15.1 Products of combustion check
Note: To obtain a products of combustion reading, unscrew the left hand sampling point cap on the flue elbow, located on top of boiler, see diagram 15.1. Connect the analyser tube onto sampling point. Refer to the combustion product values in Section 1 Technical Data. Switch on the electrical supply and gas supply, then operate the boiler. On completion of the test switch off the electrical supply and the gas supply, remove analyser tube and replace sampling point cap.
15.2 Service Check and Preparation.
Isolate boiler from the gas and electrical supplies. (F24E Only) Drain the Domestic hot water circuit, refer to diagram 15.2. Drain the boiler, refer to diagram 15.2. On completion check all gas-carrying parts for soundness with leak detection fluid.
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

Diagram 18.5 GROMMET GAS SUPPLY PIPE IGNITION ELECTRODE ASSEMBLY
Note: Take care not to damage the insulation. When refitting burner injector assembly ensure the gas connection locates correctly through the grommet. Note: Make sure that injector size, marked on each injector, is the same as that given in Section 1 Technical Data for the type of gas being used.
Remove the burner injector assembly by lifting up, easing the gas connection through the grommet in the sealing chamber.

Diagram 18.6

18.10 Overheat thermostat
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. Locate overheat thermostat on heating flow pipe on right hand side of boiler, see part of diagram 18.7. Disconnect electrical connections from thermostat Remove the thermostat and bracket assembly from heating flow pipe by unclipping at the side of the bracket. Remove the thermostat, fit new thermostat and replace assembly. When refitting electrical connections to replacement thermostat the polarity is not important.
CLIP PIPE SECURING CLIP 2 OFF
OVERHEAT THERMOSTAT RESET BUTTON ELECTRICAL LEADS

18.11 Ignition electrode

Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Remove burner from boiler, refer to Section 15.9. Remove the left hand side panel, refer to Section 15.6. Undo and remove screw securing electrode assembly to the burner injector assembly, see diagram 18.6. Disconnect the electrical connections at the ignition unit, see diagram 18.22. Note the routing of the cables.

Diagram 18.7

18.12 Flame sense electrode
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Remove burner, refer to Section 15.9. Remove the right hand side panel, refer to Section 15.6. Undo and remove screw securing sense assembly to the burner injector assembly, see diagram 18.6. Disconnect the electrical connection from the inline connector, Note the routing of the cable.

SENSE ELECTRODE ASSEMBLY

18.9 Burner injector assembly, refer to diagram 18.6.
18.13 Heat exchanger, refer to diagram 18.7.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 18.1. Remove the fan, refer to Section 15.10. Remove air pressure switch sensing tube from the side of the flue hood, see diagram 15.9. Release both side panels, refer to section 15.6. Remove the flue hood, lift up and off. When refitting ensure the rear of the flue hood locates in the tabs. Disconnect the electrical leads from the overheat thermostat. Remove the two pipe securing clips.

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.
18.20 Central heating pump head, refer to diagram 18.11.
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 central heating water circuit of the boiler only, refer to relevant part of diagram 18.1. Note: it is not necessary to drain down the entire heating system to carry out this work. For ease of access if required remove the right hand side panel, refer to Section 15.6. Undo four head fixing screws and remove pump head. Gain access to the pump electrical connection box and remove cover. Disconnect pump cable from pump (avoid straining cables). Connect electrical connection to replacement pump head. Fit replacement pump head.
18.19 (F24E Only) Analogue programmer, refer to diagram 18.10
18.21 (F24E Only) Filling system tap, refer to diagram 18.12.
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 diagram 18.1. Pull of the filling loop tap extension. Pull out slotted metal clip securing tap into housing, remove tap. Pull out slotted metal clip and remove pipe from tap.

18.22 (F24E Only) Reduced pressure zone valve (RPZ), refer to diagram 18.12.
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. Pull out slotted metal clip securing pipe to RPZ. Pull out slotted metal clip securing RPZ into housing, remove RPZ.
WATER FLOW SENSOR Diagram 18.14 BYPASS VALVE
SYSTEM WATER PRESSURE SENSOR
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. Pull out slotted metal clip securing boiler drain valve into housing, remove boiler drain valve.

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.

STEPPER MOTOR

18.28 Gas Control valve, refer to diagram 18.17.
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. Disconnect gas supply pipes union nuts at the gas control valve. Disconnect supply pipe union nut at the burner injector bar. Remove the locking nut and brass washer from underside of gas control valve. Ease gas control valve forwards and disconnect electrical connections to gas control valve. Withdraw gas control valve assembly.

Diagram 18.18

PRESSURE RELIEF VALVE
Note: Use the new washers supplied with the gas control valve. Fit gas valve restrictor to replacement gas control value. Fit replacement gas control valve. Check the Min. gas pressure and if it requires adjusting, refer to Section 13 Changing Gas Type.

Diagram 18.19

9768 9769
18.29 Gas control valve stepper motor, refer to diagram 18.18
Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Remove the gas control valve, refer to Section 18.28. Disconnect the electrical connection from stepper motor. Remove the two screws securing stepper motor to the gas control valve. Fit replacement gas control valve stepper motor. Note: Take care not to damage the 'O' ring.
18.30 Discharge safety valve, refer to diagram 18.19.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Undo discharge pipe union nut. Pull out slotted metal clip from valve body and remove valve.
18.31 (F24E Only) Three-way valve head, refer to diagram 18.20.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Remove gas control valve, refer to Section 18.28. (It will not be necessary to remove the gas control electrical cables). Remove electrical plug from valve head. Pull out slotted metal clip from valve body and remove valve head from body. Fit replacement valve head. Note : 1) When refitting clip, ensure that letters YES are as shown. 2) It is not necessary to drain boiler to carry out this work.