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
If your guarantee registration return literature is missing you can obtain a copy by telephoning
Saunier Duval Service on 00 44 (0)1773 828100.
RECORD YOUR SAUNIER DUVAL APPLIANCE DIRECT BY CALLING
the document envelope.
0208 247 9857
Customer Service:
Saunier Duval GB GREAT BRITAIN:
Tel. 00 44 (0)1773 828100
Fax. 00 44 (0)1773 828070
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
Saunier Duval IE IRELAND:
Tel. 00 353 (0)14191919
Fax. 00 353 (0)14584806
Hevac
,
Muirfield Drive
Naas Road
Dublin 12
Technical Advice Line:
4000124050-2
Tel. 00 44 (0)1773 828400
General and Sales enquiries :
Tel. 00 44 (0)1773 824141
Fax. 00 44 (0)1773 820569
(0)
2
Page 3
Contents
CONTENTSDESCRIPTIONSECTIONPAGE No.
Important Information4
Draining and Filling5
INSTRUCTION
FOR USE
INSTALLATION
INSTRUCTIONS
Appliance Introduction5
Appliance Safety Devices6
Maintenance and Servicing6
User Controls and Lighting7
Analogue Programmer F24E only8
Digital Programmer Kit F24E only8
Technical Data111
General Information212
Heating System Design313
Domestic Hot Water System Design F24E only415
Boiler Schematic F24E516
Boiler Schematic F18E SB5a16
Boiler Location, flue and ventilation617
Fixing Jig718
Piping System Installation819
Boiler installation920
Horizontal Telescopic Top Flue Installation1021
Horizontal Top Flue Installation10a23
Electrical Connection1125
Commissioning1227
Changing Gas Type1329
Bypass Settings1429
SERVICING
INSTRUCTIONS
Routine Cleaning and Inspection1530
Fault Finding1634
Wiring Diagram F24E1740
Wiring Diagram F18E SB1741
Replacement of Parts1842
Spare Parts1952
3
4000124050-2
Page 4
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.
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.
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.
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.
Control of Substances Hazardous to Health
The adhesives and sealants used in this appliance are cured
and give no known hazard in this state.
Insulation pads / ceramic fibre
These can cause irritation to skin, eyes and the respiratory
tract.
If you have a history of skin complaint you may be susceptible to irritation. High dust levels are usual only if the material
is broken.
Normal handling should not cause discomfort, but follow
normal good hygiene and wash your hands before eating,
drinking or going to the lavatory.
If you do suffer irritation to the eyes or severe irritation to the
skin seek medical 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 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 85
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 6
Any other exposed areas of the system should be protected by
a separate frost thermostat.
o
C insulated cable, not less
0
C.
4000124050-2
4
Page 5
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. Make sure that, if fitted,
the immersion heater in the cylinder is switched off.
If in doubt, consult your servicing company.
F24E Only
• If the boiler loses water: the pressure will be indicated, see
diagram 1 (a) and the boiler ON indicator (b) will flash red
indicating a fault. Fill the system by the filling device (c) at the
bottom of the boiler until the pressure gauge reads 1.0 bar.
A mains inlet 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 seconds. Turn the On/Off switch to ( I ) to reset the
appliance.
F18E SB Only
• If the boiler loses water: the pressure will be indicated, see
diagram 1 (a) and the running lamp (b) will flash red indicating
a fault. Fill the system with the external filling device until the
pressure gauge reads 1.0 bar.
Reset boiler: refer to diagram 2, turn the On/Off switch to (0),
wait for five seconds. Turn the On/Off switch to ( I ) to reset the
appliance.
• Warning:Take care not to overfill the boiler. At a pressure of
2.5 bar or above indicating over pressure, the boiler ON
indicator (b) will flash red indicating a fault. The pressure must
be reduced to 1.0 bar by opening the drain valve, refer to
diagram 1. If the fault continues call the relevant Servicing
BOILER DRAIN
VALVE
(b)
(a)
3.5
bar
75
65
55
45
35
➜
(c)
3
2.5
2
1.5
1
0.5
Diagram 1
organisation or Saunier Duval Service using the telephone
number on the inside front cover of this literature.
9744
Appliance Introduction
The F24E and F18E SB boilers are wall mounted modulating
boilers with electronic ignition providing central heating and
hot water.
The boiler is of the II
Gas (G20) as distributed in the United Kingdom, but can be
converted to use Butane (G30), Propane (G31) with the
appropriate kit.
Thema Classic F24E LPG boilers are factory set for use
on Butane (G30) and Propane (G31) without requirement
for any additional adjustments.
The boiler has a fan assisted balanced flue which both
discharges the products of combustion to and draws the
combustion air from the outside of the room.
This boiler is not suitable for outdoor installation.
This boiler may be installed in any room, although particular
attention is drawn to the installation of a boiler in a room
containing a bath or shower where reference must be made to
the relevant requirements.
Any electrical switch or boiler control utilising mains electricity
should be placed so that it cannot be touched by a person
using the bath or shower.
In GB this is the current I.E.E. WIRING REGULATIONS and
BUILDING REGULATIONS.
category and is for use with natural
2H3+
In IE reference should be made to the current edition of I.S.813
"Domestic Gas Installations" and the current ETCI rules.
The central heating and domestic hot water (F24E only)
temperatures are user adjustable.
F24E Only. Domestic hot water demand always has priority
over heating demand.
The boiler is designed for use as part of a sealed water central
heating system with fully pumped circulation. The pump,
expansion vessel and associated safety devices are all fitted
within the boiler.
The boiler can be installed against either an external wall or on
an adjacent inside wall, that is, the flue system will pass directly
to the rear or to either side to the terminal fitted on the outside
wall face.
These instructions should be carefully followed for the safe and
economical use of your boiler. The 'User Controls and Lighting'
section describes how to safely use the boiler.
Note: The boiler serial number is marked on the data label
attached to the rear of the control box.
Accessories
A range of accessories are available.
For further information contact your supplier.
5
4000124050-2
Page 6
Appliance Safety Devices
Air flow rate safety device
If the flue is obstructed, the built in safety system will turn the
boiler OFF, the fan will continue to run. The boiler will be ready
to operate when the fault has been cleared.
Overheating safety
In the event of the boiler overheating the safety devices will
cause a safety shutdown. If this happens, call your Installation/
Servicing company.
Electrical supply failure
The boiler will not operate without an electrical supply. Normal
operation of the boiler should resume when the electrical
supply is restored.
Reset any central heating system controls, to resume normal
operation.
If the boiler does not resume normal operation turn the mains
reset switch off and on. If the boiler does not resume normal
operation it is advisable to consult your installation / servicing
company.
Frost protection
The appliance has a built in frost protection device that
protects the boiler from freezing. With the gas and electric
supplies ON and irrespective of any room thermostat setting,
the frost protection device will light the boiler when the
temperature of the boiler water falls below 6°C.
When the temperature reaches 16°C, the boiler stops.
Any other exposed areas of the system should be protected by
a separate frost thermostat.
Heating safety valve
CAUTION: A heating safety valve with a discharge pipe is fitted
to this boiler.
The valve MUST NOT BE TOUCHED except by a competant
person. If the valve discharges at any time, switch the boiler off
and isolate it from the electrical supply. Contact your installation/
service company.
Maintenance and Servicing
Cleaning
WARNING: This appliance contains metal parts (components)
and care should be taken when handling and cleaning with
particular regard to edges of sheet metal parts to avoid any
possibility of personal injury.
The boiler casing can be cleaned with a damp cloth, followed
by a dry cloth to polish.
Do not use abrasive or solvent cleaners.
Maintenance and Servicing
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.
Please be advised that the ‘Benchmark’ logbook should be
completed by the engineer on completion of commissioning
and servicing.
All CORGI Registered Installers carry a CORGI ID card, and
have a registration number. Both should be recorded in your
benchmark Logbook. You can check your installer is CORGI
registered by calling CORGI direct on: 00 44 (0) 1256 372300.
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.
4000124050-2
6
Page 7
User Controls and Lighting
Central heating temperature selector
minimum setting (approx. 38˚C) up to
maximum setting (approx. 73°C).
2
4
Pressure gauge (bar)
and temperature
gauge (°C)
3
Domestic hot water temperature selector (F24E 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
(showers, washing up etc.). The maximum setting should be reserved for occasional use
when very hot water is required.
Boiler ON indicator
5
(fault indicated by
light flashing red)
On/Off
switch
6
Programmer
(F24E Only).
11880
1
1. Lighting the boiler :
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 to ON ( I )
• The boiler ON indicator will illuminate green.
1
5
2. Stop the boiler :
• Turn the On/Off switch to OFF ( 0 ) the
electrical supply is OFF.
1
3. Domestic hot water adjustment
(F24E Only) :
• Position ( 0 ): Domestic hot water
OFF
• Position ( I ) and ECO: Domestic
hot water between approx. 38˚C
and 50˚C
• ECO: Maximum recommended
for constant use
• Between ECO and maxi:
Occasional use for water above
approx. 50˚C
3
4. Heating temperature adjustment :
• Winter: Set the control knob
between 1 and 5 (Heating ON)
• Summer: Set the control knob
to (Heating OFF)
2
5. If a fault occurs (indicated by
red flashing light) :
• 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.
6. Pressure gauge:
• The boiler pressure gauge will show a reading
between 1.0 and 1.5 bar.
Refer to Section Draining and Filling if required.
5
4
Diagram 2
7
4000124050-2
Page 8
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 positionI:Heating on continuously
Middle position
Lower position0:Heating off
To override or advance the programmer
:Heating on timed
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
11460
OFF
TIMES
ON TIMES
BLACK TAPPETS
INDICATOR
ARROW
Diagram 4
LCD Display
The LCD incorporates a number of different elements to display
various data and information.
Diagram 3
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.
4000124050-2
8
Page 9
Programmer Instructions for Use
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.
Selecting AM/PM or 24 Hour Time
After pressing reset, the display may show AM (below). The
numbered day symbols will be flashing on and off.
If the display does not show AM, it is in 24 hour time. To change
to AM/PM mode, press and hold the h key and press the ±1h
key once. AM will appear in display.
If display is in AM/PM mode and 24 hour time mode is desired,
press and hold the h key, press the ±1h key once.
Setting the Time
IF THE h AND m KEYS ARE HELD DOWN LONGER THAN 2
SECONDS, THE NUMBERS WILL ADVANCE RAPIDLY.
Press and hold the
(If British Summer Time is in effect, press ±1h first)
1. Press h to advance to the current hour
(while holding down the
2. Press m to advance to the current minute
(while holding down the key)
3. Press Day repeatedly to advance to current day
(while holding down the
key during the following:
key)
key)
Day Key Selections
Press Day KeyDisplay ShowsDays
0 times1 2 3 4 5 6 7Every Day
1 time1 2 3 4 5 6Mon.–Sat.
2 times1 2 3 4 5Mon.–Fri.
3 times 6 7Sat. & Sun.
4 times1Monday
5 times 2Tuesday
6 times 3Wed.
7 times 4Thursday
8 times 5Friday
9 times 6Saturday
10 times 7Sunday
NOTE: If the days are flashing, it indicates the day of the week
was not set when setting the time. The timer cannot be
programmed unless the day of the week is entered.
Manual GMT/BST Time Changeover
Each year, in the Spring, press ±1h to advance the time an
hour. In the Autumn, press ±1h to set back an hour.
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:
Event 1 (ON at 7:00AM Monday through Saturday)
Press
Press h key to 07AM
Press m key once to 00
Press Day key once 1 2 3 4 5 6 is displayed
Press Prog. key to enter
Event 2 (OFF at 5:00PM Monday through Friday)
Press
Press h key to 05PM
Press m key once to 00
Press Day key two times 1 2 3 4 5 is displayed
Press Prog. key to enter
Event 3 (OFF at 7:00PM Saturday)
Press
Press h key to 07PM
Press m key once to 00
Press Day key 9 times until only 6 is displayed
Press Prog. key to enter
Press
IF AN "ON" TIME WAS PROGRAMMED THAT IS EARLIER IN
THE DAY THAN THE CURRENT TIME, PRESS ONCE TO
TURN THE TIMER "ON". (IT DOES NOT "LOOK BACK" TO
DETERMINE IF IT SHOULD BE ON OR OFF AFTER
PROGRAMMING).
IF 24 HOUR TIME CONTROL (SAME SCHEDULE EVERY DAY
OF THE WEEK) IS DESIRED, IGNORE Day KEY.
If an ON or OFF symbol is not entered, the ON symbol will flash,
and programme will not be accepted.
key once. ON symbol appears
key twice. OFF symbol appears
key twice. OFF symbol appears
key to enter Run Mode
9
4000124050-2
Page 10
Programmer Instructions for Use
Event Review
To review the programs at any time, press Prog. key. Events will
appear in the order they were entered with repeated presses of
the Prog. key. After all events have been reviewed, the blank
display will appear to allow entering another event. Another
press of the Prog. key will display the number of free events
available, such as Fr 16 if 4 events have been entered.
Manual Override
While in the Run Mode, pressing the key once will reverse
the current mode; ON to OFF or OFF to ON. The symbol
appears in the display to indicate a temporary override.
At the next scheduled switching time, automatic control
resumes, eliminating the override.
CONTINUOUS OPERATION: While in the Run Mode, press
the
Pressing the
permanently.
To terminate a continuous override, press the
appears in the display.
key twice to turn the output to permanently ON.
symbol appears in display.
key three times will turn the output OFF
symbol appears in display.
key until
Changing an Event
Select the event to be changed with the Prog. key. A new set
of days may be selected with the Day key just as in initial
programming.
Hours and minutes can be changed with the h and m keys.
Press Prog. or
key to store the new programme.
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.
Press key, display will flash for several seconds and then
enter the Run Mode. Using the reset key will delete ALL events,
the time of day, and day of the week.
Troubleshooting
PROBLEM: Days are flashing, pressing any key does nothing
except
SOLUTION: Time of Day and Day of Week have not been set.
See "SETTING THE TIME"
This is the condition after a reset. If the timer is found in this
condition after it has been installed, programmed and operating
for a while, it may indicate that interference has disrupted the
microprocessor causing a loss of programme information.
A second, but very unlikely cause of loss of programme is a
power failure with the backup capacitor low or dead. Check by
disconnecting power and monitoring how long the capacitor
keeps the time of day in the display. Typically, the capacitor will
maintain the time and programmes for 4 days, but not more
than 5 days.
PROBLEM: Time of day was set while holding the
down, but days are still flashing.
SOLUTION: Current day of week was not set while holding
down
PROBLEM: It is 10AM and an ON event for 8AM was entered,
but the output is not ON. Display shows the
SOLUTION: After programming, the timer does not "look back"
to determine if it should be ON. Press the
override) to turn the output ON;
The timer will assume automatic operation at the next
programmed event.
PROBLEM: An event for 8AM Monday through Friday was
entered,
but it will not accept it and
SOLUTION: The ON
of the program. ON or OFF must be selected.
key turns output ON and OFF.
key
the key. See "SETTING THE TIME"
and
symbols.
key (temporary
appears in display.
is flashing.
or OFF was not entered as part
4000124050-2
10
Page 11
1 Technical Data
F24E
Heating
Heat input (max) NET Q26,94 kW
91,200 BTU/H
Heat input (min) NET Q9,91 kW
33,820 BTU/H
Heat output (max) NET P23,6 kW
81,550 BTU/H
Heat output (min) NET P8,9 kW
30,370 BTU/H
Efficiency - Sedbuk D78,3%
Maximum heating temperature87° C
Expansion vessel effective capacity5 litres
Expansion vessel charge pressure0,5 bar
Maximum system capacity at 75°C110 litres
Safety valve,maximum service pressure 3 bar
Hot water
Heat input (max) NET Q26,94 kW
91,200 BTU/H
Heat input (min) NET Q9,91 kW
33,820 BTU/H
Heat output (max) NET P23,6 kW
81,550 BTU/H
Heat output (min) NET P8,9 kW
30,370 BTU/H
Maximum hot water temperature60 °C
Minimum hot water temperature38 °C
Specific flow rate (for 35°C temp rise)9,8 litres/min.
Threshold flow rate1,7 litres/min.
Maximum supply pressure10 bar
Minimum supply pressure0,5 bar
Combustion
Products outlet diameter60 mm
Fresh air inlet diameter100 mm
Combustion products valuesCO (60 ppm)
CO2 (6,7%)
NOx (48ppm)
Electrical
Electrical supply230 V ~ 50Hz
Electrical rating122 W fused at 3A
Level of protectionIPX4D
Fuse rating125mA
F18E SB
Heating
Heat input (max) NET Q21,9 kW
74,722 BTU/H
Heat input (min) NET Q11 kW
37,532 BTU/H
Heat output (max) GROSS P19,8 kW
67,556 BTU/H
Heat output (min) GROSS P9,2 kW
31389 BTU/H
Efficiency - Sedbuk D78,8%
Maximum heating temperature87° C
Expansion vessel effective capacity5 litres
Expansion vessel charge pressure0,5 bar
Maximum system capacity at 75°C110 litres
Safety valve,maximum service pressure 3 bar
Combustion
Products outlet diameter60 mm
Fresh air inlet diameter100 mm
Combustion products valuesCO (30 ppm)
CO2 (5,9%)
NOx (76 ppm)
Electrical
Electrical supply230 V ~ 50Hz
Electrical rating122 W fused at 3A
Level of protectionIPX4D
Fuse rating1,25mA
Natural Gas (G20)
Ø Burner injector1,2 mm
Inlet pressure20 mbar
Maxi. Burner pressure8,82 mbar
Mini. Burner pressure2,25 mbar
Gas rate maximum2,3 m3/h
Natural Gas (G20)
Ø Burner injector1,2 mm
Inlet pressure20 mbar
Maxi. Burner pressure12,2 mbar
Mini. Burner pressure2,25 mbar
Gas rate maximum2,74 m3/h
Gas rate minimum1,16 m3/h
Butane Gas (G30)
Ø Burner injector0,73 mm
Inlet pressure29 mbar
Maxi. Burner pressure23,2 mbar
Mini. Burner pressure4,41 mbar
Gas rate maximum2,01 kg/h
Gas rate minimum0,87 kg/h
Propane Gas (G31)
Ø Burner injector0,73 mm
Inlet pressure37 mbar
Maxi. Burner pressure29,8 mbar
Mini. Burner pressure5,4 mbar
Gas rate maximum2,01 kg/h
Gas rate minimum0,83 kg/h
Butane Gas (G30)
Ø Burner injector0,73 mm
Inlet pressure29 mbar
Maxi. Burner pressure17,65 mbar
Mini. Burner pressure4,41 mbar
Gas rate maximum1,72 kg/h
Gas rate minimum0,87 kg/h
Propane Gas (G31)
Ø Burner injector0,73 mm
Inlet pressure37 mbar
Maxi. Burner pressure22,52mbar
Mini. Burner pressure5,4 mbar
Gas rate maximum1,70 kg/h
Gas rate minimum0,83 kg/h
11
4000124050-2
Page 12
The F24E and F18E SB 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)
F24E34 kg
F18E SB32 kg
Gross lift weight
(boiler, hanging bracket
isolation valves and packaging)
F24E35 k g
F18E SB33 kg
1 Technical Data
9699
2 General Information
IMPORTANT NOTICE.
Where no British Standards exists, materials and equipment
should be fit for their purpose and of suitable quality and
workmanship.
Refer to Manual Handling Operations, 1992 regulations.
The installation of this boiler must be carried out by a competent
person in accordance with the rules in force in the countries of
destination.
Manufacturer’s instructions must not be taken as overriding
statutory requirements.
2.1 Sheet Metal Parts
WARNING: When installing the appliance, care should be taken
to avoid any possibility of personal injury when handling sheet
metal parts.
2.2 Statutory Requirements
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB the installation of the boiler MUST be carried out by a
competent person as discribed in the following regulations:
Manufacturer’s instructions, supplied.
The Gas Safety (Installation and Use) Regulations.
The appropriate Building Regulations, either The Building
Regulations, The Building Regulations (Scotland), The building
Regulations (Nothern Ireland).
Diagram 1.1
The Water Fittings Regulations or Water Bylaws in Scotland.
The Health and Safety at Work Act, Control of Substances
Hazardous to Health (COSHH).
The Current I.E.E. Wiring 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
and installed in accordance with the current edition of I.S. 813
"Domestic Gas Installations", the current Building Regulations
and reference should be made to the current ETCI rules for
electrical installation.
In GB the following Codes of Practice apply:
BS4814, BS5440 Part 1 and 2, BS5449, BS5546 Part 1, BS6700,
BS6798, BS6891 and BS7074 Part 1 and 2, BS7478, BS7593,
BS7671.
In IE: I.S.813, BS5546, BS5449, BS7074, BS7593.
Manufacturer’s notes must not be taken as overriding statutory
requirements.
BSI Certification
This boiler certificated to the current issue of EN 483 for
performance and safety.
It is important that no alteration is made to the boiler, without
permission, in writing, from Hepworth Heating Ltd.
Any alteration that is not approved by Hepworth Heating Ltd.,
could invalidate the warranty and could also infringe the current
issue of the Statutory Requirements.
4000124050-2
12
Page 13
2 General Information
2.3 Gas Supply
The gas installation must be 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".
The supply from the governed meter must be of adequate size
to provide a steady inlet working pressure of 20mbar (8in wg) at
the boiler.
3 Heating System Design
Bypass fully shut
1
Open 1/4 turn
2
Open 1/2 turn
3
Open 1 turn
4
50
40
30
20
Important Notice
If your boiler has been converted to use L.P.G. Propane the
following note applies:
Propane cylinders are under pressure and should never be
stored or used indoors residentially.
They should only be kept outside.
Under no circumstances should L.P.G. Propane cylinders be
fitted or stored in basement areas or boiler houses.
On completion, test the gas installation for soundness using the
pressure drop method and suitable leak detection fluid, purge in
accordance with the above standard.
9700
1
2
3
4
5
10
Open 2 turns
5
The installation of the boiler must comply with the requirements
of the current issue of BS6798, in Ireland, refer also to the
current edition of I.S.813"Domestic Gas Installations".
In GB it is necessary to comply with the Water Supply (Water
Fittings) Regulations 1999 (for Scotland, the Water Byelaws
2000, Scotland).
To comply with the Water Regulations your attention is drawn
to: The Water Regulations guide published by the Water
Regulation Advisory Service (WRAS) which gives full details of
the requirements.
In IE the requirements given in the current edition of I.S.813
"Domestic Gas Installations" and the current Building
Regulations must be followed.
• The F24E and F18E SB are for use with sealed central heating
systems.
• Heating surfaces may consist of radiators, convectors or fan
assisted convectors.
• The safety valve is an integral part of the boiler and it cannot
be adjusted.
• The circulation pump is integral with the boiler.
• Pipe sectional areas shall be determined in accordance with
normal practices, using the output/pressure curve
(diagram 3.1). The distribution system shall be calculated in
accordance with the output requirements of the actual system,
not the maximum output of the boiler. However, provision shall
be made to ensure sufficient flow so that the temperature
difference between the flow and return pipes be less than or
equal to 20°C. The minimum flow rate is shown in table 1.
Available pressure (kPa)
05001000
(10 kPa = 1 m WG)
Flow rate through heating system (I/h)
Diagram 3.1
• The system can be fitted with a lockable control valve if
necessary in the main flow or return pipes shown as valve 'A'
in diagram 3.2.
• The piping system shall be routed so as to avoid any air
pockets 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
depends, amongst other things, on the static head in the cold
condition. The expansion vessel on the boiler is pressurised at
0.5 bar and allows a maximum system volume of 110 litres for
an average temperature of 75°C and a maximum service
pressure of 3 bar. This pressure setting can be modified at
commissioning stage if the static head differs. An additional
expansion vessel can be fitted to the system if required, see
diagram 3.2.
Guidance on vessel sizing is also given in a current issue of a
BS5449 and BS7074 Part 1, for IE refer to the current edition
of I.S.813 "Domestic Gas Installations".
• Provision shall be made for a drain valve at the lowest point
of the system.
• Where thermostatic radiator valves are fitted, not all radiators
must be fitted with this type of valve, and in particular, where
a room thermostat is installed.
• In the case of an existing installation, it is ESSENTIAL that the
system is thoroughly flushed prior to installing the new boiler,
using a proprietary product from Fernox or Sentinel.
13
4000124050-2
Page 14
D
l
d)
D
p
circuit
l
d)
3 Heating System Design
3.1 Bypass
• The boiler is fitted with an adjustable automatic bypass.
Ensure that under 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 aminimum water flow
rate.
• Where a bypass has to be fitted, the bypass must be placed
at least 1.5 metres away from the appliance, see diagram 3.2.
3.2 Filling the system F24E.
• An integral filling device is fitted to the boiler to initially fill the
system and replace water lost during servicing, see the relevant
parts of diagram 2 controls and lighting and diagram 1.
Additiona
expansion
vessel
(if require
omestic
water
Boiler
Filling device
3.3 Filling the system F18E SB.
• Provision for filling the system must be made. The methods
are shown in diagram 3.3. There must be no permanent
connection to the mains water supply, even through a nonreturn valve.
NOTE: It is important that fittings used for connection to
potable water comply with the water undertakings requirements.
TABLE 1. FLOW RATE
ModelMinimum flow rate
F24E16.94 litres per minute
F18E SB13.21 litres per minute
This is equal to 20°C differential at maximum
heat input.
SUPPLY
PIPE
9898
BOILER
CONTROL
VALVE
11593
DOUBLE
CHECK
Hot water out
Cold supply in
Drain
point
Control
valve
Drain
point
Bypass
valve
*
'A'
Flow
Heating
circuit
Additional
Bypass valve
*
(if required)
Return
HEATING
CIRCUIT
Method 1
RETURNFLOW
CONTROL
VALVE
DRAIN
POINT
VALVE
HOSE
UNION
HOSE
UNION
TEMPORARY
CONNECTION
F24E
Boiler
Bypass
valve
Control
valve
'A'
*
Additiona
expansion
vessel
(if require
Additional
Bypass valve
*
(if required)
10157
BOILER
HEATING
CIRCUIT
RETURNFLOW
CONTROL
VALVE
TYPE CA BACKFLOW
PREVENTION DEVICE
CONTROL
VALVE
SUPPLY
AIR GAP
PIPE
rain
oint
F18E SB
4000124050-2
Flow
Heating
Return
Method 2
Diagram 3.2
14
DRAIN
POINT
TUNDISH
Diagram 3.3
Page 15
4 Domestic Hot Water System Design. F24E Only
General - All domestic hot water circuits, connections, fittings
must be in accordance with the relevant standards and water
supply regulations.
For GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulation Guide.
For IE: The current edition of I.S.813 "Domestic Gas
Installations".
• Copper tubing or plastic Hep
hot water system. Unnecessary pressure losses should be
avoided.
• Provision shall be made for a drain valve at the lowest points
of the system.
0 may be used for the domestic
2
• 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 10 litres/min.
• The boiler will operate with a minimum supply pressure of 0.5
bar, at a reduced flow rate.
Best operating performance will be obtained from a supply
pressure of 1 bar or greater.
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.
15
4000124050-2
Page 16
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
5 Boiler Schematic F24E
9899
FITTED TO
REAR OF
APPLIANCE
A - Heating return
B - Cold water inlet
C - Heating flow
D - Domestic hot water outlet
E - Gas
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).
Diagram 5.1
5a Boiler Schematic F18E SB
11450
FITTED TO
REAR OF
APPLIANCE
A - Heating return.
B - Heating flow.
C - Gas.
4000124050-2
ABC
Diagram 5a.1
16
Page 17
6 Boiler Location, Flue and Ventilation
*
m
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
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.
6.4 Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or compartment without
the need for permanent ventilation.
25mm
11652
20mm
5mm
above
elbow
11508
MINIMUM SITING DIMENSIONS FOR THE
POSITIONING OF FLUE TERMINALSMM
HORIZONTAL FLUES
ADIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING, AIR BRICK,
OPENING WINDOWS, AIR VENT, OR ANY
OTHER VENTILATION OPENING300
BBELOW GUTTER, DRAIN/SOIL PIPE75
CBELOW EAVES200
DBELOW A BALCONY OR CAR PORT200
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES150
F FROM INTERNAL/EXTERNAL CORNERS
OR TO A BOUNDARY ALONGSIDE THE
TERMINAL 300
GABOVE ADJACENT GROUND OR
BALCONY LEVEL300
HFROM SURFACE OR A BOUNDARY
FACING THE TERMINAL600
IFACING TERMINALS1200
JFROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING1200
KVERTICAL FROM A TERMINAL1500
LHORIZONTALLY FROM A TERMINAL300
VERTICAL FLUES
M FROM ADJACENT WALL TO FLUE300
NFROM ANOTHER TERMINAL600
PFROM ADJACENT OPENING WINDOW1000
QABOVE ROOF LEVEL300
Diagram 6.2
600mm
*Note: It is permissible to
install the boiler with smaller
clearances than those quoted
PROVIDING that consideration
is given for Servicing/Repairs.
450mm
*
300mm
20mm
5m
*
Diagram 6.1
17
Diagram 6.3
4000124050-2
Page 18
7 Fixing Jig
The fixing jig is made up as follows:
A - Heating return fitting with isolating valve.
B (F24E Only) - Cold water inlet fitting with isolating
valve (m). 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 (F24E Only) - 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
F24E shown
Diagram 7.1
4000124050-2
18
Page 19
8 Piping System Installation
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.
• Rear hole cutting
• Mark correct position of Top Rear flue outlet hole from
template, then remove template, before cutting, for use, later.
• Side hole cutting
• Mark the horizontal centre line for the hole on the rear wall.
Extend the horizontal centre line to the side wall and mark the
vertical centre line of flue hole as shown in diagram 8.1.
IMPORTANT NOTE: When cutting the flue hole and when
extending the flue centre line to a side wall, remember that the
flue system must have a fall of about 35mm per metre of flue
downward towards the terminal. There MUST never be a
downward incline towards the boiler.
• Making allowance for the slope of the flue, cut hole in external
wall, preferably using a core drill. For installations with internal
and external access use a 105mm diameter core drill.
• For installations with internal access only use a 125 mm
diameter core drill.
8.2 Fixing jig, refer to diagram 7.1
• IMPORTANT NOTE: Ensure that the hanging bracket is fitted
to a flat and true wall area for correct alignment with the boiler.
Side Flue - Check the horizontal centre line and reposition the
template if necessary.
Rear Flue - Reposition the wall template over the hole in wall.
• Mark the securing position holes.
• Check that the hanging bracket is level.
• Drill, plug and secure the bracket to the wall, using suitable
screws (not supplied) for the wall type and capable of supporting
the total weight of the appliance (refer to wall template for fixing
points).
8.3 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.
8.4 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".
F24E shown
Diagram 8.1
19
4000124050-2
Page 20
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.
• If fitted ensure the plastic plugs are removed from water
and gas pipes. NOTE: There will be some spillage of water.
• (F24E Only) Fit the cold water inlet restrictor (supplied in the
document envelope) into cold water inlet isolating valve, see
diagram 7.1.
Important 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 hanging bracket,
refer to diagram 7.1.
• Fit the boiler connection pipes and washers between the boiler
and isolating valves, see diagram 7.1.
9.3 Discharge safety valve (diagram 9.1)
The discharge safety valve pipe and sealing washer supplied
in the connections pack, when fitted to the safety valve, will
extend the valve below the boiler. The discharge pipe must be
extended using pipe not less than 15 mm o.d. to discharge in
a visible position outside the building, facing downward
preferably over a drain.
IMPORTANT NOTE: To facilitate servicing of the appliance,
the discharge pipe MUST ONLY be extended using a
compression fitting supplied.
The pipe must have a continuous fall and be routed to a
position so that any discharge of water, possibly boiling or
steam, cannot create any danger to persons, damage to
property or external electrical components and wiring. Tighten
all pipe connection joints.
KNURLED
UNION NUT
finger tighten only
9.4 Filling loop extension knob F24E Only
The filling loop extension knob is supplied in the discharge
safety valve pipe connection pack. Fit to the filling device on/
off knob, this is a push fit, see diagram 9.2.
9.5 Filling loop extension knob F18E SB
The filling loop extension is not required for this boiler, it can be
discarded.
DISCHARGE
SAFETY VALVE
PIPE
Diagram 9.1
10088
FILLING DEVICE
F24E Only
4000124050-2
FILLING LOOP
EXTENSION
Diagram 9.2
20
Page 21
10 Horizontal Telescopic Top Flue Installation
m
R
The Horizontal Telescopic Top Flue, Kit No.
A2004500
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 10.2. is less than 430 'L' Do Not
cut this flue but use the horizontal top flue 86285.
Note: Additional 1 metre extensions, 90° and 45° bends are
available. The maximum extended flue is 3.5m. The use of flue
bends requires the max extended flue lengths to be reduced by
1m. for 90° and 0.5m. for 45°.
10.1 Horizontal Telescopic Top Flue
Kit of parts, refer to diagram 10.1.
10.2 Horizontal telescopic flue system
Rear and side flue lengths and dimensions, see
diagram 10.2.
SIDE FLUE
L
70mm
205mm
11886
65m
Note :
Top of boiler
casing not
front panel
410 mm
Drill, Screw and
Tape (not supplied)
A
*
J
E
D
*
H
C
B
The flue kit A2004500 is 660 mm long and comprises:
-Telescopic flue assembly ..................................... A
- Fixing collar seal .....................................................B
- Fixing collar............................................................. C
- Elbow....................................................................... D
• 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
17mm
STEP 2.
25mm minimum
Air Duct over lap
2 off
Drill, screw 2 off
(G)
and tape the Air Duct
STEP 3.
FLUE LENGTH
(A)
IMPORTANT
"BUTT FIT"
(B)
25mm
(A)
(D)
90mm
centre line
BOILER
FIXING
COLLAR
SEAL
ELBOW
C
L
Flue
11879
(D)
4 off
(G
(A)
E)
XTERNAL RUBBER
SEALING COLLAR
'O' RING
(H)
GASKET
(F)
BOILER
STEP 4.
RESTRICTOR
11874
fitted for flue lengths
less than 0.5m
(E)
(A)
(G)
STEP 5.
(A)
(E)
FIXING
The restrictor must be fitted
to the inside of the fan outlet.
Diagram 10.3
COLLAR
(D)
2 off
(G)
(C)
Diagram 10.4
Diagram 10.4
2 off
(D)
4000124050-2
22
Page 23
10a Horizontal Top Flue Installation
m
R
10a.1 The Horizontal Top flue - kit 86285H
Is 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" of 260mm rear or 300mm side. See diagram 10a.2 for
min. flue lengths.
Note: Additional 1 metre extensions, 90° and 45° bends are
available. The maximum extended flue is 3.5m. The use of flue
bends requires the maximum extended flue lengths to be
reduced by 1m. for 90° and 0.5m. for 45°.
10a.2 Flue systems rear and side, refer to
diagram 10a.1.
10a.3 Flue cutting, refer to diagram 10a.2.
Important: Do not leave any burrs or sharp edges on the cut
ends of the pipes.
SIDE FLUE
L
70mm
205mm
11886
65m
Note :
Top of boiler
casing not
front panel
410 mm
G
F
B
E
A
J
H
The flue kit 86285 comprises:
- Air duct pipe .......................................................... A
10a.4 Installation of horizontal top flue
assembly
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.
• Remove the backing from the self adhesive gasket (H) and
carefully fit gasket to base of elbow (C).
• Fit both ‘O’ rings (J) into the flue elbow (C), one at the inlet,
one at the outlet. By necessity, they are a loose fit, apply a small
amount of suitable lubricant to each ‘O’ ring when fitting.
• Fit rubber sealing collar (F), into groove at the outer end of pipe
(A).
• Insert flue duct pipe (B) into inner end of air duct pipe (A), rotate
flue duct pipe to locate into groove inside air duct pipe.
• Fit air/flue duct pipe assembly through the wall with rubber
sealing collar to the outside.
• Fit internal plastic flange (G) onto air duct pipe (A).
• Fit the fixing collar seal (D) onto the flue duct pipe (B) ensuring
it is the correct way round (the larger diameter onto the pipe).
• Pull air/flue 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).
Carefully push the fixing collar seal onto the elbow ensuring that
the flue duct pipe locates into the flue elbow outlet while taking
care not to tear the ‘O’ ring.
• Fit the fixing collar (E) around the fixing collar seal (D) and
secure with 2 screws provided.
• Push the internal plastic flange (G) along the air duct pipe (A)
until engaged against internal wall.
Outside
all face
centre line
L
90mm
17mm
Air duct cutting length
L minus 90mm
plus 17mm =
cutting length
Flue duct cutting length
Air duct cutting length
+ 95mm = cutting length
Flue
C
L
Air duct
dimension
(cut end)
11643
Flue du
25mm
check
Diagram 10a.3
Horizontal Top flue system
The maximum permissible length (L) is 3.5 m. For flue systems up to 0.5 m length, the flue restrictor must be fitted (a) inside
the fan outlet. For longer flue systems, the restrictor must not be fitted.
For each 90° flue elbow used, (or two 45° elbows) the maximum permissible length (L) must be reduced by 1 metre.
L
FLUE
RESTRICTOR
a
Gasket
65
184
10092
4000124050-2
Diagram 10a.4
24
Page 25
11 Electrical Connection
WARNING: This appliance must be earthed. This appliance
must be wired in accordance with these instructions. Any fault
arising from incorrect wiring cannot be put right under the
terms of the Saunier Duval guarantee.
All system components must be of an approved type.
Electrical components have been tested to meet the equivalent
requirements of the BEAB.
Do not interrupt the mains supply with a time switch or
programmer.
Connection of the whole electrical system and any heating
system controls to the electrical supply must be through a
common isolator.
Isolation should preferably be by a double pole switched fused
spur box having a minimum contact separation of 3mm on
each pole. The fused spur box should be readily accessible
and preferably adjacent to the boiler. It should be 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) Both the plug and socket comply with the current issue of
BS1363.
11.1 Mains Cable
Important: If a replacement supply cable is required it must be
purchased. Part No. S1008600.
11.2 Voltage Free 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.
This boiler will operate continuously on heating, as supplied, if
the wire link (E), fitted between the two terminals of the heating
controls connection, is left in place, see diagram 11.1.
External heating controls e.g. Room thermostat, should be
fitted in accordance with the rules in force and as shown in the
example, diagram 11.2.
RETAINING SLOTS
VOLTAGE FREE
HEATING CONTROLS
CONNECTION
TERMINAL
CONTROLS PANEL REAR
COVER
SECURING SCREW (3)
WIRE LINK(E)
11911
11994
Diagram 11.1
25
Diagram 11.2
4000124050-2
Page 26
z
T
SUPPLY
z
T
SUPPLY
11 Electrical Connection
11.3 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 11.3.
Route the external heating controls cable (not supplied) and
connect to the plug
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 11.1.
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 11.4.
Close and secure rear cover of control panel.
IMPORTANT: Remove the wire link from the voltage free
heating controls connector terminal, see diagram 11.1.
Connect external heating controls as diagram 11.5.
External controls should be fitted in accordance with the rules
in force.
11.4 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.
CONTROL PANEL USER INTERFACE
, see diagram 11.3.
➜
RETAINING LATCHES
➜
9762
F24E only
CONTROLS
INTERFACE PCB
3
2
1
EXTERNAL
FROST
THERMOSTAT
THERMOSTAT
INTERNAL PROGRAMMER
EXTERNAL 230V AC ROOM THERMOSTAT
EXTERNAL 230V AC FROST THERMOSTAT
CONNECT
HEATING CONTROLS
CONNECTION PLUG
EXTERNAL
ROOM
X
DO NOT
MAINS VOL TAGE
PROGRAMMER
TO MAIN PCB
CONNECTOR J15
HEATING CONTROLS
REMOVE LINK
WHEN ANY EXTERNAL
CONTROLS ARE USED
EXTERNAL
JUNCTION BOX
3 AMP FUSE
DOUBLE POLE
ISOLATOR
STRAIN
RELIEF
MAINS
CABLE
EXTERNAL
CONTROLS
CABLE
Diagram 11.4
VOLTAGE FREE
CONNECTION
(ON CONTROLS
BOX COVER)
ON/OFF
SWITCH
LNE
230V~ 50H
PERMANEN
MAINS
11992
The type of plug and
orientation may be
different to that
illustrated but the
wiring should always
be as wiring diagrams
PLUG
4000124050-2
EXTERNAL
CONTROLS
CABLE(MAINS
VOLTAGE)
CONTROLS
INTERFACE PCB
Diagram 11.3
11974
26
F18E SB only
INTERFACE PCB
EXTERNAL
FROST
THERMOSTAT
EXTERNAL
ROOM
THERMOSTAT
EXTERNAL
PROGRAMMER
EXTERNAL PROGRAMMER/CLOCK
EXTERNAL 230V AC ROOM THERMOSTAT
EXTERNAL 230V AC FROST THERMOSTAT
X
DO NOT
CONNECT
MAINS VOL TAGE
HEATING CONTROLS
CONNECTION PLUG
CONTROLS
3
2
1
TO MAIN PCB
CONNECTOR J15
HEATING CONTROLS
REMOVE LINK
WHEN ANY EXTERNAL
CONTROLS ARE USED
EXTERNAL
JUNCTION BOX
3 AMP FUSE
DOUBLE POLE
ISOLATOR
VOLTAGE FREE
CONNECTION
(ON CONTROLS
BOX COVER)
ON/OFF
SWITCH
LNE
230V~ 50H
PERMANEN
MAINS
Diagram 11.5
11993
Page 27
12 Commissioning
Important: The commissioning and first firing of the boiler
must only be done by a competant person.
Gas installation
If conversion from G20 to 30 or 31 is required, refer to section
13.
It is recommended that any air is purged from the supply at the
gas purge point on the gas valve, see diagram 12.1.
Filling the system
The following steps 1 - 8, show how to fill the system.
1.
Make sure that:
• The boiler is connected to the
electrical supply.
• The gas service cock is open.
Turn the switch OFF ( 0 )
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.
BURNER
PRESSURE
POINT
GAS
PURGE
POINT
11898
F24E shown
Diagram 12.1
9796
2.
• Open the three water isolating valves.
HEATING
RETURN
F24E shown
3.
• Undo cap on automatic air vent on top of
pump and leave undone.
COLD
WATER IN
(F24E Only)
Note: Isolating valves are shown in the: OFF position
HEATING
FLOW
9810
4.
• Turn the switch ON ( I )
• F24E Only Open the tap on the filling device
• Fill the system until the pressure indicated on
the display is 1 bar. Close filling device.
DOMESTIC HOT
WATER OUT
(F24E Only)
GAS SERVICE
COCK
9792
➜
NOTE: On initial fill there may be a small discharge
of water from the Reduced Pressure Zone valve
27
➜
4000124050-2
Page 28
12 Commissioning
5.
• Bleed each radiator to remove air, ensure all
bleed screws are re-tightened.
• If necessary repressurise the system, refer to
procedure 4
➜
7.
• Ensure the display indicates a system pressure
of 1.0 bar adjust if necessary.
Adjusting the Central heating output.
The central heating output is factory preset to approx. 15kW.
If a different central heating output is required, proceed as
follows:
To gain access to potentiometer P3, unclip the control box,
see diagram 11.1.
Ins 061a
10217
• Leave cap open on automatic air vent.
6.
8.
• Open various hot water taps to bleed system
The potentiometer P3, is shown in diagram 12.2,to adjust to
the required heating output, insert a small flat edge screw
driver into the arrowed slot in potentiometer P3, turn clockwise
to adjust to the desired setting. Use a manometer to monitor
the burner pressure.
9810
Ins 062a
MANOMETER
maxi
15 kW
P.
max.
mini
SW1
0
DIP
SWITCH
Factory set in
"OFF" position
ON
1
P6
+
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 OPERATIONDIP SWITCH 1
WITH BURNERON
P3
maxi
15 kW
P.
max.
mini
P3
POTENTIOMETER P3
1
ON
POTENTIOMETER P6
P6
P7
USER
INTERFACE
BOARD
Diagram 12.2
pump and maximum heating temperature of your boiler.
12066
WITH HEATINGOFF*
DEMAND
FACTORY SETTING
4000124050-2
* GB/IE PREFFERED SETTING
28
Page 29
12 Commissioning
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.
Completion
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.
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.
13 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 competent
person.
Conversion natural gas (G20) to G30/G31 Part No. A20027.
Setting the step pressure.
Adjusting the step pressure may be a necessary operation after
gas conversion or after changing the gas control valve when a
new replacement part is required.
Proceed as follows:
• Gain access to the gas control valve, connect a pressure
gauge.
14 Bypass Setting
Bypass
The boiler has a built-in bypass, refer to diagram 14.1.
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. in section 3 (turn clockwise
'A' to close the valve ).
• Unclip the control box, see diagram 11.1.
• Run the appliance in heating mode.
• Read the burner pressure setting in heating mode, before the
boiler modulates.
• Adjust the central heating output to the minimum setting by
adjusting potentiometer P3, refer to commissioning section.
• Adjust the potentiometer P6 burner pressure to the desired
value, by inserting a small flat edge screw driver into the
arrowed slot, turn to adjust to the desired setting, see diagram
12.2.
• Return the potentiometer P3 to its initial value.
A
F24E shown
9718
29
Diagram 14.1
4000124050-2
Page 30
15 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.
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 particular installation conditions and usage, but in general
once a year should be enough.
It is the law that any servicing is carried out by a competant
person.
15.1 Products of combustion check
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.
9532
PRODUCTS
SAMPLING
POINT
Diagram 15.1
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).
(a)
HEATING
RETURN
(b)
COLD WATER
INLET (F24E Only)
(f)
BOILER
DRAIN VALVE
HEATING
FLOW
(c)
(d)
DOMESTIC HOT
WATER OUTLET
(F24E Only)
(e)
GAS SERVICE
COCK
F24E shown
4000124050-2
Note: Isolating cocks water and gas are shown in the: OFF position
30
Diagram 15.2
Page 31
15 Routine Cleaning and Inspection
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.
9533
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.
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.
15.10 Fan, refer to diagram 15.8
• Disconnect power supply leads and earth lead from fan.
• Unscrew and remove the two fan retaining bolts.
• Ease the fan down and forwards to remove.
Diagram 15.3
9533
9733
31
9734
F24E shown
Diagram 15.4
4000124050-2
Page 32
15 Routine Cleaning and Inspection
15.11 Heat exchanger, refer to diagram 15.9
• Remove air pressure switch sensing tube from the side of
9811
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
Diagram 15.5
FINISH OF HEAT EXCHANGER.
3.5mm
IGNITION
GAP
3.5 mm
FLAME
SENSING GAP
9812
BURNER
RETAINING
SCREWS
BURNER
GUIDE
3.5mm
Diagram 15.6
9752
9816
9818
EARTH
9741
LEAD
FAN RETAINING
SCREWS
POWER
SUPPLY
LEADS
Diagram 15.8
9742
AIR PRESSURE
SWITCH
SENSING TUBE
4000124050-2
9818
Diagram 15.7
9817
32
HEAT EXCHANGER
FLUE HOOD
9750
Diagram 15.9
Page 33
15 Routine Cleaning and Inspection
15.12 (F24E Only) Domestic water inlet filter,
refer to diagram 15.10
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) diagram 15.2, on cold water inlet and
test the Domestic Hot Water circuit for soundness.
15.13 Central Heating Filter, refer to diagram
15.11
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
retaining clip.
15.14 Sealed chamber cover seal check
• Check the condition of the seal, replace as required.
• To replace remove the old seal, thoroughly clean the casing
surfaces. Fit new seal, it is supplied to the correct length, see
diagram 18.25.
DOMESTIC WATER
INLET FILTER
HOUSING
F24E only
FILTER
CLIP
9822
Diagram 15.10
11934
15.15 Combustion chamber insulation
• Check the condition of the combustion chamber insulation.
If renewing, refer to Section 18.14.
15.16 Flue system
• Check externally to make sure that flue is not blocked
• Inspect flue system to make sure that all fittings are secure.
15.17 Reassembly of parts removed for
servicing
All parts are replaced in reverse order to removal.
RETAINING
CLIP
FILTER
FLAT
11935
33
Diagram 15.11F24E shown
4000124050-2
Page 34
16 Fault Finding
Before trying to operate the boiler make sure that :
• All gas supply cocks are open and that the gas supply has
been purged of air.
• The heating system pressure is at least 1 bar.
• There is a permanent mains supply to the boiler and that the
polarity is correct.
WARNING. Always isolate the boiler from the electrical supply
before carrying out any electrical replacement work.
Always check for gas soundness after any service work.
Should there be any doubt about the voltage supply to any of
the components, it is possible to carry out a simple electrical
test to ensure all is operational in that area.
IMPORTANT: On completion of the fault finding task which has
required the breaking or remaking of the electrical connections,
the continuity, polarity, short circuit and resistance to earth
checks must be repeated using a suitable multimeter.
Overheat thermostat reset button
Refer to Section 18.10 to locate the overheat thermostat
reset button.
Depress the button to reset.
9749
OVERHEAT
THERMOSTAT
RESET
BUTTON
Diagram 16.1
4000124050-2
34
Page 35
16 Fault Finding
TYPE OF FAULTCHECK
No display on control panel• 230V supply
• PCB fuse
• Connection between PCBs
No domestic hot water F24E 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)• Faulty control or interface board (PCB's)
• Water pressure, flashing pressure
• Shortage of air or gas
• Faulty temperature sensor
• Overheating
COMPONENT TESTING DATA
COMPONENTNORMAL MEASURECHECK
Gas control valveUnder demand during ignition sparks:If 0 Volt: the gas control valve
Resistance of coil 11624V dc for 1 to 2 seconds, thenis not faulty.
12Vdc (constant) at the gas controlIf 24 Volts and then 12 Volts
valve electrical connection.but no gas at the burner:
Check if the gas control valve is
stuck. If not, check the
adjustment valve.
Adjustment valveClose the gas inlet:If the valve does not move:
(step motor)Dismantle the step motor (screw notCheck the connections at both
sealed in). Trigger a demand and checkmotor and control board (PCB).
that the valve opens during the ignition.Change the motor. Replace the
control board (PCB).
(F24E Only)
Three way valve.When heating is on:If voltages are different:
Electrical supply to motor230V ac between 1 and 2 of the motor.Connections.
0 between 1 and 3.About 25V ac to 35V ac between 2 and 3.Control board (PCB).
9.6k between 1 and 2.When hot water 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 onAbout 25V ac to 35V ac between 1 and 2.
the motor).
Thrust action of the motor.Unfasten the clip (YES, no risk of waterIf electrical supply is OK.
(remove gas control valveleak), pull out the motor and leave itbut the motor axle does not move
before testing)plugged in.Replace the motor, or replace
When hot water is on: the spindle shouldthe control board (PCB).
pull in. When heating is on : the spindle
should push out.
(F24E Only)
Domestic water flowTo test: Use a new detector and
connect it electrically in place of
the faulty one . Blow through to
simulate a demand for water.
35
4000124050-2
Page 36
16 Fault Finding
FAULT: NO HOT WATER, BUT THE HEATING IS WORKING
?
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
NO
NO
Rectify fault on external controls
Rectify, check the 230V
controls board.
Faulty main PCB.
F24E ONLY
Is the water flow rate greater
NO
than 1.7l/min. (threshold figure).
YES
Is flow detector operating ?
NO
YES
Check the connectors on the
flow sensor and the control board (PCB).
If the fault persists, fit a relplacement
control board (PCB).
Check the cold water inlet filter
for dirt. Is the cold water tap fully open
Check the heat exchanger for scaling.
Change or clean it.
11800
4000124050-2
36
Page 37
F1 or F4 FAULT DISPLAYED
3
F1 FAULT DISPLAYED
.
16 Fault Finding
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?
YES
NO
Check that the gas taps are fully open
Check the gas pressure.
Is the boiler actually designed for the
gas being used.
YES
Clean the gas filter.
Clean the burner.
FAULT: THE BURNER LIGHTS, THEN GOES OUT.
The flame is spreading across the
whole burner, but not being detected.
CHECK
THE MAINS
FAULT NOT FOUND
If the problem persists, change the
control board (PCB).
(flame detection module faulty).
NO
CHECK
THE
PROBE
Change the gas type for the boiler
(gas conversion kit).
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.
1187
37
4000124050-2
Page 38
16 Fault Finding
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
NO
Turn on the gas taps.
Check the wiring.
If the problem persists, change the
control board (PCB).
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
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.
YES
Is the heating temperature on the boiler
set high enough?
YES
4000124050-2
38
Page 39
FAULT: THE FAN RUNS BUT THERE ARE NO SPARKS.
FAULT: THE FAN DOES NOT START.
16 Fault Finding
FAUL T: THE W A TER A T THE T APS IS LUKE-WARM.
d
F24E ONLY
Is the temperature higher if you reduce
the flow through the taps?
YES
Check that the cold water inlet restrictor
is fitted.
Check the rate of flow.
Check burner pressure is correct.
Is there is 230V ac
at fan during demand?
NO
NO
Check the 3-way valve is not passing
into the radiators. (The radiators shoul
stay cold in Summer setting)
11875
Check continuity of fan harness.
YES
Faulty fan, replace.
• CHECK CONTINUITY OF IGNITION (ELECTRODES AND LEADS)
• CHECK POWER SUPPLY FROM PCB TO IGNITION UNIT
CONNECTIONS TO THE AIR PRESSURE SWITCH
Pr
P2
P1
21
LH
YES
Faulty PCB, replace.
3
11876
11877
Air flow switch take-off.
Electrical contacts.
39
4000124050-2
Page 40
17 Wiring Diagram F24E
Y
g
or
w
WATER
PRESSURE
SENSOR
FAN
OVERHEAT
THERMOSTAT
THERMISTOR
CH
bb
bg/y
br
bkbk
g
3
1
ww
p
w
AIR PRESSURE
SWITCH
IGNITION
ELECTRODES
SENSE
ELECTRODE
GAS
CONTROL
PUMP
VALVE
w
pory
g
gn
w
g
THREE-WAY
VALVE
MAINS VOLTAGE HEATING CONTROLS PLUG
230V SWITCHED LIVE FROM OPTIONAL FROST STAT.
230V SWITCHED LIVE FROM HEATING CONTROLS.
IGNITOR
UNIT
CHASSIS
EARTH
PLUG
3
1
g/y
bk
4
2
10224
USER INTERFACE
FLOW
SENSOR
PROGRAMMER
J10
J1
S1
J12
J4
J2
J7
bk- BLACK
w- WHITE
g/y- GREEN/
YELLOW
J15
br - BROWN
b- BLUE
p- PINK
g- GREY
REMOVE VOLTAGE FREE LINK
CONTROLS
INTERFACE
w
J11
b
y
r
gn
J13
VOLTAGE FREE
HEATING CONTROLS
PLUG
LINK
REMOVE THE LINK IF FITTING
VOLTAGE FREE OR 230V
EXTERNAL CONTROLS.
IF THE LINK IS NOT REMOVED
THE BOILER WILL RUN
CONTINUOUSLY.
H2
H5
H1
H4
g/y
br
b
g/y
br
b
b
br
g/y
b
FUSE
125mAT
H3
H8
H6
H7
br
CHASSIS
br
EARTH
b
g/y
KEY
r - RED
or- ORANGE
gn- GREEN
y- YELLOW
ON/OFF
SWITCH
wr
b
br
230V~50Hz
PERMANENT
MAINS SUPPL
FUSED AT 3A
g/y
4000124050-2
40
Page 41
17a Wiring Diagram F18E SB
S
g
or
w
WATER
PRESSURE
SENSOR
FAN
OVERHEAT
THERMOSTAT
THERMISTOR
CH
bb
br
bg/y
bkbk
3
1
ww
AIR PRESSURE
SWITCH
IGNITION
SENSE
ELECTRODES
ELECTRODE
GAS
CONTROL
VALVE
w
PUMP CH
pory
w
g
gn
g
IGNITOR
UNIT
MAINS VOLTAGE HEATING CONTROLS PLUG
230V SWITCHED LIVE FROM OPTIONAL FROST STAT.
230V SWITCHED LIVE FROM HEATING CONTROLS.
CHASSIS
EARTH
3
1
g/y
bk
10298
PLUG
4
2
NOT
USED
USER INTERFACE
J1
S1
J12
J4
J2
J7
bk- BLACK
w- WHITE
g/y- GREEN/
YELLOW
J15
br - BROWN
b- BLUE
p- PINK
g- GREY
J11
KEY
CONTROLS
INTERFACE
J13J10
r - RED
or- ORANGE
gn- GREEN
y- YELLOW
REMOVE VOLTAGE FREE LINK
VOLTAGE FREE
HEATING CONTROLS
PLUG
REMOVE THE LINK IF FITTING
VOLTAGE FREE OR 230V
EXTERNAL CONTROLS.
IF THE LINK IS NOT REMOVED
THE BOILER WILL RUN
CONTINUOUSLY.
H2
H5
H1
H4
H3
H8
FUSE
125mAT
H6
H7
wr
ON/OFF
SWITCH
LINK
g/y
br
b
b
br
g/y
b
br
CHASSI
br
EARTH
b
g/y
g/y
b
br
230V~50Hz
PERMANENT
MAINS SUPPLY
FUSED AT 3A
41
4000124050-2
Page 42
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).
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 the isolating valves (a), (b) and (c) .
• Open the boiler drain valve (f).
(a)
HEATING
RETURN
F24E shown
(b)
COLD WATER
INLET (F24E Only)
Note: Isolating cocks water and gas are shown in the: OFF position
(f)
BOILER
DRAIN VALVE
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".
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.
(c)
HEATING
FLOW
CENTRAL HEATING
THERMISTOR
• 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.
(d)
DOMESTIC HOT
WATER OUTLET
(F24E Only)
(e)
GAS SERVICE
COCK
Diagram 18.1
F24E shown
Diagram 18.2
9550
4000124050-2
42
Page 43
18 Replacement of Parts
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.
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.
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 tosection 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.
9646
RETAINING
CLIPS
AIR PRESSURE
SWITCH
ELECTRICAL
CONNECTORS
SENSING
TUBE
Diagram 18.3
COLD WATER INLET
RESTRICTOR
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.
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.
18.7 Burner, refer to Section 15.9.
Before starting refer to the front of Section 18 Important
information.
• Remove the front panel, refer to Section 15.3.
F24E Only
• 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
18.8 Burner injectors, refer to diagram 18.5.
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.
• 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.
• Remove and replace injectors as required.
Note: The injectors may be cleaned, remove injectors inspect
and clean. Do not use a wire or sharp implement.
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.
43
4000124050-2
Page 44
18 Replacement of Parts
18.9 Burner injector assembly, refer to diagram
18.6.
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.
• 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.
• Undo the gas supply union nut from under the sealed chamber.
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.
18.10 Overheat thermostat
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 overheat thermostat on heating flow pipe on right hand
side of boiler, see part of diagram 18.7.
• 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.
BURNER INJECTOR
BAR
9820
SENSE ELECTRODE
ASSEMBLY
9813
CLIP
9749
PIPE
SECURING
CLIP 2 OFF
9819a
Diagram 18.5
GROMMET
GAS SUPPLY
PIPE
IGNITION ELECTRODE
ASSEMBLY
9813
Diagram 18.6
OVERHEAT
THERMOSTAT
RESET
BUTTON
ELECTRICAL
LEADS
9750
18.11 Ignition electrode
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.
• 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.
• Remove the left hand side panel, refer to Section 15.6.
• Undo and remove screw securing electrode assembly to the
burner injector assembly, see diagram 18.6.
• Disconnect the electrical connections at the ignition unit, seediagram 18.22. Note the routing of the cables.
4000124050-2
HEAT EXCHANGER
Diagram 18.7
18.12 Flame sense electrode
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.
• Remove the sealed chamber cover, refer to Section 15.5.
• Remove the combustion chamber cover, refer to Section 15.7.
• Remove burner, refer to Section 15.9.
• Remove the right hand side panel, refer to Section 15.6.
• Undo and remove screw securing sense assembly to the
burner injector assembly, see diagram 18.6.
• Disconnect the electrical connection from the inline connector,
Note the routing of the cable.
44
Page 45
18 Replacement of Parts
18.13 Heat exchanger, refer to diagram 18.7.
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.
• Drain down central heating water circuit of the boiler only,
refer to relevant part of diagram 18.1.
• Remove the fan, refer to Section 15.10.
• Remove air pressure switch sensing tube from the side of the
flue hood, see diagram 15.9.
• Release both side panels, refer to section 15.6.
• 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.
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.
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
9824a
CONTROL
BOARD
COVER
10021
F24E shown
45
PCB (CONTROL BOARD)
➜
Diagram 18.8
10001
➜
Diagram 18.9
4000124050-2
Page 46
➜
18 Replacement of Parts
230V CONTROLS
➜
BOARD
➜
CONTROL PANEL
F24E shown
USER INTERFACE
BOARD
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.
9762
9757
➜
➜
PROGRAMMER
➜
MAINS
SWITCH
Diagram 18.10
HEX HEAD
SCREW
(4 OFF)
PUMP HEAD
PUMP
ELECTRICAL
CONNECTION
BOX
10019
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.
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.
18.19 (F24E Only) Analogue programmer, 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.
F24E shown
• 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.
Diagram 18.11
18.20 Central heating pump head, refer to
diagram 18.11.
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.
• Drain down central heating water circuit of the boiler only,
refer to relevant part of diagram 18.1.
Note: it is not necessary to drain down the entire heating
system to carry out this work.
• For ease of access if required remove the right hand side
panel, refer to Section 15.6.
• Undo four head fixing screws and remove pump head.
• Gain access to the pump electrical connection box and
remove cover.
• Disconnect pump cable from pump (avoid straining cables).
• Connect electrical connection to replacement pump head.
• Fit replacement pump head.
4000124050-2
46
Page 47
18 Replacement of Parts
18.21 (F24E Only) Filling system tap, refer to
diagram 18.12.
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.
• Drain down the hotwater circuit, refer to relevant part ofdiagram 18.1.
• 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.
18.22 (F24E Only) Reduced pressure zone
valve (RPZ), refer to diagram 18.12.
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.
• Drain down the boiler only, refer to relevant part of diagram
18.1.
• Pull out slotted metal clip securing pipe to RPZ.
• Pull out slotted metal clip securing RPZ into housing, remove
RPZ.
➜
➜
➜
➜
F24E only
SYSTEM WATER PRESSURE
SENSOR
➜
WATER FLOW
SENSOR
9765
Diagram 18.14
BYPASS VALVE
9758
18.23 Boiler drain point, refer to diagram
18.13.
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.
• Drain down the boiler only, refer to relevant part of diagram
18.1.
Pull out slotted metal clip securing boiler drain valve into
housing, remove boiler drain valve.
18.24 (F24E Only) Water flow sensor, refer to
diagram 18.14.
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.
Drain down the hotwater circuit, refer to relevant part of
Section 18.1.
• 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.
F24E shown
CAP
F24E shown
➜
➜
Diagram 18.15
9760
AIR
VENT
Diagram 18.16
47
4000124050-2
Page 48
18 Replacement of Parts
18.25 System water pressure sensor, refer to
diagram 18.15.
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.
Drain down the boiler, refer to relevant part of Section 18.1.
• Remove electrical connections from water pressure sensor.
• Pull off slotted metal clip and remove water pressure sensor.
Please ensure that the new "O" ring and clip supplied are fitted.
18.26 Bypass valve, refer to diagram 14.1.
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.
Drain down the boiler, refer to relevant part of Section 18.1.
• Remove the ignition unit, refer to Section 18.33.
Pull out slotted metal clip, ease out bypass valve from bypass
valve housing.
➜
F24E shown
➜
GAS CONTROL
VALVE
11591
➜
9781
➜
9782
Diagram 18.17
18.27 Automatic air vent, refer to diagram
18.16.
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.
• Drain down the boiler only, refer to relevant part of diagram
18.1.
• Unscrew to remove automatic air vent.
• After fitting replacement automatic air vent ensure the cap is
open.
18.28 Gas Control valve, refer to diagram
18.17.
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.
• Disconnect gas supply pipes union nuts at the gas control
valve.
• Disconnect supply pipe union nut at the burner injector bar.
• Remove the locking nut and brass washer from underside of
gas control valve.
• Ease gas control valve forwards and disconnect electrical
connections to gas control valve.
• Withdraw gas control valve assembly.
Note: Use the new washers supplied with the gas control valve.
• Fit gas valve restrictor to replacement gas control value.
• Fit replacement gas control valve.
Check the Min. gas pressure and if it requires adjusting, refer
to Section 13 Changing Gas Type.
10018
➜
➜
➜
➜
F24E shown
GAS CONTROL
VALVE
STEPPER
MOTOR
➜
Diagram 18.18
11585
PRESSURE
RELIEF
VALVE
Diagram 18.19
4000124050-2
48
Page 49
18 Replacement of Parts
18.29 Gas control valve stepper motor, refer to
diagram 18.18
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.
• Remove the gas control valve, refer to Section 18.28.
• Disconnect the electrical connection from stepper motor.
• Remove the two screws securing stepper motor to the gas
control valve.
• Fit replacement gas control valve stepper motor.
• Note: Take care not to damage the 'O' ring.
18.30 Discharge safety valve, refer to diagram
18.19.
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 discharge pipe union nut.
• Pull out slotted metal clip from valve body and remove valve.
9768
➜
THREE WAY
VALVE HEAD
9769
➜
18.31 (F24E Only) Three-way valve head, refer
to diagram 18.20.
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.
• Remove gas control valve, refer to Section 18.28. (It will not
be necessary to remove the gas control electrical cables).
• Remove electrical plug from valve head.
• Pull out slotted metal clip from valve body and remove valve
head from body.
• Fit replacement valve head.
Note :
1) When refitting clip, ensure that letters YES are as shown.
2) It is not necessary to drain boiler to carry out this work.
F24E only
F24E only
➜
➜
➜
Diagram 18.20
10017
THREE WAY
VALVE/ BYPASS
HOUSING
THREE WAY
VALVE
➜
ACTUATOR
Diagram 18.21
9767
9785
49
IGNITION
UNIT
➜
Diagram 18.22
4000124050-2
Page 50
18 Replacement of Parts
18.32 (F24E Only) Three-way valve actuator,
refer to diagram 18.21.
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.
• Drain down the boiler only, refer to relevant part of diagram
18.1.
• Remove the gas control valve, refer to Section 18.28.
• Remove 3-way valve head, refer to Section 18.31.
• Remove the three way valve actuator.
18.33 Ignition unit, refer to diagram 18.22.
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.
• For ease of access remove the left hand side panel, refer to
Section 15.6.
• Disconnect electrical connections.
• Remove ignition unit securing screw.
• Pull upwards to release and remove the ignition unit from the
retaining slot.
➜
➜
DOMESTIC HOT WATER PLATE TO
PLATE HEAT EXCHANGER
➜
11596
9775
➜
18.34 (F24E Only) Domestic hot water plate to
plate heat exchanger
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.
• Drain down the boiler and hotwater circuit ,refer to relevantparts of diagram 18.1.
• Unclip the central heating thermistor.
• Unscrew the heating flow pipe union nut, swing pipe forwards.
• Remove the gas supply pipe between the gas control valve
and injector bar, see diagram 18.23.
• Disconnect the union connection from the expansion vessel.
• Supporting domestic hot water plate to plate heat exchanger,
unscrew and remove two screws securing it onto pump
mounting and 3-way valve/bypass housing.
• Remove plate to plate heat exchanger from boiler.
• Fit replacement plate to plate heat exchanger.
Note: Plate to plate heat exchanger mounting screws are offset
to ensure correct fitting.
F24E only
➜
9773
EXPANSION VESSEL
Diagram 18.23
9771
9772
4000124050-2
F24E shown
50
Diagram 18.24
Page 51
18 Replacement of Parts
18.35 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.
Replacing the expansion vessel
Before starting refer to the front of Section 18 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 15.3.
• Lower the control panel, refer to Section 15.4.
• Drain down the boiler only ,refer to relevant parts ofdiagram 18.1.
• Disconnect the flue system.
• Disconnect the fixing jig connection pipes at the boiler.
• Disconnect the pressure relief valve discharge pipe.
• Disconnect the mains cable and any external controls cables.
• Lift up to remove the boiler from the wall.
• Remove sealed chamber cover, refer to Section 15.4.
• Remove the right hand side panel, refer to Section 15.6.
• From the rear of the boiler, unclip wiring harness retaining wire.
• Undo pipe coupling on expansion vessel.
• Unscrew and remove expansion vessel bracket retaining screw.
• Slide expansion vessel to the left and forward to remove.
Note: Check that expansion vessel pressure is correct, see
‘Section 1 Technical Data’.
9873
➜
F24E shown
FRONT
PANEL
EXPANSION
VESSEL
9872
9871
Diagram 18.24
11436
18.36 Sealed chamber cover seal, refer to
diagram 18.25
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 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.
SEAL
SEALED
CHAMBER
COVER
Diagram 18.25
51
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Page 52
19 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
No.DescriptionPart No.G.C. No.
1Central heating thermistorS57398•••••••
2FanS10088•••••••
3Air pressure switchS10089•••••••
4F24E only Domestic water flow sensorS57202•••••••
5Printed circuit board - MainS10082•••••••
6Pump headS10052•••••••
7System water pressure sensorS57205•••••••
8Gas control valve (G20)S10045•••••••
9Gas control valve (G30)S10046•••••••
10Discharge safety valveS10067•••••••
11Overheat thermostatS10080•••••••
12Ignition electrodeS10038•••••••
13Flame sense electrodeS10037•••••••
14230V controls boardS10091•••••••
15User interface PCBS10081•••••••
16Stepper motor (G20)S57434•••••••
17Stepper motor (G30)S57435•••••••
18Ignition unitS57427•••••••
19F24E only Three way valve headS57206•••••••
20Three way valve actuatorS10064•••••••
21Heat exchangerS10030•••••••
22BurnerS10042•••••••
Because of our constant endeavour for improvement details may vary slightly from those in the instructions.
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52
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