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Saunier Duval Thema Classic F24E

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Documents

doc0

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.

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 or advice is required contact the relevant service organisation or Heatcall 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.
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.

Diagram 2

Programmer Instructions for Use
Analogue Programmer (F24E Only) Part No. A20086. Fitted as standard.
Setting the time, see diagram 3 Rotate the dial clockwise, by hand, until the indicator arrow is pointing to the current time. Note: The time is set in 24 hour format. Setting the programme on and off times, see diagram 3 Select the on times by pushing the black tappets to the outside. Select the off times by pushing the black tappets to the inside. To override or advance the programmer The clock has a manual on/off switch which operates as follows: Upper position I : Heating on continuously Middle position Lower position 0 : : Heating on timed Heating off
Digital Programmer Kit. (F24E Only) Part No. A20087. Not fitted as standard.
KEYPAD DESCRIPTION See diagram 4 for position of keypads as described below, Time/Automatic Run Mode selection Prog. Programme selection Res.* Reset clears all settings ON/OFF selector in Prog. Mode, Manual Override selector in Run Mode 1h* Summer/Winter time setting h Sets the Hour (12: - - AM) m Sets the Minute (- -: 01 AM) Day Sets Day(s) for time and programmes *Recessed keys; use a pen point to press
To override or advance the programmer
INDICATOR ARROW Diagram 4 OFF TIMES ON TIMES BLACK TAPPETS Diagram 3

LCD Display

The LCD incorporates a number of different elements to display various data and information.

Programmes

The Digital Programmer will accept up to 20 events Each event consists of: 1. An ON or OFF command 2. Time of day (Hour and Minute) 3. Single day or multiple days An event is required for each ON and OFF.
NOTE: MULTIPLE ON OR OFF EVENTS MAY BE PROGRAMMED, SEE EXAMPLE. BEFORE PROCEEDING WITH SETTING THE TIME AND PROGRAMMING THE UNIT, PRESS THE RESET KEY TO CLEAR ALL DATA FROM THE MEMORY.
Programming 24 Hour or 7 Day Schedules
It may be helpful to write out the programme schedules before beginning. THE CURRENT TIME OF DAY AND DAY OF WEEK MUST BE SET PRIOR TO PROGRAMMING. SEE "SETTING THE TIME" Example Event 1: ON at 7:00AM Monday through Saturday Event 2: OFF at 5:00PM Monday through Friday Event 3: OFF at 7:00PM Saturday Three events need to be entered. Press Prog. key only once. Display shows:

Deleting an Event

To delete only one or a few events: Press Prog. key until the desired program is displayed. Press m key to :59 and press once more to blank out. Press h key to 11PM and press once more to blank out. key, display will flash for several seconds and then Press enter the Run Mode. Using the reset key will delete ALL events, the time of day, and day of the week.
SOLUTION: The ON or OFF was not entered as part of the program. ON or OFF must be selected.

1 Technical Data F24E

Heating
Heat input (max) NET Q Heat input (min) NET Q 26,94 kW 91,200 BTU/H

F18E SB

Heat input (max) NET Q Heat input (min) NET Q 21,9 kW 74,722 BTU/H
9,91 kW 33,820 BTU/H Heat output (max) NET P 23,6 kW 81,550 BTU/H Heat output (min) NET P 8,9 kW 30,370 BTU/H Efficiency - Sedbuk D 78,3% Maximum heating temperature 87 C Expansion vessel effective capacity 5 litres Expansion vessel charge pressure 0,5 bar Maximum system capacity at 75C 110 litres Safety valve, maximum service pressure 3 bar

Hot water

Heat input (max) NET Q Heat input (min) NET Q Heat output (max) NET P Heat output (min) NET P Maximum hot water temperature Minimum hot water temperature Specific flow rate (for 35C temp rise) Threshold flow rate Maximum supply pressure Minimum supply pressure 26,94 kW 91,200 BTU/H 9,91 kW 33,820 BTU/H 23,6 kW 81,550 BTU/H 8,9 kW 30,370 BTU/H 60 C 38 C 9,8 litres/min. 1,7 litres/min. 10 bar 0,5 bar
11 kW 37,532 BTU/H Heat output (max) GROSS P 19,8 kW 67,556 BTU/H Heat output (min) GROSS P 9,2 kW 31389 BTU/H Efficiency - Sedbuk D 78,8% Maximum heating temperature 87 C Expansion vessel effective capacity 5 litres Expansion vessel charge pressure 0,5 bar Maximum system capacity at 75C 110 litres Safety valve, maximum service pressure 3 bar

Combustion

Products outlet diameter Fresh air inlet diameter Combustion products values 60 mm 100 mm CO (30 ppm) CO2 (5,9%) NOx (76 ppm)

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
MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS

6.3 Flue options

There are various flue systems to choose from as follows: Horizontal telescopic top flue pack. Horizontal top flue pack. Vertical flue pack. Twin flue pack. Extensions, 90 and 45 bends. For detailed information refer to flue options guide. This is available from your nearest stockist.

70mm 184mm 65mm

The flue kit A2004500 is 660 mm long and comprises: - Telescopic flue assembly.. A - Fixing collar seal... B - Fixing collar... C - Elbow... D - External rubber sealing collar. E - *Gasket... F - *Screws 6 off... G - *'O' rings... H - *Screws 4 off.. J
* supplied in plastic bag

Telescopic Top flue kit

Diagram 10.1

Diagram 10.2

The Horizontal Telescopic Top Flue, Kit No. A2004500
For flue lengths up to 0.5m fit the restrictor (supplied in the document envelope) inside the fan outlet, see diagram 10.3. Remove the elbow (D) and the telescopic flue assembly (A) from the flue kit. Refer to Step 1. diagram 10.4. Fit the telescopic flue assembly (A) into the prepared hole in the wall. Position the elbow (D) on the boiler, do not secure. Position the telescopic flue assembly (A) as it would be fitted. Refer to Step 2. diagram 10.4. Remove the telescopic flue assembly (A) from the prepared hole in the wall, make sure the air duct is extended to its required length. The flue duct at the elbow end must protrude 25mm. Drill ,secure with two screws and tape to secure the air duct, take care not to drill the inner flue pipe. Fit the fixing collar seal (B) to the telescopic flue assembly (A). Refer to Step 3. diagram 10.4. Fit the telescopic flue assembly (A) with the fitted fixing collar seal into the prepared hole in the wall. Remove the backing from the self adhesive gasket (F) and carefully fit gasket to base of flue elbow. Fit the O rings (H) into the grooves in the flue ducts within the elbow (D). Lubricate the O rings with silicone. Fit flue elbow (D) onto boiler and secure with the four screws (G). Refer to Step 4. diagram 10.4. Fit rubber sealing collar (E), into groove at the outer end of the air duct pipe (A). Carefully pull flue duct pipe into the elbow (D). (If the telescopic flue has been pulled apart care must be taken not to damage the O ring on the flue duct when re-assembling). Secure with two screws (G). Pull telescopic flue assembly (A) inwards to bring rubber sealing collar hard up against external wall. Refer to Step 5. diagram 10.4. Fit the fixing collar (C) using the two screws (G).

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

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.

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

FAULT: NO HEATING Are the external heating controls calling for heat? YES Is the polarity correct? YES Connect 1 and 2 on J10, does boiler fire in central heating? YES Faulty 230V controls board. NO Faulty main PCB. NO Rectify, check the 230V controls board. NO Rectify fault on external controls.

F24E ONLY

FAULT: NO HOT WATER, BUT THE HEATING IS WORKING Is the water flow rate greater NO than 1.7l/min. (threshold figure). YES Is flow detector operating ? YES Check the connectors on the flow sensor and the control board (PCB). If the fault persists, fit a relplacement control board (PCB). NO Change or clean it. Check the cold water inlet filter for dirt. Is the cold water tap fully open ? Check the heat exchanger for scaling.
F1 FAULT DISPLAYED FAULT: THE BURNER LIGHTS BUT THEN GOES OUT. THERE IS NO FLAME DETECTED. The flame is not spreading across the whole burner and is not reaching the sensing electrode. Is the gas pressure correct?
Check that the gas taps are fully open Check the gas pressure.
YES Is the boiler actually designed for the gas being used. NO Change the gas type for the boiler (gas conversion kit).
YES Clean the gas filter. Clean the burner.
F1 or F4 FAULT DISPLAYED FAULT: THE BURNER LIGHTS, THEN GOES OUT. The flame is spreading across the whole burner, but not being detected. CHECK THE CHECK PROBE THE MAINS With the power turned off, check the continuity between the flame sense electrode and terminal H2. 4 on the control board (PCB). Check the connector on the end of the wire. Check that the spark electrode is pointing towards the flame. Check the spark electrode. Change it.
FAULT NOT FOUND If the problem persists, change the control board (PCB). (flame detection module faulty).
F1 FAULT DISPLAYED FAULT: THE BURNER DOES NOT LIGHT AT ALL, BUT THERE IS AN IGNITION SPARK. Are the gas taps on? YES Is there 24Vdc at the gas control valve? for testing see component testing data. YES Test the gas control valve. Check resistance of safety valve coil. NO Check the wiring. If the problem persists, change the control board (PCB). NO Turn on the gas taps.
FAULT: THE ROOM TEMPERATURE IS INADEQUATE AND RADIATORS ARE LUKE-WARM. Is the room thermostat and or radiator set high enough and calling for duty? NO Turn up settings YES Is the heating temperature on the boiler set high enough? YES Is the heating power adequate? - Check set point P3. (Refer to Commissioning) - Check dip switch setting. (Refer to Commissioning) - Check the adjustment of the by-pass internal and external (If fitted). - F24E Only Check the 3-way valve is not passing into the domestic hot water heat exchanger.
16 Fault Finding F24E ONLY
FAULT: THE WATER AT THE TAPS IS LUKE-WARM. Is the temperature higher if you reduce the flow through the taps? NO Check the 3-way valve is not passing into the radiators. (The radiators should stay cold in Summer setting)

YES Check that the cold water inlet restrictor is fitted. Check the rate of flow. Check burner pressure is correct.
FAULT: THE FAN DOES NOT START. Is there is 230V ac at fan during demand? YES Faulty fan, replace. NO
Check continuity of fan harness. YES

Faulty PCB, replace.

FAULT: THE FAN RUNS BUT THERE ARE NO SPARKS. CHECK CONTINUITY OF IGNITION (ELECTRODES AND LEADS) CHECK POWER SUPPLY FROM PCB TO IGNITION UNIT CONNECTIONS TO THE AIR PRESSURE SWITCH Pr
Air flow switch take-off.

Electrical contacts.

17 Wiring Diagram F24E
FAN g/y br b w OVERHEAT THERMOSTAT or w THERMISTOR CH WATER PRESSURE SENSOR b b w g THREE-WAY VALVE bk bk w p y g or gn CHASSIS EARTH w GAS CONTROL VALVE PUMP g/y AIR PRESSURE SWITCH bk IGNITION PLUG ELECTRODES IGNITOR UNIT

SENSE ELECTRODE

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

CONTROLS INTERFACE

VOLTAGE FREE HEATING CONTROLS PLUG

b r gn

REMOVE THE LINK IF FITTING VOLTAGE FREE OR 230V EXTERNAL CONTROLS. IF THE LINK IS NOT REMOVED THE BOILER WILL RUN CONTINUOUSLY.

J10 J1 S1 J12

J13 H2 H5 H1
g/y br br b g/y b b br g/y

J2 FUSE 125mAT

CHASSIS EARTH
g/y w r b br ON/OFF SWITCH 230V~50Hz PERMANENT MAINS SUPPLY FUSED AT 3A
bk- BLACK w- WHITE g/y- GREEN/ YELLOW br bpgBROWN BLUE PINK GREY rorgnyRED ORANGE GREEN YELLOW

USER INTERFACE

17a Wiring Diagram F18E SB
FAN g/y br b w w GAS CONTROL VALVE bk WATER PRESSURE SENSOR THERMISTOR CH b b w g bk w p y g or gn IGNITOR UNIT PUMP CH g/y CHASSIS EARTH
AIR PRESSURE SWITCH SENSE ELECTRODE IGNITION ELECTRODES PLUG

REMOVE VOLTAGE FREE LINK

J15 J11
b br g/y b br CHASSIS EARTH g/y br b

NOT USED

r b br
g/y 230V~50Hz PERMANENT MAINS SUPPLY FUSED AT 3A

18 Replacement of Parts

To Drain the central heating circuit
Open drain valve fitted at the lowest point in the system. Allow air into the system by opening a radiator bleed screw or the boilers drain valve (f).
Close the isolating valves (a), (b) and (c). Open the boiler drain valve (f).
HEATING COLD WATER RETURN INLET (F24E Only)
Note: Isolating cocks water and gas are shown in the: OFF position Diagram 18.1

IMPORTANT INFORMATION

WARNING: Before commencing the replacement of any component, isolate appliance from electrical supply and turn off gas at service cock. Replacement of parts must be carried out by a competent person. When replacing components it may be necessary to renew sealing washers, gaskets and 'O' rings. If new ones are supplied with replacement components they must be used. All parts are replaced in reverse order to removal. If any gas-carrying components are disturbed, removed or replaced it will be necessary on completion of assembly to test for gas soundness and purge in accordance with the current issue of BS6891 or in IE, the current edition of I.S.813 "Domestic Gas Installations".

CENTRAL HEATING THERMISTOR

Diagram 18.2

Locate central heating thermistor on heating flow pipe on centre of boiler, see diagram 18.2. Unclip thermistor from pipe. Disconnect electrical connections from thermistor. Fit electrical connections to replacement thermistor and fit thermistor to pipe. The polarity is not important.
18.1 Central heating thermistor
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.

18.2 Fan.

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 fan, refer to Section 15.10.
RETAINING CLIPS AIR PRESSURE SWITCH ELECTRICAL CONNECTORS SENSING TUBE

18.3 Air pressure switch

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 air pressure switch situated at the top right hand side, see diagram 18.3. Remove air pressure switch tube. Note: Do not fit tube until the air pressure switch is in position. Disconnect air pressure switch electrical connections. Unclip to remove air pressure switch.
Diagram 18.3 COLD WATER INLET RESTRICTOR
18.4 (F24E Only) Domestic water inlet filter
If the water flow rate through the appliance has reduced it may be necessary to clean or replace the water inlet filter, refer to section 15.12. 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. Clean or replace the water inlet filter, refer to Section 15.12.
COLD WATER IN ISOLATING VALVE
18.5 Central Heating Filter
It may be necessary to clean or replace the central heating filter. Before starting refer to the front of Section 18 Important information. Isolate flow and return valves (a) and (c). Clean or replace the central heating filter, refer to Section 15.13. 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.

Diagram 18.4

18.6 ( F24E Only) Cold water inlet restrictor
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. Isolate cold water inlet valve (b). Drain down domestic hot water circuit of boiler only, refer to relevant part of diagram 18.1. Undo union nuts from boiler cold water in isolating valve. Clean and inspect restrictor, replace if necessary, see diagram 18.4.

18.15 Printed circuit board (PCB), refer to diagram 18.9.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Lower the control panel, refer to Section 15.4. Undo and remove the two front retaining screws. Hinge up the control panel cover and ease forwards from the rear retaining lugs to gain access to PCB. Do not strain the cables attached to the PCB. Note the routing of the cables. Carefully pull off electrical connections to PCB. Unclip and lift out PCB. Fit replacement PCB. Be careful not trap any of the cables. Make sure that PCB connections are fully pushed onto replacement PCB.

INSULATION

18.14 Combustion chamber insulation, refer to diagram 18.8.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 15.3. Remove the sealed chamber cover, refer to Section 15.5. Remove the combustion chamber cover, refer to Section 15.7. Remove the heat exchanger, refer to Section 18.13. Pull out side insulation panels from combustion chamber. Tilt rear insulation panel forwards and out. Fit replacement insulation.

Diagram 18.8

PCB (CONTROL BOARD)

10021 10001

CONTROL BOARD COVER

Diagram 18.9

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

230V CONTROLS BOARD

CONTROL PANEL F24E shown

USER INTERFACE BOARD

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

Diagram 18.11

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

doc1

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

Gas leak or fault

WARNING: If a gas leak or fault exists or is suspected, turn the boiler off and consult the local gas supply company or your installation/service company.

CE Mark

This boiler meets the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore is deemed to meet the requirements of Directive 92/42/EEC on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels. Type test for purposes of Regulation 5 certified by: Notified body 0049. Product/production certified by: Notified body 0049. The CE mark on this appliance shows compliance with: 1. Directive 90/396/EEC on the approximation of the laws of the Member States relating to appliances burning gaseous fuels. 2. Directive 73/23/EEC on the harmonization of the Laws of the Member States relating to the electrical equipment designed for use within certain voltage limits. 3. Directive 89/336/EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility.

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.

300mm 50mm above boiler (rear flue only)

25mm above elbow

20mm 5mm

600mm 450mm

*Note: It is permissible to install the boiler with smaller
clearances than those quoted PROVIDING that consideration is given for Servicing/Repairs.

Diagram 6.1

6.1 Boiler Location
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:

6.3 Flue options

There are various flue systems to choose from as follows: Horizontal rear flue pack. Horizontal telescopic top flue pack. Horizontal top flue pack. Horizontal extended flue pack. Vertical flue pack. Twin flue pack. Extensions, 90 and 45 bends. For detailed information refer to flue options guide. This is available from your nearest stockist. MINIMUM SITING DIMENSIONS FOR THE POSITIONING OF FLUE TERMINALS MM
6.4 Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or compartment without the need for permanent ventilation.
HORIZONTAL FLUES A DIRECTLY BELOW, ABOVE OR HORIZONTALLY TO AN OPENING, AIR BRICK, OPENING WINDOWS, AIR VENT, OR ANY OTHER VENTILATION OPENING 300 B BELOW GUTTER, DRAIN/SOIL PIPE 75 C BELOW EAVES 200 D BELOW A BALCONY OR CAR PORT 200 E FROM VERTICAL DRAIN PIPES AND SOIL PIPES 150 F FROM INTERNAL/EXTERNAL CORNERS OR TO A BOUNDARY ALONGSIDE THE TERMINAL ABOVE ADJACENT GROUND OR BALCONY LEVEL H FROM SURFACE OR A BOUNDARY FACING THE TERMINAL I FACING TERMINALS J FROM OPENING (DOOR/WINDOW) IN CAR PORT INTO DWELLING K VERTICAL FROM A TERMINAL L HORIZONTALLY FROM A TERMINAL G VERTICAL FLUES M FROM ADJACENT WALL TO FLUE N FROM ANOTHER TERMINAL P FROM ADJACENT OPENING WINDOW Q ABOVE ROOF LEVEL 300

1000 300

Diagram 6.2

Diagram 6.3

Tower flue components Ltd. Morley road Tonbridge Kent TN9 1RA

7 Fixing Jig

The fixing jig is made up as follows: A - Heating return fitting with isolating valve. B - Cold water inlet fitting with isolating valve. The cold water inlet restrictor supplied with boiler is fitted when the boiler is installed. Refer to Section 9. C - Heating flow fitting with isolating valve. D - Domestic hot water outlet. E - Gas service cock. Other components within the fixing jig pack. F - Hanging bracket G - wall template J - sealing washers and screws

Diagram 8.1

8.5 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".

8.4 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.
8.1 Cutting the flue hole

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.
9.2 Installing the boiler
IMPORTANT NOTE: The system must be thoroughly flushed using a propriety cleanser from Fernox or Sentinel to eliminate any foreign matter and contamination e.g. metal filings, solder particles, oil, grease etc. Solvent products could cause damage to the system. Remove front panel, unscrew and remove the two retaining screws from the bottom of the front panel. Remove front panel by lifting up and forward. To remove the self adhesive wiring diagram label from the document envelope. Fit the self adhesive wiring diagram label to the inside of the front panel, put front panel in a safe place to avoid damaging it.
KNURLED UNION NUT finger tighten only
DISCHARGE SAFETY VALVE PIPE Diagram 9.1
(Horizontal Rear Flue Only)
Note: Firstly remove the fan as described in section 10.3. Fit the flue adaptor and gasket , refer to diagram 9.3, supplied in the flue pack to the rear of the appliance, having first moved and secured the blanking plate to the top outlet.

13.3 Mains Voltage External Controls
WARNING: UNDER NO CIRCUMSTANCES MUST ANY MAINS VOLTAGE BE APPLIED TO ANY OF THE TERMINALS ON THE VOLTAGE FREE HEATING CONTROLS CONNECTION TERMINAL. When mains voltage external controls are used, remove the MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG from the fittings pack and install on the control interface PCB as follows. Gain access to the control interface by unclipping the fascia panel and hinging forward, see diagram 13.3. Route the external heating controls cable (not supplied) and connect to the plug, see diagram 13.3. Insert plug onto controls interface PCB, see diagram 11.3. Close the fascia panel and remove the screws to open the rear cover of control panel, see diagram 13.1. Secure the external heating control cable in the strain relief, and thread the cable through rear of the control panel and out of the cables exit, see diagram 13.4. Close and secure rear cover of control panel. IMPORTANT: Remove the wire link from the voltage free heating controls connector, see diagram 13.1. Connect external heating controls as diagram 13.5. External controls should be fitted in accordance with the rules in force.
EXTERNAL FROST THERMOSTAT

STRAIN RELIEF

MAINS CABLE
EXTERNAL CONTROLS CABLE Diagram 13.4
TO MAIN PCB CONNECTOR J15 CONTROLS INTERFACE PCB
DO NOT CONNECT MAINS VOLTAGE HEATING CONTROLS CONNECTION PLUG
VOLTAGE FREE HEATING CONTROLS CONNECTION (ON CONTROLS BOX COVER)
REMOVE LINK WHEN EXTERNAL CONTROLS ARE USED
13.4 Electrical Connections - Testing
Carry out preliminary electrical system checks as below: 1. Test insulation resistance to earth of mains cables. 2. Test the earth continuity and short circuit of cables. 3. Test the polarity of the mains.
INTERNAL PROGRAMMER EXTERNAL 230V AC ROOM THERMOSTAT

EXTERNAL ROOM THERMOSTAT

PROGRAMMER

ON/OFF SWITCH

EXTERNAL JUNCTION BOX 3 AMP FUSE DOUBLE POLE ISOLATOR
CONTROL PANEL USER INTERFACE RETAINING LATCHES
EXTERNAL 230V AC FROST THERMOSTAT
230V~ 50Hz PERMANENT MAINS SUPPLY

CONTROLS INTERFACE PCB

EXTERNAL CONTROLS CABLE(MAINS VOLTAGE)
ON/OFF SWITCH EXTERNAL PROGRAMMER
EXTERNAL JUNCTION BOX 3 AMP FUSE
EXTERNAL PROGRAMMER/CLOCK EXTERNAL 230V AC ROOM THERMOSTAT EXTERNAL 230V AC FROST THERMOSTAT

DOUBLE POLE ISOLATOR

Diagram 13.3

Diagram 13.5

TO MAIN PCB CONNECTOR J15

14 Commissioning

Important: The commissioning and first firing of the boiler must only be done by a competant person.

Air in pipes

Important: A central heating system can not operate correctly unless it is filled with water and air bled from the system. If these conditions are not met the system may be noisy. Bleed the air in the radiators and adjust the pressure if system requires. If the system requires filling to often this may be due to minor leaks or corrosion in the system.

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

Completion

Remove the magnetic user instructions label from the document envelope and position it on the surface of the boiler casing. Adjust the boiler temperature control and any system controls to their required settings. For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance to I.S.813. An example of this is given in the current edition of I.S.813. 29

Ins 062a

8. Open various hot water taps to bleed system

Bypass

The boiler is supplied with the bypass open half a turn. It should not be necessary to adjust the bypass, but if required ensure that under no circumstances does the flow rate fall below the figures specified, refer to Table 1. and diagram 1.1. (turn clockwise to close the valve).
The boiler has a built-in bypass, see diagram 15.1.

Diagram 15.1

15 Boiler Settings
Boiler settings (for use by installers and Service Providers only)
and keep pressed for 10 seconds. This gives access to both the operating parameters and the fault history.

1 Press the button

2 When the menu

using button + or -.

2.0 bar
is shown on display, select code 96 , to show the first menu to be adjust
3 Press the button : Heating ouput
Note : The display will revert back to normal if no changes are made after 1 minute or if the button is again pressed for more than 10 seconds. Parameter 1 : Setting the heating output The maximum heating output of the boiler is adjustable between the maximum and minimum values given in the Technical Data section.

1 flashing, press on

Factory setting
if you want to adjust this menu. Select a parameter between 0 and 10 according to the following table. Flue parameter following flue length - Horizontal Setting Flue length for F 24 E 0,3 m 0,7 m 1,2 m 1,6 m 2m 2,3 m 2,7 m 3,1 m 3,3 m 3,8 m 4m Flue length for F 30 E 0,3 m 0,6 m 0,9 m 1,3 m 1,6 m 1,9 m 2,2 m 2,5 m 2,9 m 3,2 m 3,5 m
Use the heating + and - button to set the desired heating output in kW. Note : Adjustment of the heating output does not affect the hot water output. For kW to Btu/hr conversion refer to table : kW 18 Btu/hr 34,120 40,940 47,770 54,590 61,420 kW 28 Btu/hr 68,240 75,060 81,890 88,710 95,540
Parameter 02 : Setting the flue parameters This adjustment is made to ensure the boiler operates at maximum efficiency with longer flue lengths.
Flue parameter following flue length - Rear Setting 10 Parameter 5 : Pump operation This can be set to one of three values : 1 - intermittent (with room thermostat) 2 - intermittent (with burner) 3 - permanently on 0,3 m 0,6 m 0,9 m 1,2 m 1,5 m 0,3 m 0,6 m 0,9 m 1,2 m 1,5 m Parameter 4 : Setting the maximum heating temperature This can be set to one of four values : 50C, 73C, 80C and 87C. Flue length for F 24 E Flue length for F 30 E Parameter 3 : Setting the minimum heating temperature This can be set to one of two values : 38C or 50C.
Flue parameter following flue length - Vertical Setting 10 Flue length for F 24 E 1,2 m 2,6 m 3,9 m 5m 6,1 m 7,1 m 8,2 m 9,3 m 10,4 m 11,5 m 12 m Flue length for F 30 E 0,3 m 0,6 m 0,9 m 1,0 m 2,0 m 3,0 m 4,0 m 5,0 m 6,0 m 7,0 m 8m

16 Changing Gas Type

Should it be necessary to change the gas type, a conversion kit with instructions will be required. This modification must only be carried out by a suitably qualified engineer. F30E Plus Conversion natural Gas (G20) to G30/G31 Part No. A2011700. F24E Plus Conversion from natural gas (G20) to LPG (G30 or G31), Part No. A20027. 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 24, 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.

Diagram 17.1

17.4 Control panel
Lower forwards to gain access to lower part of boiler.
17.5 Sealed chamber cover
Unscrew and remove the two retaining screws from the sealed chamber cover, see diagram. 17.3. Lift cover up and off pins on top of boiler.
17.2 Service Check and Preparation.
Isolate boiler from the gas and electrical supplies. Drain the Domestic hot water cuircuit and the boiler, refer to diagram 17.2. On completion check all gas-carrying parts for soundness with leak detection fluid. Remove boiler casing as follows:
17.6 Side panels (for ease of access if available), refer to diagram 17.4
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.

17.3 Front panel

Unscrew and remove the two retaining screws from the bottom of the front panel. Remove front panel by lifting up and forward.
To Drain the Domestic hot water circuit
Close boiler isolating valve (b). Turn on one or more hot water taps.

To Drain the boiler

Close isolating isolating valves (a) and (c). Open the boiler drain valve (f).

COLD WATER INLET

(c) (f)
BOILER DRAIN VALVE HEATING FLOW
DOMESTIC HOT WATER OUTLET
Note: Isolating cocks water and gas are shown in the: OFF position

Diagram 17.3

F30E shown

Diagram 17.4

17.7 Combustion chamber cover
Unscrew and remove the two screws securing combustion chamber cover to combustion chamber, see diagram 17.5. Remove combustion chamber cover from boiler. retaining clip.
17.14 Sealed Chamber Cover - Seal Check
Check the condition of the seal, replace as required. To replace remove the old seal, thoroughly clean the casing sufaces. Fit the new seal, it is supplied to the correct length, see diagram 20.29.
17.8 Spark and Sense Gaps
Check that the spark and sense gaps as shown in diagram 17.6. Note: To gain access to spark and sense electrodes for removal, refer to Section, 20.12 and 20.13 in Replacement of Parts.
17.15 Combustion Chamber Insulation
Check the condition of the combustion chamber insulation. If renewing, refer to Section 20.15.
17.9 Burner, refer to diagram 17.7
Unscrew and remove the two burner retaining screws. Remove burner from boiler by easing it forward off the two burner guides, taking care not to damage the insulation. Clean burner by washing in soapy water. Dry thoroughly before refitting. Note: To gain access to injectors for removal and cleaning, refer to Section, 20.9.

17.16 Flue system

Check externally to make sure that flue is not blocked Inspect flue system to make sure that all fittings are secure.
17.17 Reassembly of parts removed for servicing
All parts are replaced in reverse order to removal.
17.10 Fan, refer to diagram 17.8
Disconnect power supply leads and earth lead from fan. Disconnect the electrical plug from the fan sensor. Unscrew and remove the two fan retaining bolts. Ease the fan down and forwards to remove.
17.11 Heat exchanger, refer to diagram 17.9
Remove air pressure switch sensing tube from the side of the flue hood. Unscrew and remove the two retaining screws from front of each side panel. Unhook each panel from the front retaining tabs and ease outwards. Remove the flue hood. When refitting ensure the rear of the flue hood locates in the tabs. Use a soft brush or vacuum clean the heat exchanger. DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED FINISH OF HEAT EXCHANGER.

Diagram 17.5 3.5mm

17.12 Domestic water inlet filter, refer to diagram 17.10
If the water flow rate through the appliance has reduced it may be necessary to clean or replace the domestic water inlet filter. Close isolating valve (b) on cold water inlet. Pull out slotted clip securing the filter in its housing, remove the filter to clean or renew if necessary. Push the filter fully into its housing and replace the securing clip. Open isolating valve (b) on cold water inlet and test the Domestic Hot Water circuit for soundness.

SPARK GAP

3.5 mm
17.13 Central Heating Filter, refer to diagram 17.11
Remove the filter retaining clip and filter clean or renew if necessary. Push the filter fully into its housing, ensuring the correct orientation. The flat and hole in the filter as shown. Secure with

SENSE GAP

Diagram 17.6
BURNER RETAINING SCREWS BURNER GUIDE
AIR PRESSURE SWITCH SENSING TUBE

FLUE HOOD

Diagram 17.7 HEAT EXCHANGER FAN RETAINING BOLTS EARTH LEAD FAN SENSOR PLUG

Diagram 17.9 CLIP

DOMESTIC WATER INLET FILTER HOUSING

POWER SUPPLY LEADS

20.6 Central Heating Filter
It may be necessary to clean or replace the central heating filter. Before starting refer to the front of Section 20 Important information. Isolate flow and return valves (a) and (c) Clean or replace the central heating filter, refer to section 17.13.
20.9 Burner injectors, refer to diagram 20.5.
Before starting refer to the front of Section 18 Important information. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Remove the sealed chamber cover, refer to Section 17.5. Remove the combustion chamber cover, refer to Section17.7. Remove burner from boiler, refer to Section 17.9. Remove and replace injectors as required. Note: The injectors may be cleaned, remove injectors inspect and clean. Do not use a wire or sharp instrument. 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.
20.7 Cold water inlet restrictor
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. Isolate cold water inlet valve (b). Drain down domestic hot water circuit of boiler only, refer to relevant part of diagram 20.1. Remove the retaining wire.

BURNER INJECTOR BAR

20.10 Burner injector assembly, refer to diagram 20.5 and 20.6.
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. Remove the sealed chamber cover, refer to Section 17.5. Remove the combustion chamber cover, refer to Section17.7. Remove burner from boiler, refer to Section 17.9. Undo the gas supply union nut from under the sealed chamber.

Diagram 20.5

GROMMET GAS SUPPLY PIPE IGNITION ELECTRODE ASSEMBLY
Note: The fibre washer between the burner injector assembly and gas supply must be kept for use on reassembly. Undo and remove the sense and ignition electrode assemblies. Remove the burner injector assembly securing screws. Remove the burner injector assembly by lifting up, easing the gas connection through the grommet in the sealing chamber. 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.

SENSE ELECTRODE ASSEMBLY

Diagram 20.6
20.11 Overheat thermostat
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Remove the sealed chamber cover, refer to Section 17.5. Locate overheat thermostat on heating flow pipe on left hand side of boiler, see part of diagram 20.7. 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

20.12 Ignition electrode

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. Remove the sealed chamber cover, refer to Section 17.5. Remove the combustion chamber cover, refer to Section 17.7. Remove the burner, refer to Section 17.9. Remove the right hand side panel, refer to Section 17.6. Undo and remove screw securing electrode assembly to the burner injector assembly, see diagram 20.6. Disconnect the electrical connections at the ignition unit, see diagram 20.22. Note the routing of the cables. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Remove the sealed chamber cover, refer to Section 17.5. Remove the combustion chamber cover, refer to Section 17.7. Remove burner, refer to Section 17.9. Remove the left hand side panel, refer to Section 17.6. Undo and remove screw securing sense assembly to the burner injector assembly, see diagram 20.6. Disconnect the electrical connection from the inline connector, Note the routing of the cable.

HEAT EXCHANGER

Diagram 20.7
20.13 Flame sense electrode
Before starting refer to the front of Section 20 Important information.
20.14 Heat exchanger, refer to diagram 20.7.
Before starting refer to the front of Section 20 Important information. Remove the front panel, refer to Section 17.3. Remove the sealed chamber cover, refer to Section 17.5. Remove the combustion chamber cover, refer to Section 17.7. Drain down central heating water circuit of the boiler only, refer to relevant part of diagram 20.1. Remove the fan, refer to Section 17.10. Remove air pressure switch sensing tube from the side of the flue hood, see diagram 17.9. Release both side panels, refer to section 17.6. 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. Lift to remove the heat exchanger taking, care not to damage the insulation.

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.

20.39 Expansion vessel, refer to diagram 20.28.
Renewal of the expansion vessel requires the boiler to be removed from the wall. As an alternative, a separate expansion vessel of the same specification may be connected as close as possible to the boiler, leaving the original in position, refer to the installation instructions.
20.37 Micro accumulator vessel, refer to diagram 20.26.
Before starting refer to the front of Section 20 Important information. For this operation the boiler must be removed from the wall. IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift. Remove the front panel, refer to Section 17.3. Drain down the boiler and hot water ,refer to relevant parts of diagram 20.1. Note: It is not necessary to drain down entire heating system to carry out this work. Disconnect the flue system. Disconnect the boiler pipes. Disconnect the pressure relief valve discharge pipes. Disconnect the mains cable and any external controls cables. Lift up to remove the boiler from the wall. From the rear of the boiler. Disconnect the inline electrical connection plug to the micro accumulator vessel thermistor. Remove the slotted metal clips to disconnect pipes from the bottom of the micro accumulator vessel. Note: Take care there will be a loss of water. Remove the right hand side panel, refer to Section 17.6. Bend back securing tab to release vessel from boiler frame. Remove the vessel from the boiler, taking care not to strain the heating element electrical cable. Pull out slotted metal clip and pull to remove heating element from micro accumulator vessel.
MICRO ACCUMULATION VESSEL THERMISTOR

Diagram 20.25

Bend back securing tab to release micro accumulation vessel
MICRO ACCUMULATION VESSEL
20.38 Micro accumulator vessel heating element, refer to diagram 20.27.
Remove the micro accumulatior vessel, refer to Section 20.37. Lower the control panel, refer to Section 17.4. Gain access to rear of control panel, see diagram 20.9. Disconnect the electrical connection plug to the micro accumulator vessel heating element at the control board PCB connection H4, see diagram 20.9.
Drain hot water circuit only.

Diagram 20.26

Replacing the expansion vessel Before starting refer to the front of Section 20 Important information. For this operation the boiler must be removed from the wall. IMPORTANT: With regards to the manual handling operations, 1992 regulations, the following operation exceeds the recommended weight for one man lift. Remove the front panel, refer to Section 17.3. Lower the control panel, refer to Section 17.4. Drain down the boiler only ,refer to relevant parts of diagram 20.1. Disconnect the flue system. Disconnect the boiler pipes at the fixing jig. Disconnect the pressure relief valve discharge pipe. Disconnect the mains cable and any external controls cables.

 

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