Table of Contents
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4000123924-2 07.03
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
F30E
Fanned Flue Combination Boiler
G.C.No. 47-920-36
Themaclassic
F30E SB
Fanned Flue System Boiler
G.C.No. 41-920-45
Themaclassic
F35E
Fanned Flue Combination Boiler
G.C.No. 47-920-40
Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT
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Table of Contents
Related Manuals for Saunier Duval 47-920-36
Summary of Contents for Saunier Duval 47-920-36
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Page 1: Instructions For Use
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 F30E Fanned Flue Combination Boiler G.C.No. 47-920-36 Themaclassic F30E SB Fanned Flue System Boiler G.C.No. 41-920-45 Themaclassic... -
Page 2: Guarantee Registration
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. -
Page 3: Table Of Contents
Contents CONTENTS DESCRIPTION SECTION PAGE No. Important Information Draining and Filling Appliance Introduction INSTRUCTION Appliance Safety Devices FOR USE Maintenance and Servicing User Controls and Lighting Digital Programmer F30E/F35E only Technical Data General Information Heating System Design Domestic Hot Water System Design (F30E/F35E) Boiler Schematic F30E/F35E Boiler Schematic F30E SB Boiler Location, Flue and Ventilation... -
Page 4: Important Information
Important Information Gas safety (Installation and use) Regulations All external wiring between the appliance and the electrical supply and earthing requirements shall comply with the current In your interests and that of gas safety, it is the law that ALL gas IEE Regulations. -
Page 5: Draining And Filling
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. -
Page 6: Appliance Safety Devices
Appliance Safety Devices Air flow rate safety device Frost protection If the flue is obstructed, the built in safety system will turn the The appliance has a built in frost protection device that boiler OFF, the fan will continue to run. The boiler will be ready protects the boiler from freezing. -
Page 7: User Controls And Lighting
User Controls and Lighting Domestic hot water temperature selector (F30E/F35E Only) minimum setting approx. 38˚C up to maximum setting 60˚C. The ECO setting is ideally suited for all the requirements of normal family use Boiler ON indicator (showers, washing up etc.). The maximum setting should be reserved for (fault indicated by occasional use when very hot water is required. -
Page 8: Programmer Instructions For Use
Programmer Instructions for Use General description The Programmer is fitted as standard to the Themaclassic F30E/F35E. The programmer is factory preset which switches the boiler “ON” and “OFF” up to three times a day as shown below. FACTORY PRESET TIMES 6.30 8.30 2nd ON... - Page 9 Programmer Instructions for Use To set the programmer ON and OFF times Note: The programmer can be set to give a minimum of one and a maximum of three ON and three OFF times. Place the slide switch to “SET” (C1). Press the “enter”...
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Page 10: Technical Data
1 Technical Data F30E F30E SB F35E Heating Heat input (max) NET Q 32,6 32,6 37,8 BTU/H 111,231 111,231 128,973 Heat input (min) NET Q 13,3 13,3 BTU/H 45,380 45,380 40,944 Heat output (max) NET P 29,6 29,6 34,8 BTU/H 100,995 100,995 118,739... -
Page 11: General Information
1 Technical Data The Themaclassic F are delivered in two separate packages: • The boiler including hanging bracket complete with isolating valves and fittings. • The flue system Net lift weight (boiler only) F30E 37 kg F30E SB 36 kg F35E 38 kg Gross lift weight... -
Page 12: Heating System Design
2 General Information 2.3 Gas Supply Important Notice If your boiler has been converted to use L.P.G. Propane the The gas installation must be in accordance with the relevant following note applies: standards. Propane cylinders are under pressure and should never be In GB this is BS 6891. - Page 13 3 Heating System Design 3.1 Bypass 3.3 Filling the system F30E SB •The boiler is fitted with an adjustable automatic bypass. • Provision for filling the system must be made. The methods are shown in diagram 3.2. There must be no permanent Ensure that under no circumstances does the flow rate drop connection to the mains water supply, even through a non- below the figure specified, see Table 1.
- Page 14 4 Domestic Hot Water System Design. F30E and F35E Only General - All domestic hot water circuits, connections, fittings • The flow restrictor, supplied in the document envelope, must must be in accordance with the relevant standards and water be fitted as diagram 7.1, limiting the flow through the boiler to supply regulations.
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Page 15: Boiler Schematic F30E/F35E
5 Boiler Schematic F30E - F35E 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. -
Page 16: Boiler Location, Flue And Ventilation
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. -
Page 17: Fixing Jig
7 Fixing jig The fixing jig is made up as follows: Other components within the fixing jig pack. A - Heating return fitting with isolating valve. F - Hanging bracket B (F30E and F35E Only) - Cold water inlet fitting with G - wall template isolating valve. -
Page 18: Boiler Preparation And System Connections
8 Boiler Preparation and System Connections 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. •... -
Page 19: Boiler Installation
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. -
Page 20: Horizontal Rear Flue Installation
10 Horizontal Rear Flue Installation The Horizontal Rear flue - kit No A2009700 is suitable for installations that require a flue length from 190mm minimum to 667mm maximum, without extensions, measurement taken from the rear of the boiler to outside wall face, see diagram 10.4 (3.). - Page 21 10 Horizontal Rear Flue Installation SELF PLASTIC ADHESIVE INTERNAL SELF RUBBER SEALS SAMPLE FLANGE ADHESIVE 40mm SEALING POINT GASKET COLLAR INNER WALL STANDARD FLUE ASSEMBLY ADAPTOR INNER STANDARD (1.) WALL FLUE ASSEMBLY Diagram 10.5 PLASTIC INTERNAL FLANGE RESTRICTOR (F30E/F30E SB only) SELF ADHESIVE...
- Page 22 10 Horizontal Rear Flue Installation Preparing the boiler FAN RETAINING EARTH • Lift the boiler up and engage boiler upper part onto the SCREWS LEAD hanging bracket. • Fit the washers between the boiler pipes and the inlet and outlet fittings on the fixing jig and connect the various couplings between the boiler and jig.
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Page 23: Horizontal Telescopic Top Flue Installation
11 Horizontal Telescopic Top Flue Installation The Horizontal Telescopic Top Flue, Kit No. A2004500 SIDE FLUE Suitable for installations that require a flue length "L" from 430 minimum to 660 maximum. If longer flueing is required extensions and bends are available, see note below. If the flue length, see diagram 11.2. - Page 24 11 Horizontal Telescopic Top Flue Installation 11.3 Installation of telescopic flue assembly STEP 1. • For flue lengths less than 0.5m fit the restrictor (supplied in the document envelope) inside the fan outlet (F30E/F30E SB FLUE LENGTH Outside Only - see diagram 11.3) wall face •...
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Page 25: Horizontal Top Flue Installation
12 Horizontal Top Flue Installation 12a.1 The Horizontal Top flue - kit 86285 SIDE FLUE 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"... - Page 26 12 Horizontal Top Flue Installation 12a.4 Installation of horizontal top flue Outside Flue assembly wall face centre line 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.
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Page 27: Electrical Connection
13 Electrical Connection 13.1 Mains Cable WARNING: This appliance must be earthed. This appliance must be wired in accordance with these instructions. Any fault Important: If a replacement supply cable is required it must be arising from incorrect wiring cannot be put right under the purchased. - Page 28 13 Electrical Connection 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 STRAIN CONNECTION TERMINAL. RELIEF 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.
- Page 29 14 Commissioning Important: The commissioning and first firing of the boiler must Air in pipes only be done by a competant person. Important: A central heating system can not operate correctly unless it is filled with water and air bled from the system. If these Gas installation conditions are not met the system may be noisy.
- Page 30 14 Commissioning 5. • Bleed each radiator to remove air, ensure all • Leave cap open on automatic air vent. bleed screws are re-tightened. • If necessary repressurise the system, refer to procedure 4 8. • Open various hot water taps to bleed system 7.
- Page 31 14 Commissioning 14.3 : Setting the flue parameters for Themaclassic F 35E Flue length for Themaclassic F 35 E This adjustment is made to ensure the boiler operates at maximum efficiency with longer flue lengths. Setting Horizontal Rear Vertical flue (L) Vertical flue (L) Twin •...
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Page 32: Changing Gas Type
15 Changing Gas Type Should it be necessary to change the gas type, a conversion kit • Gain access to the gas control valve, connect a pressure with instructions will be required. gauge. This modification must only be carried out by a competent •... -
Page 33: Routine Cleaning And Inspection
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. - Page 34 17 Routine Cleaning and Inspection • Drain the boiler, refer to diagram 17.2. • On completion check all gas-carrying parts for soundness with leak detection fluid. 17.3 Front panel • Unscrew and remove the two retaining screws from the bottom of the front panel.
- Page 35 17 Routine Cleaning and Inspection 17.7 Combustion chamber cover 17.14 Sealed chamber cover seal check • Unscrew and remove the two screws securing combustion Check the condition of the seal, replace as required. chamber cover to combustion chamber, see diagram 17.5. To replace remove the old seal, thoroughly clean the casing •...
- Page 36 17 Routine Cleaning and Inspection BURNER RETAINING SCREWS BURNER AIR PRESSURE GUIDE SWITCH SENSING TUBE FLUE HOOD Diagram 17.7 HEAT EXCHANGER Diagram 17.9 FAN RETAINING EARTH BOLTS LEAD CLIP DOMESTIC WATER INLET FILTER HOUSING POWER SUPPLY LEADS FILTER F30E/F30E SB shown Diagram 17.8 F30E/F35 E Only Diagram 17.10...
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Page 37: Fault Finding
18 Fault Finding Before trying to operate the boiler make sure that : Overheat thermostat reset button • All gas supply cocks are open and that the gas supply has Refer to Section 20.10 to locate the overheat thermostat been purged of air. reset button. - Page 38 18 Fault Finding TYPE OF FAULT CHECK No display on control panel • 230V supply • PCB fuse • Connection between PCBs No domestic hot water (F30E/F35E Only) • Loose connections on control board (PCB) No central heating • Connections on air pressure switch (electrical or tubes) (Red flashing warning light and flashing disconnected fault code in display)
- Page 39 18 Fault Finding FAULT: NO HEATING Are the external heating Rectify fault on external controls. controls calling for heat? Rectify, check the 230V Is the polarity correct? controls board. Connect 1 and 2 on J10, Faulty main PCB. does boiler fire in central heating? Faulty 230V controls board.
- Page 40 18 Fault Finding 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 • Check that the gas taps are fully open the sensing electrode.
- Page 41 18 Fault Finding F1 FAULT DISPLAYED FAULT: THE BURNER DOES NOT LIGHT AT ALL, BUT THERE IS AN IGNITION SPARK. Are the gas taps on? Turn on the gas taps. Is there 24Vdc at the gas control valve? Check the wiring. for testing see component testing data.
- Page 42 18 Fault Finding F30E/F35E ONLY FAULT: THE WATER AT THE TAPS IS LUKE-WARM. Is the temperature higher if you reduce Check the 3-way valve is not passing the flow through the taps? into the radiators. (The radiators should stay cold in Summer setting) Check that the cold water inlet restrictor is fitted.
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Page 43: Wiring Diagram F30E
19 Wiring Diagram F30E AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES IGNITOR UNIT SENSE ELECTRODE PUMP CONTROL OVERHEAT VALVE THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR THREE-WAY VALVE MAINS VOLTAGE HEATING CONTROLS PLUG 230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS. REMOVE VOLTAGE FREE LINK CONTROLS VOLTAGE FREE... -
Page 44: Wiring Diagram F30E Sb
19a Wiring Diagram F30E SB AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES SENSE ELECTRODE IGNITOR UNIT CONTROL VALVE OVERHEAT PUMP CH THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR MAINS VOLTAGE HEATING CONTROLS PLUG 230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS. REMOVE VOLTAGE FREE LINK CONTROLS VOLTAGE FREE... -
Page 45: Wiring Diagram F35E
19b Wiring Diagram F35E AIR PRESSURE SWITCH IGNITION PLUG ELECTRODES IGNITOR UNIT SENSE ELECTRODE SENSOR PUMP CONTROL OVERHEAT VALVE THERMOSTAT CHASSIS THERMISTOR EARTH WATER PRESSURE SENSOR THREE-WAY VALVE MAINS VOLTAGE HEATING CONTROLS PLUG 230V SWITCHED LIVE FROM OPTIONAL FROST STAT. 230V SWITCHED LIVE FROM HEATING CONTROLS. -
Page 46: Replacement Of Parts
20 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). (F30E/F35E Only) To Drain the Domestic hot water circuit •... - Page 47 20 Replacement of Parts 20.2 Fan, refer to Section 17.10. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. RETAINING • Remove the sealed chamber cover, refer to Section 17.5. CLIPS •...
- Page 48 20 Replacement of Parts 20.9 Burner injector assembly, refer to diagram 20.6. BURNER INJECTOR 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. •...
- Page 49 20 Replacement of Parts 20.13 Heat exchanger, refer to diagram 20.7. • Remove the front panel, refer to Section 17.3. Before starting refer to the front of Section 20 Important • Unclip control panel user interface and hinge forward . Do information.
- Page 50 20 Replacement of Parts CONTROL BOARD PCB (CONTROL BOARD) COVER Diagram 20.9 F30E shown CONTROL PANEL 230V CONTROLS BOARD MAINS SWITCH USER INTERFACE PROGRAMMER FOAM PACKING BOARD (F30E/F35E Only) Diagram 20.10 F30E shown 4000123924-2...
- Page 51 20 Replacement of Parts 20.20 Central heating pump head, refer to diagram HEX HEAD 20.11. SCREW Before starting refer to the front of Section 20 Important (4 OFF) information. • Remove the front panel, refer to Section 17.3. PUMP HEAD •...
- Page 52 20 Replacement of Parts 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. •...
- Page 53 20 Replacement of Parts 20.26 Bypass valve, refer to diagram 16.1. Before starting refer to the front of Section 20 Important information. • Remove the front panel, refer to Section 17.3. AIR VENT • Lower the control panel, refer to Section 17.4. Drain down the boiler, refer to relevant part of Section 20.1.
- Page 54 20 Replacement of Parts 20.30 Discharge safety valve, refer to diagram 20.19. 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. PRESSURE •...
- Page 55 20 Replacement of Parts 20.33 Ignition unit, refer to diagram 20.22. 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. •...
- Page 56 20 Replacement of Parts 20.35 Expansion vessel EXPANSION VESSEL 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.
- Page 57 20 Replacement of Parts • Remove the front panel, refer to Section 17.3. • Remove the sealed chamber cover, refer to Section 17.5. • Remove the old seal, thoroughly clean the casing. Fit the new seal, it is supplied to the correct length. Note: Ensure the seal is fitted correctly giving an air tight seal.
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Page 58: Spare Parts
21 Spare parts When ordering spare parts, quote the part number and description, stating the appliance model number and serial number from the data badge. Short parts list Description Part No. G.C. No. Central heating thermistor S57398 ••••••• S10119 ••••••• Air pressure switch S57441 •••••••... - Page 59 4000123924-2...
- Page 60 Because of our constant endeavour for improvement details may vary slightly from those in the instructions. 4000123924-2...