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Saunier Duval ThemaPLUS CONDENS F 30 E, Instructions For Use Installation And Servicing

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Saunier Duval ThemaPLUS CONDENS F 30 E Instructions For Use Installation And Servicing Download Page 43

42

15 Remplacement of parts

Warning!

Before starting the remplacement of 

parts, read carefully the chapter “Safety 

instructions”.

•

Ensure boiler is drained before 

replacing any hydraulic components, 

refer to chapter «Draining of the 

appliance».

•

15.1  Hydraulic block

TO

P

1

30

29

28

27

24

23

22

21

18

20

19

17

16

14

15

2

4

3

5

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7

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13

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Summary of Contents for ThemaPLUS CONDENS F 30 E

Page 1: ...Instructions for use Installation and servicing ThemaPLUS CONDENS F 30 E CONDENSING BOILER ACCUMULATED HOT WATER ...

Page 2: ...4 6 Servicing 4 7 Recycling 4 8 Appliance use 6 8 1 Control panel 6 8 2 Display 6 8 3 Commissioning 7 8 4 Temperature adjustment 7 8 5 Adjustment of the time and day of the week 7 8 6 Heating programme adjustment 8 8 7 Boost function 8 9 Turn the boiler off 8 10 Fault finding 9 11 Frost protection 10 11 1 Boiler frost protection 10 11 2 Installation frost protection 10 12 Maintenance After Sales S...

Page 3: ...d list please contact your supplier or visit our website www saunier duval co uk 2 Documents Please keep this manual as well as any documents enclosed with it safe for future reference We accept no liability in case of damage due to the non compliance of the instructions of the present manual 3 Safety 3 1 Gas Leak or Fault Do not switch on nor switch off the light Do not activate the electrical sw...

Page 4: ...unier Duval undertake to repair or replace parts free of charge which are recognised by us to be of faulty manufacture if necessary after return to our factory for examination on condition that The appliance was installed by a qualifled gas installer in accordance with installation instructions and all the relevant codes of practice standards and legislation in force The appliance has been used for...

Page 5: ... produce hot water using gas Any other use is considered as inappropriate and is forbidden The manufacturer shall not be responsible for any damage caused by another use In that case the user shall be the responsible 6 Servicing Clean the case of the appliance with wet soapy cloth Do not use any abrasive cleaning product as they could damage the housing or plastic parts 7 Recycling The appliance c...

Page 6: ...5 Instructions for Use ...

Page 7: ...1 2 0 2 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0 1 9 8 7 6 5 4 3 2 0 1 2 3 4 5 6 7 1 2 4 3 5 7 6 8 9 10 11 Legend 1 Selected operating mode 2 Current operating mode 3 Heating pressure display 4 Fault code display installation customer service menu 5 Fault symbols 6 Boiler operation 7 Fault code value display installation customer service menu 8 Heating temperature measured 9 Current time and date 10 ...

Page 8: ...stic hot water temperature adjustment Push or on the side to adjust the domestic hot water temperature The ECO symbol remains until 49 C 8 4 2 Heating temperature adjustment Push or on the side to adjust the water temperature of the central heating The ECO symbol remains until 49 C Observation A quick push on or side displays the temperature value previously selected 8 5 Adjustment of the time and...

Page 9: ...de to authorise heating 24 hours a day every day of the week switch off heating 24 hours a day every day of the week restore the previously saved heating programme 8 7 Boost function The boost function authorises heating in a programming zone where heating is not authorised This function will remain active until the next heating programme zone Comment this function can only be activated in the DHW...

Page 10: ...matically once the power supply is on If the fault persists please contact a skilled professional code F1 F4 Ignition fault Switch off the boiler Wait 5 seconds and then start the boiler again If the fault continues please contact a skilled professional code F2 F3 Air flow failure code F5 Overheating fault Please contact a skilled professionnal Insufficient water pressure in the system 0 5 bar Ope...

Page 11: ...ostat If you leave home for a long period see chapter Draining of the appliance in the installation manual 12 Maintenance After Sales Service Please note that incorrect servicing can affect the safety of the appliance and can lead to injury 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 The fr...

Page 12: ...ulations 16 5 Appliance installation 17 5 1 Recommendations before mounting 17 5 2 Dimensions 18 5 3 List of delivered equipment 18 5 4 Fixing to the wall 19 5 5 Gas and water connection 19 5 6 Connection to the condensate trap 21 5 7 Flue connection 22 5 8 Electrical connection 24 5 9 Wiring diagram 26 6 Commissioning 28 7 Specific adjustments 28 7 1 Heating circuit adjustment 28 7 2 Access to th...

Page 13: ...14 Servicing 36 14 1 Casing 36 14 2 Removable plate Silencer 37 14 3 Condensate trap 37 14 4 Hydraulic block 38 14 5 Combustion block 40 15 Remplacement of parts 42 15 1 Hydraulic block 42 15 2 Combustion block 44 15 3 Expansion vessel Storage vessel 46 15 4 Ignition module Ignition and control electrode Sight glass 47 15 5 Control panel 48 16 Technical data 50 ...

Page 14: ...ion of the laws of the Member States relating to appliances burning gaseous fuels Directive 73 23 EEC on the harmonisation of the Laws of the Member States relating to electrical equipment designed for use within certain voltage limits Directive 89 336 EEC on the approximation of the Laws of the Member States relating to electromagnetic compatibility IMPORTANT With regards to the Manual Handling O...

Page 15: ...14 2 3 Block diagram 34 ...

Page 16: ...ular attention is drawn to the installation of an appliance in a room containing a bath or shower where reference must be made to the relevant requirements In GB this is the current I E E WIRING REGULATIONS and BUILDING REGULATIONS In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules Make sure you keep an appropreate distance betwee...

Page 17: ...he following safety instructions must be imperatively followed during the maintenance and the replacement of spare parts Stop the appliance see chapter Deactivation of the Instructions for use Disconnect the appliance from the mains power supply with the socket or the double pole switch with a minimum gap of 3mm for both poles Turn off the gas control valve Close the shut off valves located on the...

Page 18: ...s If the appliance is to be installed in a timber frame building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 If in doubt seek advice from the local gas undertaking or Saunier Duval 5 Appliance installation All the dimensions in this chapter are expressed in mm 5 1 Recommendations before mounting 5 1 1 Domestic hot water circuit design The circuit sho...

Page 19: ...to installing the new boiler the system is thoroughly flushed For optimum performance after installation of a new system the boiler and its associated central heating system should also be flushed Flushing should be carried out in accordance with BS7593 1992 using a cleanser such as Sentinel X300 or X400 Fernox Superfloc or Salamander corrosion guard cleaner For long term corrosion protection after fl...

Page 20: ...ds different oils and greases that may be present These foreign bodies may enter the boiler and disrupt the operation Do not use any solvents that could damage the heating circuit Take care when soldering pipes as the heat could damage the seals and cause leakage Fit washers after joints have cooled The pipes from the heating and domestic hot water safety discharge valves must not discharge above ...

Page 21: ...x4 9 Heating isolating valve 10 Cold water inlet isolating valve 11 Gas inlet isolating valve 12 Domestic hot water outlet pipe angular bush to weld Ø 15 13 Nut 3 4 14 Gas pipe angular bush to weld Ø 15 nut 1 2 19 Hanging bracket Gasket limiter pack 1 Flat gasket x2 7 Cold water flow limiter 8 Gasket 3 4 x5 Valves pack 1 Flat gasket 3 Nut 15 Evacuation pipe for DHW safety valve 16 Biconical ring nu...

Page 22: ...screw the filling trap 2 located under the condensate trap Fill the trap 3 4 full with water 2 Replace the filling trap 2 in the condensate trap 1 Warning The condensate trap must be pre filled before the first operation of the boiler 5 6 2 Condensate drain 2 3 3 4 1 Legend 1 Condensate trap retaining clips 2 Condensate trap 3 Condensate outlet 4 Outlet siphon Connect the condensate outlet 3 to a disc...

Page 23: ...iated accessories Warning You can only use flue accessories approved for the ThemaPLUS CONDENS Ensure a slope of 44 mm m between the elbow and the terminal extremity to enable the return of condensate to the appliance 44mm 1 M 4 4 Whatever the kind of flue system chosen observe the minimum distances indicated in the chart below to position the flue terminals R S ...

Page 24: ... door window in car port into dwelling 1200 M vertical from a terminal 1500 N horizontally from a terminal 300 Vertical flues P from another terminal 600 Q above roof level 300 R from adjacent opening window 1000 S from adjacent wall to flue 300 5 7 1 Horizontal concentric flue Ø 60 100 C13 type installation 1 L 72 Legend 1 Gasket Maximum flue index 150 Pa This value is reached with the length of th...

Page 25: ...45 the length L should be redu ced by 2 m 5 8 Electrical connection Warning Incorrect installation can cause electric shock or appliance damage Connect the power cable of the boiler to the 230 V single phase earth network Observe the live and neutral connection on the boiler Do not use cable over 10 mm in diameter for electrical connections Important Electrical connection of the appliance must be ...

Page 26: ... distance between the terminal block 1 and the stripped sheath 3 Otherwise fasten the electrical wires 2 together with a cable tie Secure the cables with the electrical box cable clamp 5 8 3 Separation of high and low voltage cables 2 3 1 Legend 1 Main board 2 Passage for high voltage 3 Passage for low voltage Respect passage 2 for low voltage cables and 3 for high voltage cables 5 8 4 External co...

Page 27: ...26 5 9 Wiring diagram 1 2 3 4 5 6 7 11 9 8 10 12 13 14 15 16 17 18 ...

Page 28: ...e 2 Ignition and control electrode 3 Heating return thermistor 4 Overheat thermostat 5 Pump 6 User interface 7 On Off switch 8 Fuse 9 Main board 10 Water flow sensor 11 Water pressure sensor 12 Three way valve 13 Heating flow thermistor 14 DHW temperature sensor 15 Storage vessel 16 Gas valve 17 Fan 18 Thermal fuse ...

Page 29: ...tween 1 and 2 bars Re fill system as necessary Operate the appliance for at least 15 minutes on heating with a heating temperature equal or greater to 50 C Flush the domestic hot water system by openning the hot water taps for several minutes Make sure the display indicates a system pressure of between 1 and 2 bars Re fill system as necessary 7 Specific adjustments 7 1 Heating circuit adjustment Thi...

Page 30: ...s 29 Output pressure curve 70 60 50 40 30 20 10 500 1400 1000 2 3 9 1 4 6 5 Legend Speed II 1 By pass fully shut 2 Open 1 2 turn 3 Open 1 turn Speed I 4 By pass fully shut 5 Open 1 2 turn 6 Open 1 turn Heating circuit flow rate l h Available pressure kPa between heating flow and return ...

Page 31: ...quired or on on the side to change menu Note the indicator goes back to its normal position after 10 minutes without any operation or after having pressed the MODE key for more than 3 s N menu Title Action COD 1 maximum heating power Press the keys to set the required value factory setting 15 COD 2 flue configuration No adjustment required for this kind of boiler Flue codes have no effect on the b...

Page 32: ...t a value between 0 and 199 COD 24 set the offset on the minimum fan speed Select a value between 0 and 99 99 990 rpm no 10 rpm COD 25 rmaximum condensation power Select a value between 0 and 99 99 1485 rpm no 15 rpm Heating curve 1 2 50 60 70 80 90 30 40 25 15 20 4 0 0 2 0 6 1 2 3 0 1 5 1 0 2 0 2 5 3 5 Legend 1 Menu 6 setting 2 Menu 7 setting Outdoor temperature C Heating flow temperature C ...

Page 33: ... CO2 analyser to the flue elbow 3 1 2 Legend 1 Plug 2 Test point 3 Maximum power setting screw Take off cap 1 then insert a sampling tube in the test point 2 in the flue system 9 1 Maximum power setting In domestic hot water with CO2 Fully open a hot water tap Wait for 2 minutes or so until the CO2 reading has stabilized In heating with CO2 Adjust the boiler on Burner forcing at P max using menu COD...

Page 34: ...lace front panel Note After re fitting the front panel the CO2 values must correspond to that given in the table below 1 2 Legend 1 Gas change label position Stick the gas change label in its place 1 on the cover of the electric box After adjusting and remounting the sealed panel switch the COD 8 menu burner forcing back to its normal operating mode factory setting 0 if maximum power has been adjus...

Page 35: ...e broken Thermistor faulty Check that thermistor attached correctly to pipe F7 DHW thermistor fault F8 Tank thermistor fault F9 Water pressure sensor fault Faulty sensor connection Check wiring F10 Central heating return thermistor fault Thermistor cable defective broken thermistor faulty Check that thermistor attached correctly to pipe F11 User interface connection fault Check wiring between main...

Page 36: ...Installation and servicing instructions strictly reserved for qualified gas installers 35 ...

Page 37: ...ser all of the manuals and documents concerning the appliance and tell the user to keep them near the appliance Explain more precisely the safety principles they should observe Remind the user to regularly service the appliance 13 Spare parts In order to guarantee a long lasting operating of the parts of the appliance and keep it in good condition only original spare parts from SAUNIER DUVAL shoul...

Page 38: ...tions in reverse to reassemble the unit 14 3 Condensate trap 2 3 3 4 1 Legend 1 Condensate trap retaining clips 2 Condensate trap 3 Condensate outlet 4 Outlet siphon Drain the filling siphon of the condensate trap see chapter on Filling the condensate trap Disconnect the outlet pipe located under the condensate trap 2 Disconnect the condensate trap pipe located under the combustion chamber see chap...

Page 39: ...38 14 4 Hydraulic block TOP 1 30 29 28 27 24 23 22 21 18 20 19 17 16 14 15 2 4 3 5 6 7 8 9 10 11 12 13 25 26 ...

Page 40: ...valve retaining clip 19 Discharge valve 20 Heating safety valve 21 Filling tap 22 Heating pressure sensor retaining clip 23 Discharge retaining clip 24 Three way valve 25 DHW safety valve retaining clip 26 DHW safety valve 27 DHW exchanger 28 Three way valve connector 29 Heating pressure sensor connector 30 Heating pressure sensor 14 4 1 Cold water filter Release the retaining clip from the filter 8...

Page 41: ...2 Gasket 3 Burner 4 Burner unit 5 Burner unit retaining nuts 6 Ignition and control electrode retaining screw 7 Ignition and control electrode connector 8 Ignition and control electrode 9 Gas valve connector 10 Gas pipe 11 Fan connector 12 Fan 13 Heat exchanger 14 Resistance 15 Thermal fuse connector ...

Page 42: ... Cleaning the heat exchanger Clean the resistance 14 in the heat exchanger 13 using ordinary vinegar Rinse with a high powered jet of water 14 5 3 Burner verification The burner 3 needs no maintenance or cleaning Check that its surface is not damaged If necessary replace the burner After checking or replacing the burner assemble the burner unit 4 as described in the following chapter 14 5 4 Assembl...

Page 43: ...of parts read carefully the chapter Safety instructions Ensure boiler is drained before replacing any hydraulic components refer to chapter Draining of the appliance 15 1 Hydraulic block TOP 1 30 29 28 27 24 23 22 21 18 20 19 17 16 14 15 2 4 3 5 6 7 8 9 10 11 12 13 25 26 ...

Page 44: ...mp motor by repeating the operations in reverse 15 1 2 DHW exchanger Remove the two retaining screws 17 accessible from the front of the boiler Remove the DHW exchanger 27 Fit the new DHW exchanger by repeating the operations in reverse Check the assembly direction the word TOP printed on the exchanger edge 27 must be positioned towards the top 15 1 3 Flow sensor Remove the retaining clip from the...

Page 45: ...e pipe 4 from the discharge valve Remove the discharge valve 19 Fit the new discharge valve by repeating the operations in reverse 15 1 8 DHW safety valve Release the DHW safety valve retaining clip 25 Remove the DHW safety valve 26 Fit the new DHW safety valve by repeating the operations in reverse 15 2 Combustion block 1 2 3 4 11 13 14 5 7 6 10 15 16 17 18 9 8 21 20 19 23 24 22 12 ...

Page 46: ... chapter on Maintenance 15 2 2 Burner Remove the burner unit 7 see chapter on Maintenance Remove the 3 screws 11 on the burner and remove it Fit the new burner and new gasket Replace the burner unit 7 see chapter on Maintenance 15 2 3 Heat exchanger Remove the silencer see chapter on Maintenance Remove the burner unit 7 see chapter on Maintenance Remove the heat fuse connector 24 Remove the 2 heat...

Page 47: ...gend 1 Hanging bracket retaining screw 2 Expansion vessel retaining screw 3 Expansion vessel 4 Expansion vessel coupling 5 Storage vessel retaining clips 6 Storage vessel 7 Hanging bracket 8 Pressure test point 15 3 1 Expansion vessel Loosen the coupling 4 from the expansion vessel 3 Loosen screws 1 and 2 on the hanging bracket 7 and remove it Remove the expansion vessel 3 towards the front Fit th...

Page 48: ...ing screw 4 Ignition and control electrode connector 5 Ignition and control electrode 6 Ignition and control electrode retaining screw 7 Circlip 8 Gasket 9 Sight glass 10 Gasket 11 Spring leaf 15 4 1 Ignition module Remove the ignition and control electrode connector 4 from the ignition module 1 Remove the ignition module harness connector 2 Remove the 2 ignition module 1 retaining screws 3 Fit th...

Page 49: ... A Disconnect connectors 1 2 3 4 5 and 6 from the main PCB Disconnect the power supply cable connector 7 Remove the main PCB 9 from the clips B on the electrical box 8 Fit the new main PCB by repeating the operations in reverse 15 5 2 User interface PCB 2 1 3 4 Legend 1 User interface retaining clips 2 Main PCB harness 3 User interface PCB 4 User interface retaining screws Push on the 2 retaining ...

Page 50: ...Installation and servicing instructions strictly reserved for qualified gas installers 49 ...

Page 51: ...low rate l h 500 Maximum heating temperature C 80 Minimum heating temperature C 28 Expansion vessel useful capacity l 8 Expansion tank initial pressure bar 0 75 Maximum system capacity at 75 C l 160 Safety valve maximum service pressure PMS bar 3 Domestic hot water Heating output P kW 29 6 Minimum calorific flow rate Q min kW 8 7 Maximum calorific flow rate Q max kW 29 6 Maximum hot water temperat...

Page 52: ...t with G20 reference gas CO ppm 80 mg kWh 86 CO2 9 2 NOx balance ppm 22 5 mg kWh 39 7 Dimensions Height mm 742 Width mm 410 Depth mm 394 Net weight kg 41 8 Supply voltage V Hz 230 50 Maximum absorbed power W 174 Electrical rating A 0 76 Fuse A 2 Electric protection IP4Xd Class 1 CE number 1312 BQ 4207 Technical data depending on the gas type Unit ThemaPLUS CONDENS F 30 E Natural gas G 20 1 DHW flo...

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Page 54: ...0020009248 02 06 05 Saunier Duval Nottingham Road Belper Derbyshire DE56 1JT Tel 00 44 0 1773 525914 Fax 00 44 0 1773 828070 www saunier duval co uk ...

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