Saunier duval THEMA CLASSIC F30E, THEMA CLASSIC F30E SB Manual

4000123924-2 07.03

Instructions for Use

Installation and Servicing

To b e l e f t w i t h t h e u s e r

Themaclassic

F30E

Fanned Flue Combination Boiler

G.C.No. 47-920-36

Themaclassic

F30E SB

Fanned Flue System Boiler

G.C.No. 41-920-45

Themaclassic

F35E

Fanned Flue Combination Boiler

G.C.No. 47-920-40

Hepworth Heating Ltd., Nottingham Road, Belper, Derbyshire. DE56 1JT

Guarantee Registration

Thank you for installing a new Saunier Duval appliance in your home.

Saunier Duval appliances' are manufactured to the very highest standard so we are pleased to offer our customersÕ 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 the document envelope.

If your guarantee registration return literature is missing you can obtain a copy by telephoning

Saunier Duval Service our Customer Service Company on 00 44 (0)1773 828100.

RECORD YOUR SAUNIER DUVAL APPLIANCE DIRECT BY CALLING

0208 247 9857

Customer Service:

Saunier Duval GB Great Britain:

Tel. [phone]

Fax. [phone]

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:

Tel. [phone]

General and Sales enquiries :

Tel. [phone]

Fax. [phone]

		2
4000123924-2

Contents

CONTENTS	DESCRIPTION	SECTION	PAGE No.
	Important Information		4
	Draining and Filling		5
INSTRUCTION	Appliance Introduction		5
FOR USE	Appliance Safety Devices		6
	Maintenance and Servicing		6
	User Controls and Lighting		7
	Digital Programmer F30E/F35E only		8

INSTALLATION INSTRUCTIONS

Technical Data	1	10
General Information	2	11
Heating System Design	3	12
Domestic Hot Water System Design (F30E/F35E)	4	14
Boiler Schematic F30E/F35E	5	15
Boiler Schematic F30E SB	5a	15
Boiler Location, Flue and Ventilation	6	16
Fixing jig	7	17
Boiler Preparation and System Connections	8	18
Boiler Installation	9	19
Horizontal Rear Flue Installation	10	20
Horizontal Telescopic Top Flue Installation	11	23
Horizontal Top Flue Installation	12	25
Electrical Connection	13	27
Commissioning	14	29
Changing Gas Type	15	32
Bypass Settings	16	32

		Routine Cleaning and Inspection	17	33
	SERVICING	Fault Finding	18	37
	INSTRUCTIONS	Wiring Diagram F30E	19	43
		Wiring Diagram F30E SB	19a	44
		Wiring Diagram F35E	19b	45
		Replacement of Parts	20	46
		Spare Parts	21	58

3	4000123924-2

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.

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 or 1312.

Product/production certified by: Notified body 0049 or 1312.

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.

All external wiring between the appliance and the electrical supply and earthing requirements shall comply with the current IEE Regulations.

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 85oC insulated cable, not less than 0.75mm2 (24/0.20mm).

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.

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 60C.

Any other exposed areas of the system should be protected by a separate frost thermostat.

4000123924-2

4

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.

F30E and F 35E

• If the boiler loses water: the pressure will be indicated (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 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.

F30E SB Only

•If the boiler loses water: the pressure will be indicated (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

9744

BOILER DRAIN

VALVE

(a)

(b)

(c)
	Diagram 1

valve, refer to diagram 1. If the fault continues call the relevant Servicing organisation or Saunier Duval Service using the telephone number on the inside front cover of this literature.

Appliance Introduction

The F30E and F35 E boilers are wall mounted modulating boilers with electronic ignition providing central heating and hot water.

The F30E SB boiler is wall mounted modulating boiler with electronic ignition providing central heating only.

The boiler is of the II2H3+ category for use with Natural Gas (G20) as distributed in the United Kingdom, or Butane (G30), Propane

(G31) with the appropriate conversion kit.

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.

The central heating and domestic hot water (F30E/F35E only) temperatures are user adjustable.

Domestic hot water demand (F30E/F35E only) 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.

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.

In IE reference should be made to the current edition of I.S.813 "Domestic Gas Installations" and the current ETCI rules. 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	4000123924-2

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 ÔBenchmarkÕ 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 Saunier Duval Service 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.

4000123924-2

6

1

6

Programmer (F30E/F35E

Central heating temperature selector Only). minimum setting (approx. 38ûC) up tomaximum setting (approx. 87¡C). It is supplied factory set to 38ûC to 73ûC

5 Boiler ON indicator (fault indicated by light flashing red)

On/Off switch

User Controls and Lighting

Domestic hot water temperature selector (F30E/F35E Only) minimum setting approx. 38ûC up to maximum setting 60ûC.

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. 2

11443

4

Pressure gauge (bar)

and temperature 3 gauge (°C)

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).

¥Switch to ON ( I ) 1

• The boiler ON indicator 5 will illuminate green.

2. Stop the boiler :

¥ Switch to OFF ( 0 ) the electrical supply is OFF. 1

3. Domestic hot water adjustment

(F30E/F35E Only) : 3

¥ Position ( 0 ): Domestic hot water OFF

¥ Position ( I ) and ECO: Domestic hot water between approx. 38ûC and 55ûC

¥ECO: Maximum recommended for constant use

¥Between ECO and maxi:

Occasional use for water above approx. 55ûC

4. Heating temperature adjustment : 2

¥ Winter: Set the control knob between 1 and 5 (Heating On) ¥ Summer: Set the control knob

to (Heating Off)

5. If a fault occurs (indicated by

red flashing light) : 5

¥ Reset boiler: Switch the On/Off switch to ( 0 ), wait for five seconds. Switch 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: 4

• The boiler pressure gauge will show a reading between 1.0 and 1.5 bar.

Refer to Section Draining and Filling if required.

Diagram 2

7	4000123924-2

Programmer Instructions for Use

General description

The Programmer is fitted as standard to the Themaclassic

F30E/F35E.

The programmer is factory preset which switches the boiler ÒONÓ and ÒOFFÓ up to three times a day as shown below.

FACTORY PRESET TIMES

1st	ON	6.30
1st	OFF	8.30
2nd	ON	12.00
2nd	OFF	12.00
3rd	ON	16.30
3rd	OFF	22.30

NOTE: The 2nd ÒONÓ and ÒOFFÓ preset time will not bring the boiler on. In most cases this may not be required but can be programmed by the user if desired.

The programmer has an ÒadvanceÓ feature to manually switch the boiler ÒONÓ or ÒOFFÓ and a holiday feature to able you to programme the boiler to start automatically when returning from holiday. Details on how to set these feature are given further on in these instructions.

Setting the Time

Make sure there is an electrical supply to the boiler and the boiler is switched ÒONÓ.

Place the slide switch to

Press the ÒRESETÓ (res) button for a few seconds, using a pointed object such as a pencil. When released the display will begin to flash, see diagram 3. Using the + and - buttons, set the display to the correct time in twenty four hour format, for example, 1300 for 1pm, see diagram 4.

Helpful hint The + and - buttons are used to change the times. Press and release for small changes, hold the button down and the time will change quickly.

To use the internal, factory set, programmes place the slide switch to the ÒRUNÓ (AUTO) position. The display will show the current time and the ÒONÓ or ÒOFFÓ symbol will be displayed according to whether the programmer has switched the boiler ÒONÓ or ÒOFFÓ.

To Override or Advance the programmer

To advance the time clock operation, that is, switch the heating on when it is off or vice versa, press the ÒON/OFFÓ button. The programmer will switch the heating on or off and the ÒONÓ or ÒOFFÓ symbol will flash on the display to show that it has been

overridden, see diagram 5.

Note: The boiler will stay ÒONÓ or ÒOFFÓ, as selected, until the programmer reaches its next on or off time. From then on, the programmer will switch the boiler on and off according to the internal programme.

When the boiler is again controlled by the internal programme the ÒONÓ or ÒOFFÓ symbol will stop flashing. The operation of the

programmer can be overridden in this way at any time.

10205

Diagram 3

10302

Diagram 4

10303

Diagram 5

10304

Diagram 6

4000123924-2

8

Programmer Instructions for Use

To set the programmer ON and OFF times

Note: The programmer can be set to give a minimum of one and a maximum of three ON and three OFF times.

Place the slide switch to ÒSETÓ (C1).

Press the ÒenterÓ button. The display will show the first on time, see diagram 6.

Using the + and - buttons, change the first on time to the time you require then press the ÒenterÓ button twice. This stores the new time and displays it to confirm it has been stored in the programmer memory.

Press the ÒenterÒ button again. The display will show the first

OFF time, see diagram 7.

Using the + and - buttons, change the first ÒOFFÓ time to the time you require. Press the ÒenterÓ button twice. The display will show the first ÒONÓ time.

Press the ÒenterÓ button again. The display will now show the first ÒOFFÓ time you have just entered.

Repeat the above for the remaining ÒONÓ and ÒOFFÓ times.

ON

When the ÒONÓ and ÒOFFÓ times have been set, place the slide switch to ÒRUNÓ (AUTO).

Note: If all three ÒONÓ and ÒOFFÓ times are not required, follow the above instructions but after setting the desired times, set the other times to show a series of dashes, using the + and - buttons, see diagram 8. The series of dashes are between times 23.59 and 0.00.

Helpful Hint If you get confused and wish to start again, press the ÒResetÓ (res) button and the programmer will revert to the internal factory set programme. You can now reset the current time and start again.

To check the programme “ON” and “OFF” times

The programmed ÒONÓ and ÒOFFÓ times can be checked at any time by moving the slide switch from ÒRUNÓ (AUTO) to ÒSETÓ (C1).

Successive presses of the ÒenterÓ button will show the ÒONÓ and ÒOFFÓ times.

Always return the slide switch to ÒRUNÓ (AUTO) to return to normal timed working.

To set the 'Holiday' feature

The programmer has a holiday feature which can be set, if required, to keep the central heating ÒOFFÓ for a period between one hour and twenty seven days. This can be used, for example, to keep the central heating ÒOFFÓ during a holiday. After the programmed time has elapsed, the boiler will return to its normal programmes and switch on the boiler in time for a return from holiday.

Place the slide switch to Ò HolidayÓ (TIMER), the letter ÒhÓ will appear on the display, see diagram 9.

Using the + and - buttons, set the ÒHolidayÓ time required.

After the display has shown Òtwenty three hoursÓ, the ÒhÓ symbol on the display will change to a ÒdÓ. The Holiday time will now be displayed in days, instead of hours, see diagram 10.

Use the ÒON/OFFÓ button to set the boiler to the required operation during the ÒHolidayÓ period.

Place the slide switch to ÒRUNÓ (AUTO).

After the programmed ÒHolidayÓ time, the boiler will return to normal timed operation.

10305

Diagram 7

10306

Diagram 8

10307

Diagram 9

10308

Diagram 10

9	4000123924-2

1 Technical Data

	Heating		F30E	F30E SB	F35E
	Heat input (max) NET Q	kW	32,6	32,6	37,8
		BTU/H	111,231	111,231	128,973
	Heat input (min) NET Q	kW	13,3	13,3	12
		BTU/H	45,380	45,380	40,944
	Heat output (max) NET P	kW	29,6	29,6	34,8
		BTU/H	100,995	100,995	118,739
	Heat output (min) NET P	kW	10,8	10,8	10,2
		BTU/H	36,849	36,849	34,803
	Efficiency - Sedbuk D	%	79,6	79,6	78,5
	Maximum heating temperature	°C	87	87	87
	Expansion vessel effective capacity	litres	8	8	8
	Expansion vessel charge pressure	bar	0,5	0,5	0,5
	Maximum system capacity at 75°C	litres	156	156	156
	Safety valve, maximum service pressure	bar	3	3	3
	Hot water
	Heat input (max) NET Q	kW	32,6	/	37,8
		BTU/H	111,231	/	128,973
	Heat input (min) NET Q	kW	13,3	/	12
		BTU/H	45,380	/	40,944
	Heat output (max) NET P	kW	29,6	/	34,8
		BTU/H	100,995	/	118,739
	Heat output (min) NET P	kW	10,8	/	10,2
		BTU/H	36,849	/	34,803
	Maximum hot water temperature	°C	60	/	60
	Minimum hot water temperature	°C	38	/	38
	Specific flow rate (for 35°C temp rise)	litres/min.	12,1	/	14,3
	Threshold flow rate	litres/min.	1,7	/	1,7
	Maximum supply pressure	bar	10	/	10
	Minimum supply pressure	bar	0,5	/	0,5
	Combustion
	Products outlet diameter	mm	60	60	60
	Fresh air inlet diameter	mm	100	100	100
	Combustion products values	CO (ppm)	40	40	30
		CO2 (%)	7,6	7,6	6,3
		NOx (ppm)	82	82	65
	Electrical
	Electrical supply	V/Hz	230/50	230/50	230/50
	Electrical rating (fused at 3A)	W	130	130	130
	Level of protection		IPX4D	IPX4D	IPX4D
	Fuse rating	mA	1,25	1,25	1,25
	Natural Gas (G20)
	Ø Burner injector	mm	1,15	1,15	1,25
	Inlet pressure	mbar	20	20	20
	Maxi. Burner pressure	mbar	14,4	14,4	12
	Mini. Burner pressure	mbar	2,45	2,45	1,18
	Gas rate maximum	m3/h	3,45	3,45	4
	Butane Gas (G30)
	Ø Burner injector	mm	0,73	0,73	0,77
	Inlet pressure	mbar	29	29	29
	Maxi. Burner pressure	mbar	25,5	25,5	24,2
	Mini. Burner pressure	mbar	3,73	3,73	2,35
	Gas rate maximum	kg/h	2,57	2,57	2,98
	Propane Gas (G31)
	Ø Burner injector	mm	0,73	0,73	0,77
	Inlet pressure	mbar	37	37	37
	Maxi. Burner pressure	mbar	32,5	32,5	30,9
	Mini. Burner pressure	mbar	4,7	4,7	3
	Gas rate maximum	kg/h	2,53	2,53	2,94

4000123924-2

10

1 Technical Data

The Themaclassic F are delivered in two separate packages:

¥The boiler including hanging bracket complete with isolating valves and fittings.

¥The flue system

Net lift weight (boiler only)

F30E	37 kg
F30E SB	36 kg
F35E	38 kg

Gross lift weight

(boiler, hanging bracket, isolating valves and packaging)

F30E	41,5 kg
F30E SB	40,5 kg
F35E	43,5 kg

11658

365	232

798

450

Diagram 2.1

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.

ManufacturerÕs 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:

ManufacturerÕs 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).

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.

ManufacturerÕs 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.

11	4000123924-2

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.

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.

3 Heating System Design

1 Bypass fully shut

2 Open 1/4 turn

3 Open 1/2 turn

4 Open 1 turn

5 Open 2 turns

		70							11357
	return	60		1
	heating supply and	50		2
pressure (kPa)					3
		40			4
					5
		30
		20
Available	between
		10
		0
		0	200	400	600	800	1000	1200	1400
	(10 kPa = 1 m WG)				Flow rate through heating system l/h

Diagram 3.1

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 "DomesticGasInstallations"andthecurrentBuildingRegulations must be followed.

¥The Themaclassic F is 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.

¥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 156 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.

4000123924-2

12

3 Heating System Design

3.1 Bypass

3.3 Filling the system F30E SB

¥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 a minimum water flow rate.

¥Where a bypass has to be fitted, the bypass must be place at least 1.5 metres away from the appliance, see diagram 3.1.

3.2 Filling the system F30E-F35E

A 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 3.1.

¥ Provision for filling the system must be made. The methods are shown in diagram 3.2. 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
Model		Minimum flow rate
F30E		21.26 litres per minute
F30E SB		21.26 litres per minute
F35E		24,98 litres per minute

This is equal to 20¡C differential at maximum heat input

					9898			SUPPLY	11593
				Additional				PIPE
		Boiler
				expansion		BOILER
Domestic
				vessel
		Filling device
water
				(if required)				CONTROL
waterHot out	supplyCold in
								VALVE
								DOUBLE
								CHECK
						FLOW	RETURN	VALVE
								HOSE
								UNION
	Drain	Bypass		Additional
		valve
	point			* Bypass valve
		*				HEATING		TEMPORARY
				(if required)
	Control					CIRCUIT	CONTROL	HOSE CONNECTION
	valve	'A'					VALVE	UNION
		Flow	Return
	point						POINT
	Drain						DRAIN
		Heating				Method 1
		circuit
F30E - F35E
		Boiler		Additional	10157	BOILER
				expansion
				vessel
				(if required)
							TYPE CA BACKFLOW
							PREVENTION DEVICE
						FLOW	RETURN
		Bypass					CONTROL	CONTROL
							VALVE	VALVE
		valve		Additional				SUPPLY
								PIPE
		'A'*	* Bypass valve
	Control
				(if required)		HEATING
	valve	Flow	Return			CIRCUIT		AIR GAP
	Drain
	point	Heating					DRAIN	TUNDISH
							POINT
		circuit				Method 2
F30E SB				Diagram 3.2				Diagram 3.3
					13			4000123924-2

4 Domestic Hot Water System Design. F30E and F35E 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.

ForIE:ThecurrenteditionofI.S.813"DomesticGasInstallations".

¥Copper tubing or plastic Hep20 may be used for the domestic hot water system. Unnecessary pressure losses should be avoided.

¥Provision shall be made for a drain valve at the lowest points of the system.

¥The flow restrictor, supplied in the document envelope, must be fitted as diagram 7.1, limiting the flow through the boiler to a maximum of 12 litres/min for F 30 E and 14 litres/min for F 35 E.

¥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.

4000123924-2

14

5 Boiler Schematic F30E - F35E

1 - Fan.

2 - Air pressure switch.

3 - Heat exchanger.

4 - Overheat thermostat.

5 - Combustion chamber.

6 - Expansion vessel.

7 - Flame sense electrode.

8 - Burner.

9 - Ignition electrode.

10 - Pump.

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

A - Heating return B - Cold water inlet C - Heating flow

D - Domestic hot water outlet E - Gas

FITTED TO REAR OF APPLIANCE

5a Boiler Schematic F30E SB

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).

A - Heating return.

B - Heating flow.

C - Gas.

FITTED TO REAR OF APPLIANCE

9720

10294

A B C

Diagram 5.1

15	4000123924-2

6 Boiler Location, Flue and Ventilation

6.1 Boiler Location

The recommended clearances are shown in diagram 6.1.

Note: The boiler must be mounted on a flat wall which is sufficiently robust to take its weight when full. If in doubt, expert advice should be obtained.

The minimum acceptable spacings from the terminal to obstructions 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:

TowerfluecomponentsLtd.

Morleyroad

Tonbridge

Kent

TN91RA

6.3 Flue options

There are various flue systems to choose from as follows:

Horizontal rear flue pack.

Horizontal telescopic top flue pack.

Horizontal top flue pack.

Horizontal extended flue pack.

Vertical flue pack.

Twin flue pack.

Extensions, 90¡ and 45¡ bends.

For detailed information refer 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.

300mm
*
50mm
above boiler
(rear flue only)
20mm
*5mm
*Note: It is permissible	600mm
to install the boiler with	*450mm
smaller clearances than

those quoted PROVIDING that consideration is given for Servicing/Repairs.

25mm	11651
elbow
above

20mm *5mm

300mm

Diagram 6.1

11508

MINIMUM SITING DIMENSIONS FOR THE
POSITIONING OF FLUE TERMINALS	MM

HORIZONTAL FLUES

ADIRECTLY BELOW, ABOVE OR HORIZONTALLY TO AN OPENING, AIR BRICK,

	OPENING WINDOWS, AIR VENT, OR ANY
	OTHER VENTILATION OPENING	300
B	BELOW GUTTER, DRAIN/SOIL PIPE	75
C BELOW EAVES		200
D	BELOW A BALCONY OR CAR PORT	200

EFROM VERTICAL DRAIN PIPES AND

SOIL PIPES

150

FFROM INTERNAL/EXTERNAL CORNERS OR TO A BOUNDARY ALONGSIDE THE

TERMINAL

300

GABOVE ADJACENT GROUND OR

BALCONY LEVEL

300

HFROM SURFACE OR A BOUNDARY

FACING THE TERMINAL	600
I FACING TERMINALS	1200

JFROM OPENING (DOOR/WINDOW)

	IN CAR PORT INTO DWELLING	1200
K	VERTICAL FROM A TERMINAL	1500
L	HORIZONTALLY FROM A TERMINAL	300
VERTICAL FLUES
M	FROM ADJACENT WALL TO FLUE	300
N	FROM ANOTHER TERMINAL	600
P	FROM ADJACENT OPENING WINDOW	1000
Q	ABOVE ROOF LEVEL	300

Diagram 6.2

Diagram 6.3

4000123924-2

16

7 Fixing jig

The fixing jig is made up as follows:

A - Heating return fitting with isolating valve.

B (F30E and F35E Only) - Cold water inlet fitting with isolating valve. The cold water inlet restrictor supplied with boiler is fitted when the boiler is installed.

Refer to Section 9.

C - Heating flow fitting with isolating valve.

D (F30E and F35E Only) - Domestic hot water outlet. E - Gas service cock.

Other components within the fixing jig pack. F - Hanging bracket

G - wall template

J - sealing washers and screws

F30E/F35E shown		Diagram 7.1

17	4000123924-2

8Boiler Preparation and System Connections

8.1Cutting 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.

	• Horizontal Rear hole cutting	63
	¥ Mark position of Rear flue outlet hole from template, then
	remove template, before cutting, for use, later. The core drill	145
	used should be 115 mm diameter.

• Top Outlet Side / Rear hole cutting

¥Mark the centre line for the hole on the wall. Extend the horizontal centre line to the side wall if required and mark the vertical centre line of the hole as shown in diagram 8.1.

¥Making allowance for the slope of the flue, cut hole in wall, preferably using a core drill. For installations with internal and externalaccessusea105mmdiametercoredrill. Forinstallations with only internal access use a 125mm diameter core drill.

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.

Note: If the appliance is not to be fitted for some time, cover the hole in the wall.

8.2 Rear Flue - Internal Installation Only

Refer to "Horizontal Rear Flue" instructions, section 10 and prepare the flue system. Insert the flue system into the hole such that it will not interfere with the appliance when lifting into position.

8.3 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.

F30E/F35E shown

Diagram 8.1

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).

8.4 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.

8.5 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".

4000123924-2

18