CONDENSING BOILER + INSTANTANIOUS HOT WATER Instructions for use Installation and servicing Thema CONDENS F 18 E SB Thema CONDENS F 24 E Thema CONDENS F 30 E
Instructions for use 1 General points .........................................................................2 2 Documents ..............................................................................2 3 Safety ......................................................................................2 3.1 3.2 Gas Leak or Fault ..............................................................................2 Safety regulations and recommendations ..........................................
1 General points We accept no liability in case of damage due to non-compliance of the instructions of the present manual. The Thema CONDENS boiler is an appliance that uses condensing technology, which recovers heat present in waste gas. Thanks to this operating principle, the boiler consumes less energy and decreases NOx and CO2 emissions. 3 Safety 3.1 Gas Leak or Fault • Do not switch on nor switch off the light. The Thema CONDENS boiler has a double use (heating + instantanious hot water).
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. • Never carry out by yourself maintenance or repair on the appliance. • In case of a water leakage, immediately close the cold water inlet of the appliance and call a skilled professional to repair the leak.
This guarantee is in addition to your statutory and other legal rights, which will not be excluded or diminished by the return of the guarantee registration card. 5 Appliance use Saunier Duval’s appliances are manufactured according to the latest technical evolutions and current safety regulations. This appliance is used to 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.
5 Instructions for Use
8 Appliance use: Thema Condens 8.1 Control panel 5 1 time 6 prog 2 3 7 4 Legend 1 Operating mode indicators 2 LCD display 3 Operating mode selection 4 DHW temperature adjustment 5 6 7 8.2 8.3 1 LCD display 21 3 4 • Push switch (6) until the “I” symbol appears. The display and operational mode indicator light up. bar 15 Operating and lighting • Make sure that: - The boiler is connected to the electrical supply. - The gas service cock is open.
• Push “MODE” to modify the operating mode of the boiler. The green LED indicates the selected mode. • Use the + or – keys on the “time” side to set minutes, then press MODE key to validate. Domestic hot water + Timed central heating 8.6 Central heating and domestic hot water • Press the MODE key until the green indicator is in front of the “prog” mode. Domestic hot water only • Use the key on the “prog” side to select on periods. A black square appears on the display each time the key is pressed.
Appliance use: Thema Condens SB 9.1 Control panel 1 5 6 2 3 4 Legend 1 Operating mode indicators 2 LCD display 3 Operating mode selection 4 5 6 9.2 9.3 1 LCD display Heating temperature adjustment Operating indicator On/off switch Operating and lighting • Make sure that: - The boiler is connected to the electrical supply. - The gas service cock is open. COD. VAL. 2 • Push switch (6) until the “I” symbol appears. The display and operational mode indicator light up.
The appliance is no longer supplied with electric power. We advise you to turn off the appliance gas supply if you leave home for a long period. Central heating Appliance frost protection 9.4 11 Fault finding When a fault occurs, the operating indicator flashes red and the display shows a fault code, symbolized by the letter F followed by a number, for example F1. As a user, you can act only in the following cases.
12 Frost protection 13 Maintenance/After Sales Service 12.1 Boiler frost protection Please note that incorrect servicing can affect the safety of the appliance and can lead to injury. In case of frost risk, do as follows: • Make sure the boiler is supplied with electrical power and gas. 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.
Installation and servicing 1 Comments on the instructions...............................................13 2 Appliance description ............................................................13 2.1 2.2 2.3 Data label .........................................................................................13 Mandatory WARNING for EEC countries .........................................13 Block diagram .................................................................................
9 Gas conversion .....................................................................32 9.1 9.2 Maximum power setting .................................................................32 Reactivation .....................................................................................33 10 Fault finding...........................................................................34 11 Control / Commissioning .......................................................36 12 User information ................
1 Comments on the instructions Member States relating to appliances burning gaseous fuels. • Please give all of the instructions to the user. The user shall keep them for future reference. We accept no liability in case of damage due to the non-compliance of the instruction manual. - 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.
2.
3 Appliance location Any alteration not approved by Saunier Duval, could invalidate the certification, appliance warranty and may also infringe the current issue of the statutory requirements. • This appliance is not suitable for outdoor installation. • This appliance may be installed in any room, although particular 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.
The following safety instructions must be imperatively followed during the maintenance and the replacement of spare parts. In GB the installation of the appliance must be carried out by a competent person as described in the following regulations: • Stop the appliance (see chapter “Deactivation” of the Instructions for use). - The manufacturer’s instructions supplied. - The Gas Safety (Installation and Use) Regulations.
must not be taken as overriding statutory requirements. (see chapter “Heating circuit adjustment”). The system will be calculated according to the flow corresponding to the power that is really required without taking into account the maximum power that the boiler can supply. Nevertheless, we advise you to have a flow big enough so that the temperature difference between outgoing and return is under or equal to 20°C.
5.1.3 Water treatment 5.3 In the case of an existing installation, it is Essential that prior 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.
5.6 • Chose the location of the appliance. See chapter “Appliance location”. The hanging bracket will be adapted to the features of the bearing wall and will have to take into account the weight of the boiler filled with water. • Before undertaking any operation, carefully clean the pipes with an appropriate product in order to remove impurities such as filings, welds, different oils and greases that may be present. These foreign bodies may enter the boiler and disrupt the operation.
1 4 2 5 16 wa 3 ll 6 205 4 ,5 7 15 8 9 10 2 8 13 14 6 12 9 1 A 11 Legend Connection pack: A Pressure test point 2 Heating pipe: angular bush to weld Ø 22 + nut 3/4" (x2) 4 Gasket 3/4" (x3) 5 Cold water inlet pipe (*): angular bush to weld Ø 15 + nut 1/2" 6 Gasket 1/2" (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
5.7 Connection to the condensate trap 5.7.2 Condensate drain 5.7.1 Filling of the condensate trap 1 3 2 3 1 2 3 4 Legend 1 Condensate trap 2 Filling trap 3 Expansion vessel valve • Connect the condensate outlet (3) to a discharge system leading to the sewer. • Unscrew 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).
5.8 Flue connection Different flue outlet configurations can be carried out. • Consult your supplier for more information about the other possibilities and associated accessories. Warning! You can only use flue accessories approved for the Thema CONDENS. 4.4 % 44mm / 1 M • Whatever the kind of flue system chosen, observe the minimum distances indicated in the chart below to position the flue terminals.
5.8.
5.8.2 Vertical concentric flue Ø 60/100 (C33 type installation) This value is reached with 2 elbows, the separator and the maximum duct length (L1+L2) of 40 m. Every time an extra 90° elbow is used (or 2 off 45°), the length (L) should be reduced by 2 m. 5.9 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. L • Observe the live and neutral connection on the boiler.
• Open the installer connection side (2) to carry out the electrical connections. • Respect passage (2) for low voltage cables and (3) for high voltage cables. 5.9.2 Connection to the PCB 5.9.4 External controls connection 1 3 2 30 mm max. Legend 1 Terminal block 2 Electrical wires 3 Sheath 5 1 Warning ! When connecting electrical cables to the terminal block on the PCB: 4 • Keep a 30 mm maximum distance between the terminal block (1) and the stripped sheath (3).
5.
Legend 1 Ignition module 2 Ignition and control electrode 3 Heating return thermistor 4 Overheat thermostat 5 Pump 6 Main board 7 User interface 8 On/Off switch Fuse Water flow sensor Three way valve Water pressure sensor Heating flow thermistor Gas valve Fan Thermal fuse Installation and servicing instructions strictly reserved for qualified gas installers 9 10 11 12 13 14 15 16 27
6 Commissioning 7 Specific adjustments • Slide the switch until the “I” symbol appears.The display and operating mode indicator light up: the boiler is ready to run. 7.1 Heating circuit adjustment This flow rate will be adjusted according to the system calculations. When it is delivered, the (1) integrated bypass screw is open by half a turn. • Open the isolating valves located on the pipes: they will be placed in the direction of the flow.
Available pressure (kPa) between heating flow and return Output/pressure curve ThemaCondens F 24 E 70 60 50 40 1 30 2 6 20 5 3 4 10 9 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 Available pressure (kPa) between heating flow and return Output/pressure curve ThemaCondens F 18 E SB and F 30 E 70 60 50 1 40 2 30 6 20 3 5 4 10 9 500 1400 1000 Heating circuit flow rate (l/h) Legend Speed II 1 By-pass fully s
7.2 Access to the boilers technical data (for professional and After Sales Service use only) • Once again press the “MODE” key to display the first parameters menu, i.e. the heating maximum power (menu COD.1). The access to the boilers technical data allows you to make some adjustments and to analyse potential malfunctions. • When the menu «COD.1» appears on the display, press on the + or – keys on the or side to get to the next menu or press on the MODE key if you wish to change this parameter.
COD. 7 COD. 8 heating curve base Choose a value: 15°C / 16°C / 17°C / 18°C / 19°C / 20°C / 21°C / 22°C / 23°C / 24°C / 25°C burner forcing Select an operating mode: 0 - normal operation. (factory setting) 1 - forcing at P. mini. 2 - forcing at P. maxi. COD. 8 menus and following would only be used by After Sales Service Engineers. COD. 23 select product code Select 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).
8 Draining of the appliance 1 2 8.1 Heating circuit • Turn on the drain cock (1) provided at the system low point. 3 • Provide an air intake by opening a radiator bleed screw. 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. 1 9.1 Maximum power setting - In domestic hot water with CO2: • In order to drain only the water in the boiler, first shut off the heating flow and return isolating valves. 8.
9.1.2 Setting from G31 to G20 1 • Turn the screw (3) 2 full turns anticlockwise. • Wait for about 2 minutes in order to read a stabilized CO2 value. • Progressively adjust the setting in order to obtain the CO2 value in G20 shown in the chart below. • Stick the gas change label in its place (1) on the cover of the electric box. 2 Reactivation • Refit flue gas test point cap in place. • After adjusting and remounting the sealed panel, switch the COD.
10 Fault finding Important: a central heating system cannot operate efficiently if it is not filled with water and if the air it contains at first has not been completely removed. If those requirements are not fulfilled, some noise originated by the water boiling inside the boiler and noise of water chute inside the radiators could appear. You will find the list of some fault codes in the operating instructions.
35 Installation and servicing instructions strictly reserved for qualified gas installers
11 Control / Commissioning spare parts from SAUNIER DUVAL should be used when repairing and servicing the appliance. Once the appliance is installed, check whether it runs: • Only use original spare parts. • Start the appliance according to the indications of the operating instructions and check whether it runs. • Make sure that these parts have been correctly assembled with regards to their position and basic sense. • Check the appliance for leaks (gas and water) and eliminate any leakage found.
14.3 Condensate trap 14.2 Removable plate / Silencer 1 1 2 3 2 3 3 4 Legend 1 Upper silencer 2 Upper silencer retaining screw 3 Lower silencer 4 Removable plate 14.2.1 • Drain the filling siphon of the condensate trap (see chapter on “Filling the condensate trap”). Removable plate • Disconnect the outlet pipe located under the condensate trap (2). • Remove the removable plate (4) by pulling towards you. 14.2.
14.
Legend 1 Automatic air vent 2 Pump retaining screw 3 Pump 4 Discharge pipe 5 Flow sensor retaining clip (*) 6 Flow sensor (*) 7 Flow sensor retaining clip (*) 8 Cold water filter retaining clip (*) 9 Cold water filter (*) 10 Filling tap (*) 11 Filling pipe retaining clip (*) 12 Filling pipe retaining clip (*) 13 Flow sensor connector (*) 14 “Foaming” filter retaining clip 15 “Foaming” filter 14.4.
14.
14.5.4 Dismantling the burner unit • Remove the silencer (see chapter on “Maintenance”). • Replace the gasket (2). • Place the burner unit (4) on the heat exchanger (13). • Disconnect the ignition and control electrode connector (7) from the ignition module. • Progressively tighten the 4 nuts (5) diagonally. • Remove the gas pipe (10). • Replace the silencer. • Remove the connectors from the gas valve (9) and the fan. • Connect the gas pipe (10) with a new gasket to the burner unit (4).
15 Remplacement of parts Warning! • Ensure boiler is drained before replacing any hydraulic components, refer to chapter «Draining of the appliance». • Before starting the remplacement of parts, read carefully the chapter “Safety instructions”. 15.
Legend 1 Automatic air vent 2 Pump retaining screw 3 Pump 4 Discharge pipe 5 Flow sensor retaining clip (*) 6 Flow sensor (*) 7 Flow sensor retaining clip (*) 8 Cold water filter retaining clip (*) 9 Cold water filter (*) 10 Filling tap (*) 11 Filling pipe retaining clip (*) 12 Filling pipe retaining clip (*) 13 Flow sensor connector (*) 14 “Foaming” filter retaining clip 15 “Foaming” filter (*) Not required on SB models Pump • Unscrew the cold water inlet joint under the boiler.
• Remove the 3-way valve (24). • Remove the clips (12), (16) and (23). • Fit the new 3-way valve by repeating the operations in reverse. • Remove the pipe (4) from the discharge valve. 15.1.7 • Remove the discharge valve (18). Discharge valve • Fit the new discharge valve by repeating the operations in reverse. • Release the discharge outlet. 15.
Legend 1 Heat exchanger retaining screw 2 Heat exchanger retaining plate 3 Heat exchanger retaining screw 4 Burner 5 Burner unit retaining nuts 6 Ignition and control electrode connector 7 Burner unit 8 Fan retaining screw 9 Gas valve retaining screw 10 Gas valve connector 11 Burner retaining screw 12 Insulator Burner unit Gasket Heat exchanger retaining screw Gas valve Gas pipe Fan Fan connector Heating pipes retaining clips Condensate trap pipe Heat exchanger retaining plate Insulator Heat exchanger The
15.2.5 15.3 Expansion vessel Fan • Remove the gas valve (15) (see previous paragraph). 1 6 2 • Remove the fan connector (18). 5 1 3 • Loosen the 4 screws (8) located on the burner unit (7). • Remove the fan (7). • Screw the new fan to the burner unit (7). • Repeat the above operations in reverse to reassemble the fan.
15.4.2 • After fitting a new expansion vessel, fill and purge the appliance or installation if necessary. Ignition and control electrode • Remove the ignition and control electrode connector (4) from the ignition module (1). 15.4 Ignition module / Ignition and control electrode / Sight glass • Remove the 2 ignition and control electrode (5) retaining screws (6). • Fit the new ignition and control electrode by repeating the operations in reverse. 1 15.4.3 2 Sight glass • Remove the circlip (7).
15.5 Control panel 15.5.1 15.5.
49 Installation and servicing instructions strictly reserved for qualified gas installers
16 Technical data Boiler type C13, C33, C53 Description Gas category Unit Heating Heating output at 80°C/60°C (P) Efficiency calculated on net calorific value at 80/60°C Heating output at 50°C/30°C (P) Efficiency calculated on net calorific value at 50/30°C Minimum calorific flow rate (Q min) Maximum calorific flow rate (Q max) Heating minimum flow rate Maximum heating temperature Minimum heating temperature Expansion vessel, useful capacity Expansion tank initial pressure Maximum system capacity at 75°C
Unit F 18 E SB F 24 E Combustion m3/h 21.8 28.5 Fresh air flow rate (1013 mbar - 0°C) Flue outlet flow rate g/s 7.71 10.1 °C 62 Flue outlet temperature at 80°C/60°C °C 42 47 Flue outlet temperature at 50°C/30°C Values of product outlet (measured on nominal heating output with G20 reference gas): ppm 48 CO mg/kWh 51 CO2 % 9.2 ppm 21.6 NOx balance mg/kWh 38.1 Dimensions : Height mm 742 Width mm 410 Depth mm 370 kg 40.5 Net weight V/Hz 230/50 Supply voltage Maximum absorbed power W 142 144 A 0.63 0.
0020009247-02 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.
