Saunier Duval 41-920-45 Instructions For Use Installation And Servicing Download Page 50 | Manualshive

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4000123924-2

20 Replacement of Parts

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Diagram 20.9

PCB (CONTROL BOARD)

CONTROL BOARD
COVER

Diagram 20.10

USER INTERFACE
BOARD

➜

10020

10021

10219

230V
CONTROLS
BOARD

MAINS
SWITCH

PROGRAMMER

(F30E/F35E Only)

FOAM PACKING

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➜

CONTROL PANEL

10212

F30E shown

F30E shown

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Summary of Contents for 41-920-45

Page 1: ...ng 4000123924 2 07 03 Hepworth Heating Ltd Nottingham Road Belper Derbyshire DE56 1JT Themaclassic F30E Fanned Flue Combination Boiler G C No 47 920 36 Themaclassic F30E SB Fanned Flue System Boiler G...

Page 2: ...nd 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 warra...

Page 3: ...tion 6 16 Fixing jig 7 17 Boiler Preparation and System Connections 8 18 Boiler Installation 9 19 Horizontal Rear Flue Installation 10 20 Horizontal Telescopic Top Flue Installation 11 23 Horizontal T...

Page 4: ...l attention The insulation is composed of non combustible material Electrical Supply WARNING This boiler must be earthed All system components shall be of an approved type and shall be connected in ac...

Page 5: ...the boiler until the pressure gauge reads 1 0 bar A mains pressure of 2 0 bar is required to reach a fill pressure of 1 0 bar Reset boiler refer to diagram 2 turn the On Off switch to 0 wait for five...

Page 6: ...ance 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...

Page 7: ...ndicator fault indicated by light flashing red Programmer F30E F35E Only Central heating temperature selector minimum setting approx 38 C up tomaximum setting approx 87 C It is supplied factory set to...

Page 8: ...Using the and buttons set the display to the correct time in twenty four hour format for example 1300 for 1pm see diagram 4 Helpful hint The and buttons are used to change the times Press and release...

Page 9: ...een times 23 59 and 0 00 Helpful Hint If you get confused and wish to start again press the Reset res button and the programmer will revert to the internal factory set programme You can now reset the...

Page 10: ...te for 35 C temp rise litres min 12 1 14 3 Threshold flow rate litres min 1 7 1 7 Maximum supply pressure bar 10 10 Minimum supply pressure bar 0 5 0 5 Hot water Electrical supply V Hz 230 50 230 50 2...

Page 11: ...ring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In I E the installation must be carried out by a competent person a...

Page 12: ...and facilitate permanent venting of the installation Bleed fittings must be provided at every high point of the system and on all radiators The total volume of water permitted for the heating system d...

Page 13: ...no circumstances does the flow rate drop below the figure specified see Table 1 A system bypass is not required on the central heating circuit unless the system controls will not ensure a minimum wate...

Page 14: ...for a drain valve at the lowest points of the system The flow restrictor supplied in the document envelope must be fitted as diagram 7 1 limiting the flow through the boiler to a maximum of 12 litres...

Page 15: ...itch 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 G...

Page 16: ...al 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...

Page 17: ...ating 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 F30E and F35E Only Domestic hot...

Page 18: ...to Horizontal Rear Flue instructions section 10 and prepare the flue system Insert the flue system into the hole such that it will not interfere with the appliance when lifting into position 8 3 Fixi...

Page 19: ...portant 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 hangi...

Page 20: ...e diagram 10 4 1 Fit the plastic internal flange G over the flue push along the pipe until engaged against internal wall see diagram 10 4 2 Remove the backing from one of the wrap around self adhesive...

Page 21: ...TANDARD FLUE ASSEMBLY 40mm Rear of boiler Outside wall face MINIMUM FLUE LENGTH 190mm MAXIMUM FLUE LENGTH 667mm 10311 Diagram 10 4 1 3 2 10234 Diagram 10 5 ADAPTOR SELF ADHESIVE GASKET STANDARD FLUE A...

Page 22: ...two screws supplied in the fittings kit see diagram 10 7 Flue Hood Outlet Restrictor refer to diagram 10 9 for F 35 Eonly Secure restrictor supplied with flue pack to the flue hood as shown in diagra...

Page 23: ...lue lengths to be reduced by 1m for 90 and 0 5m for 45 11 1 Horizontal Telescopic Top Flue Kit of parts refer to diagram 11 1 11 2 Horizontal telescopic flue system Rear and side flue lengths and dime...

Page 24: ...nd 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 a suitable lubricant Fit flue elbow D onto boiler and s...

Page 25: ...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 11886 Diagram 12a 2 70mm 65mm 410 mm 205mm 20mm Min Clear...

Page 26: ...e 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 Carefullypushthefixingcollarsealontotheelbowensuring...

Page 27: ...e identified as to its use A fused three pin plug and shuttered socket outlet may be used instead of a fused spur box provided that a They are not used in a room containing a fixed bath or shower b Bo...

Page 28: ...bles 2 Test the earth continuity and short circuit of cables 3 Test the polarity of the mains 230V 50Hz PERMANENT MAINS SUPPLY 3 AMP FUSE DOUBLE POLE ISOLATOR EXTERNAL JUNCTION BOX L N E EXTERNAL FROS...

Page 29: ...s 1 bar Close filling device 9810 9796 GAS PURGE POINT Diagram 14 1 3 Undo cap on automatic air vent on top of pump and leave undone 9792 4 Air in pipes Important A central heating system can not oper...

Page 30: ...14 2 POTENTIOMETER P3 USER INTERFACE BOARD POTENTIOMETER P6 MANOMETER 11890 SW1 DIP SWITCH Factory set in OFF position To gain access to potentiometer P3 unclip the control box see diagram 13 3 The p...

Page 31: ...truct 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 u...

Page 32: ...B Part No A2031900 for F 35E Setting the step pressure Adjustingthesteppressuremaybeanecessaryoperationafter gas conversion or after changing the gas control valve when a new replacement part is requi...

Page 33: ...cap on the flue spigot located between the boiler and the wall see diagram 17 1 Connect the analyser tube onto sampling point RefertothecombustionproductvaluesinSection1Technical Data Switchontheelec...

Page 34: ...ccess to lower part of boiler 17 5 Sealed chamber cover Unscrewandremovethetworetainingscrewsfromthesealed chamber cover see diagram 17 3 Lift cover up and off pins on top of boiler 17 6 Side panels f...

Page 35: ...cates 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 17 12 Domestic water inlet filter F30E F35E Only refer to di...

Page 36: ...SING CLIP RETAINING CLIP FILTER FLAT 11935 11934 9750 17 Routine Cleaning and Inspection 9742 Diagram 17 8 9741 Diagram 17 9 FLUE HOOD HEAT EXCHANGER AIR PRESSURE SWITCH SENSING TUBE POWER SUPPLY LEAD...

Page 37: ...led Air fault pressure switch no power to fan 05 and F and flashing red LED Overheat fault 06 and F and flashing red LED Central heating flow NTC fault 09 and F and flashing red LED Water pressure sen...

Page 38: ...ater is on Three way valve lead 9 6k between 1 and 3 230V ac between 2 and 3 of the motor 3 2 1 1 2 and 3 marked on About 25V ac to 35V ac between 1 and 2 the motor Thrust action of the motor Unfasten...

Page 39: ...O HOT WATER BUT THE HEATING IS WORKING Is the water pressure greater than 0 5 bar NO Insufficient water pressure The appliance will not operate Find out why the pressure is so low Is the water flow ra...

Page 40: ...ck the connector on the end of the wire Check that the spark electrode is pointing towards the flame Check the spark electrode Change it If the problem persists change the control board PCB flame dete...

Page 41: ...of safety valve coil FAULT THE ROOM TEMPERATURE IS INADEQUATE AND RADIATORS ARE LUKE WARM YES NO Is the heating temperature on the boiler set high enough Turn up settings YES Is the heating power ade...

Page 42: ...CONNECTIONS TO THE AIR PRESSURE SWITCH Pr 3 2 1 P2 P1 L H Electrical contacts FAULT THE FAN RUNS BUT THERE ARE NO SPARKS 11877 18 Fault Finding FAULT THE WATER AT THE TAPS IS LUKE WARM NO YES Check th...

Page 43: ...2 H1 H4 H3 H8 H6 H7 ON OFF SWITCH AIR PRESSURE SWITCH FAN THREE WAY VALVE SENSE ELECTRODE IGNITION ELECTRODES g y g y CHASSIS EARTH bk br w g w g w g p p or y gn b b w r br b g y g y br or OVERHEAT TH...

Page 44: ...J11 H5 H2 H1 H4 H3 H8 H6 H7 ON OFF SWITCH AIR PRESSURE SWITCH FAN SENSE ELECTRODE IGNITION ELECTRODES g y g y CHASSIS EARTH bk br w g w g p or y gn b b w r br b g y g y br or OVERHEAT THERMOSTAT g y g...

Page 45: ...4 H3 H8 H6 H7 ON OFF SWITCH AIR PRESSURE SWITCH FAN THREE WAY VALVE SENSE ELECTRODE IGNITION ELECTRODES g y g y CHASSIS EARTH bk br w g w g w g p p or y gn b b w r br b g y g y br or OVERHEAT THERMOST...

Page 46: ...rom 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...

Page 47: ...nt 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 6 Cold water inlet restrictor F30E F35E Only Before...

Page 48: ...he 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 Disconne...

Page 49: ...t panel refer to Section 17 3 Lower the control panel refer to Section 17 4 Gain access to rear of control panel Undo and remove the two front retaining screws Hinge up the control panel cover and eas...

Page 50: ...t of Parts Diagram 20 9 PCB CONTROL BOARD CONTROL BOARD COVER Diagram 20 10 USER INTERFACE BOARD 10020 10021 10219 230V CONTROLS BOARD MAINS SWITCH PROGRAMMER F30E F35E Only FOAM PACKING CONTROL PANEL...

Page 51: ...over Disconnect pump cable from pump avoid straining cables Connect electrical connection to replacement pump head Fit replacement pump head 20 21 F30E F35E Only Filling system tap refer to diagram 20...

Page 52: ...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 Undo the union nut on the cold water inlet isolating valve Pull o...

Page 53: ...l 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 Disconn...

Page 54: ...information Remove the front panel refer to Section 17 3 Lower the control panel refer to Section 17 4 Remove the gas control valve refer to Section 20 28 It will not be necessary to remove gas contr...

Page 55: ...it from the retaining slot 20 34 F30E F35E Only Domestic hot water plate to plate heat exchanger Before starting refer to the front of Section 20 Important information Remove the front panel refer to...

Page 56: ...17 4 Drain down the boiler only refer to relevant parts of diagram 20 1 Disconnect the flue system Disconnect the fixing jig connection pipes at the boiler Disconnect the pressure relief valve discha...

Page 57: ...cement 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 th...

Page 58: ...stem water pressure sensor S57205 8 Gas control valve G20 S10045 9 Gas control valve G30 S10046 10 Discharge safety valve S10067 11 Overheat thermostat S10080 12 Ignition electrode S10038 13 Flame sen...

Page 59: ...59 4000123924 2...

Page 60: ...60 4000123924 2 Because of our constant endeavour for improvement details may vary slightly from those in the instructions...

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