Saunier duval THEMA F SB 23 E, THEMA F SB 18 E User Manual
Heating and hot water for the professionals
Installation and Servicing Instructions
THEMA F
IN WARRANTY
THIS IS A CAT II2H3+ APPLIANCE
TECHNICAL HELPLINE
01773 828400
01773 828100
1
INSTALLATION AND SERVICING INSTRUCTIONS
THEMA F 23 E - THEMA F SB 18 E - THEMA F SB 23 E
Note!
The boiler serial number is marked on the label attached to the inside of the boiler. Refer to the
'Introduction' section page 3 for a description of the basic functions of the boiler. To safely operate
the boiler, refer to the Users Instructions.
INSTALLATION SECTION
Introduction.................................................. Page 3
Dimensions ............................................................. 3
Technical data ................................................. 4 - 5
Boiler schematic .................................................... 6
Fixing jig .................................................................. 7
Domestic hot water system design..................... 7
Heating system design ......................................... 8
Piping system installation...................................... 8
Boiler location ........................................................ 9
Boiler installation .................................................. 10
Rear outlet flue installation ......................... 11 - 12
Top outlet flue installation .................................. 13
Electrical connection ......................................... 14
Commissioning ............................................. 15 - 16
Safety devices ..................................................... 16
Settings.................................................................. 17
Changing gas type ............................................. 17
SERVICING SECTION
Routine cleaning and inspection .... Page 18 - 19
Replacement of parts ................................. 19 - 24
Microswitch assembly ......................................... 19
Fan ......................................................................... 19
Air pressure switch ............................................... 19
Spark generator................................................... 19
Main printed circuit board ................................. 19
Ignition printed circuit board............................. 20
Pump ..................................................................... 20
Temperature/Pressure gauge............................ 20
Reversing valve assembly .................................. 20
Reversing valve front section ............................ 21
Loss of water switch ............................................ 21
Water valve or diaphragm ................................ 21
Gas valve ............................................................. 22
Modulating coil ................................................... 22
Central heating safety valve ............................. 23
Heat exchanger .................................................. 23
Expansion vessel .................................................. 23
Boiler thermistor ................................................... 23
Overheat thermostat .......................................... 24
Combustion chamber insulation....................... 24
Ignition electrode ................................................ 24
Flame sense electrode ....................................... 24
Burner .................................................................... 24
Burner injectors .................................................... 24
Timeclock ............................................................. 24
Schematic wiring diagram ................................ 25
Fault finding................................................... 26 - 27
Spare parts ........................................................... 27
Mandatory warning notice for CEE countries
UK
WARNING, this appliance is designed, approved and inspected to meet the requirements of the
English market. The identification plate located on the inside of the appliance certifies the origin where the
product was manufactured and the country for which it is intended.
If you see any exception to this rule, please contact your nearest Saunier Duval dealer.
Thank you in advance for you assistance.
2
INTRODUCTION
The THEMA F 23 E boiler is a wall mounted modulating combination boiler with electronic ignition providing central heating and instantaneous domestic hot water.
Both the central heating and domestic hot water
temperature are user adjustable from the boiler
control panel.
Domestic hot water demand always has priority
over heating demand.
The
THEMA F SB 18 E and SB 23 E
mounted modulating boilers with electronic ignition providing central heating only.
The central heating temperature is user adjustable
from the boiler control panel.
The boilers are of the II2H3+ category for use with
Natural Gas (G20) as distributed in the United Kingdom, or with Butane or Propane gas (G30/G31) with
the appropriate conversion kit.
Conversion kits:
Conversion Part No.
Natural Gas (G20) to G30/G31 86161
Boilers burning LPG or similar gases MUST NOT be
fitted in basements or below ground level.
The boiler has a fan assisted balanced flue which
both discharges the products of combustion to and
draws the combustion air from the outside air.
boilers are wall
The boiler is supplied for rear outlet flue connection. Alternatively, the boiler is designed to allow
the flue system to be connected to the top of the
boiler, top outlet flue connection. Refer to the flue
fitting instructions.
Electrical components have been tested to meet
the equivalent requirements of BEAB.
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.
The installation must be carried out by a competent person in accordance with the relevant requirements of The Building Regulations, The Water
Byelaws, The Building Standards (Scotland) Regulations and any applicable local regulations.
Ancillary equipment
A range of flue accessories are available including vertical flues, twin-pipe flues, bends etc.
For further information contact your supplier.
Diagram 1
THEMA F 23 E
DIMENSIONS
Diagram 2
The boiler is delivered in three
separate packages:
- The boiler
- The fixing jig
- The flue system
Net weight: 41 kg
Gross weight : 43 kg
THEMA SB 18 E and SB 23 E
234
802
623
857
410
378
Hab 271a
3
TECHNICAL DATA
THEMA F 23 E
THEMA F SB 18 E
Heating output automatically variable from (kW) 8,9 8,9 8,9
Efficiency (%) 91,5 90,5 91,5
Heating adjustment 38°C to 90°C
Expansion vessel effective capacity (l) 6,5 6,5 6,5
Expansion vessel charge pressure (bar) 0,5 0,5 0,5
Maximum system capacity at 75°C (l) 160 160 160
Safety valve, maximum service pressure (bar) 3 3 3
Products outlet diameter ( mm) 60 60 60
Fresh air inlet diameter (mm) 100 100 100
Hot water output automatically variable from (kW) 8,9 — —
Maximum hot water temperature (°C) 65 — —
Specific flow rate (for 30°C temp rise) ( l/min) 9,6 — —
Threshold flow rate (l/min) 3 — —
Nominal water flow rate (l/min) 12 — —
Maximum supply pressure (bar) 10 — —
Minimum operating pressure (bar) 0,5 — —
Electrical supply (V) 230 230 230
Maximum absorbed power (W 150 150 150
(BTU/H) 30,000 30,000 30,000
to (kW) 23,3 18,5 23,3
(BTU/H) 80,000 63,000 80,000
(BTU/H) 30,000 — —
to (kW) 23,3 — —
(BTU/H) 80,000 — —
THEMA F SB 23 E
Burner injector mm 1,20 1,20 1,20
Inlet pressure mbar 20 20 20
Diaphragme mm — — —
(G20)
Gas rate (maximum) m3/h 2,70 2,17 2,70
Natural Gas
Butane
Propane
Town gas
Gas rate (minimum) m3/h 1,13 1,13 1,13
Burner injector mm 0,73 0,73 0,73
Inlet pressure mbar 29 29 29
Diaphragme mm 4,8 3,2 4,8
(G30)
Gas rate (maximum) kg/h 2,01 1,62 2,01
Gas rate (minimum) kg/h 1,13 1,13 1,13
Burner injector mm 0,73 0,73 0,73
Inlet pressure mbar 37 37 37
Diaphragme mm 4,8 3,2 4,8
(G31)
Gas rate (maximum) kg/h 1,98 1,60 1,98
Gas rate (minimum) kg/h 0,97 0,97 0,97
Burner injector mm 2,4 2,4 2,4
Inlet pressure mbar 8 8 8
Diaphragme mm — — —
(G130)
Gas rate (maximum) m3/h 3,88 3,88
Gas rate (minimum) m3/h 1,63 1,63 1,63
4
TECHNICAL DATA
Pressure table :
(kW) 8,9 10 11 12 13 14 15 16 17 18 19 20 21 22 23,3
(Btu/h) 30387 34142 37557 40971 44385 47799 51214 54628 58042 61456 64871 68285 71699 75113 79552
(kW) 11,9 13,2 14,4 15,7 16,9 18,1 19,2 20,4 21,5 22,7 23,8 24,9 26,0 26,9 28,3
(Btu/h) 40678 45130 49332 53481 57579 61627 65626 69575 73477 77333 81142 84906 88913 91713 96602
GAS
G 20 (mbar) 1,3 2,1 2,6 3,0 3,5 4,0 4,5 5,1 5,7 6,3 6,9 7,6 8,3 8,8 9,8
G 30 (mbar) 3,7 5,3 6,3 7,4 8,6 9,8 11,1 12,5 13,9 15,5 17,0 18,6 20,4 21,7 24,1
G 31 (mbar) 4,0 6,3 7,5 8,8 10,2 11,7 13,3 14,9 17,2 20,1 20,3 22,2 24,4 26,0 28,8
Pump :
The performance of the pump varies according to the pump bypass setting, see diagram 3.
Heat output
Heat input
50
40
30
flow and return
20
10
Available pressure (kPa) between heating
0
(10 kPa = 1 m WG)
Diagram 3
Bypass fully shut
1
Open 1/4 turn
2
1
2
3
4
5
Pom 052
500 1000
Flow rate through heating system (I/h)
Open 1/2 turn
3
4
Open 1 turn
5
Open 2 turns
5
BOILER SCHEMATIC
3-Ignition module
4-Heating temperature adjuster
5-Hot water temperature adjuster
6-Temperature/ressure gauge
8-Expansion vessel
9-Pump
10 - Automatic air vent
11 - Burner
12 - Heat exchanger bleed pipe
13 - Heatexchanger
14 - Gas valve
16 - Heating and hot water thermistor
17 - Ignition electrode
19 - Overheat thermostat
20 - Flame sense electrode
21 - Loss of water pressure switch
22 - Fan
23 - Air pressure switch
24 - Gas cock
THEMA F 23 E
23
13
20
12
11
10
9
22
19
17
16
14
A - Heating return
B - Cold water inlet
C - Heating flow
D - Domestic hot water flow
E - Gas supply
THEMA F SB 18 E - THEMA F SB 23 E
3-Ignition module
4-Heating temperature adjuster
6-Temperature/pressure gauge
8-Expansion vessel
9-Pump
10 - Automatic air vent
11 - Burner
12 - Heat exchanger bleed pipe
13 - Heatexchanger
14 - Gas valve
16 - Heating and hot water thermistor
17 - Ignition electrode
19 - Overheat thermostat
20 - Flame sense electrode
21 - Loss of water pressure switch
22 - Fan
23 - Air pressure switch
24 - Gas cock
21
23
13
12
11
10
8
6
AB C
D
E
3
5
4
24
22
19
17
16
A - Heating return
B - Cold water inlet
C - Heating flow
D - Domestic hot water flow
E - Gas supply
Diagram 4
6
21
9
8
6
ACE
14
3
4
24
Shy 131
FIXING JIG
THEMA F 23 E
From left to right, the fixing jig comprises:
A - Heating return with isolating valve (m).
B - Cold water inlet with isolating valve (p).
C - Heating flow with isolating valve (q),
drain screw (r) and safety valve (s).
D - Domestic hot water out.
E - Gas service cock.
m
2
1
A
B
THEMA F SB 18
THEMA F SB 23 E
From left to right, the fixing jig comprises:
A - Heating return with isolating valve (m).
C - Heating flow with isolating valve (q),
drain screw (r) and safety valve (s).
E - Gas service cock.
4
3
C
D
55
113
p
r
5
113
q
6
E
s
7
23
34
23
55
57,5
25
33
Filters and washers :
1 - Washer
2 - Metal filter
3 - Flow regulator
4 - Plastic filter
5, 6 & 7 - Washers
57,5
110
Pla 105c
m
2
1
A
C
Diagram 5
p
r
5
q
s
7
E
DOMESTIC HOT WATER SYSTEM DESIGN
• Copper tubing or plastic Hep2 O may be used
for the domestic hot water system. Unnecessary
pressure losses should be avoided.
• The boiler may operate with a minimum supply
pressure of 0,3 bar but under a reduced flow rate.
Optimum performance will be obtained from a
supply pressure of 1 bar.
• The flow restrictor must be fitted in the cold water inlet during installation. This limits the flow through
the boiler to a maximum of 12 l/min.
25
115
23
Pla 116b
7
HEATING SYSTEM DESIGN
• The THEMA F boiler is compatible with any type of
installation.
• Heating surfaces may consist of radiators, convectors or fan assisted convectors.
• Pipe sectional areas shall be determined in accordance with normal practices, using the output/pressure curve (diagram 3). 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 is 500 l/h.
• The piping system shall be routed so as to avoid
any air pockets and facilitate permanent venting of
the installation. Bleed fittings shall 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 1
bar (corresponding to a static head of 5 m w.g.) and
allows a maximum system volume of 140 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 6.
• 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 the 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 such as
Fernox or Sentinel. Contact the product manufacturers for specific details.
Filling the system
Provision must be made for filling the system at low
level. The use of a WRC approved filling loop is strongly
recommended, connected as shown in diagram 6.
PIPING SYSTEM INSTALLATION
• Heating system connections - Pipe diam 22 mm
• Hot water system connections - Pipe diam 15 mm
• Gas connection - Pipe diam 22 mm
• Safety valve discharge - Pipe diam 15 mm
Water connection
Connect the water pipes to the fixing jig using the
copper tails supplied, see diagram 5.
Warning: To prevent damage to the isolating cocks,
do not solder joints or fittings with the copper tails
connected.
Connect the system pipework to the boiler observing the correct flow and return format as shown in
diagram 6.
Additional
expansion
vessel
(if required)
Return
Heating
circuit
Diagram 6
Flow
control valve
Boiler
Minimum 22 mm diameter
Bypass
valve
Drain point
Tundish
(supplied)
Filling point
Domestic
water
Hot
Cold supply
Pressure
reducing
valve
(supplied)
Sch 173
Safety valve discharge
WARNING. It must not discharge above an en-
trance or window or any type of public access
area.
Connect the safety valve discharge pipe to the
boiler, the discharge must be extended using not
less than 15 m o.d. pipe, to discharge in a visible
position outside the building, facing downward
preferably over a drain. 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.
Gas connection
• The supply from the governed gas meter must
be of adequate size to provide a constant inlet
working pressure of 20 mbar (8 in w.g.).
To avoid low gas pressure problems, it is recommended that the gas supply is connected using 22
mm pipe.
• On completion, the gas installation must be
tested using the pressure drop method and purged
in accordance with the current issue of BS6891.
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.
8
BOILER LOCATION
Clearances
The position of the boiler must be such that there is
adequate space for servicing.
The recommended clearances are:
40 mm either side of the boiler.
600 mm at the front of the boiler.
300 mm below the boiler.
Fixing jig
The fixing jig comprises three parts:
1) The connecting plate which allows the connection and soundness testing of all the pipework before the boiler is fitted and helps support the weight
of the boiler.
2) The hook which supports the weight of the boiler.
3) The template which ensures the hook and con-
necting plate are correctly fitted relative to one
another.
• Place template on wall in required position, making allowances for the necessary clearances etc.,
see diagram 7.
Note: It is permissible to install the boiler with re-
duced clearances at the bottom and sides of the
boiler PROVIDING that adequate consideration is
given for Servicing/Repairs at a later date. If any
doubt exists, contact the Saunier Duval Technical
Helpline 01773 828400.
• Mark the position of the holes for the hook and
connecting plate.
• Drill, plug and fix the connecting plate and hook
to the wall using suitable screws.
• Check that both the hook and connecting plate
are level.
If the boiler is not installed immediately, protect the
various couplings to prevent any ingress of foreign
materials e.g. plaster, paint etc.
Terminal position
The minimum acceptable spacings from the terminal to obstructions and ventilation openings are
shown in diagram 8.
255 mini
234
29
Diagram 7
60
50
mini
The boiler must be installed so that the terminal is
exposed to the external air.
Note: Under certain weather conditions the flue
may produce a plume of condensation, this is quite
normal.
If the terminal is fitted within 850mm of a plastic or
painted gutter or 450m of painted eaves, an aluminium shield of a minimum length of 750mm
should be fitted to the underside of the gutter or
painted surface.
Should any doubt exist as to the permissible position of the terminal, contact the Saunier Duval
Technical Helpline 01773 828400.
Cupboard or compartment ventilation
The boiler can be fitted in a cupboard or compartment without need for permanent ventilation.
Ins 012a
Minimum dimensions (in mm) for the positioning of flue terminals
A-Under a window ................................................. 300
B-Under an air vent ................................................ 300
C-Under a gutter ....................................................... 75
D-Under a balcony.................................................300
E-From an adjacent window ................................300
F-From an adjacent air vent.................................300
G-From vertical drain pipes or soil pipes ..................75
H-From an external corner of the building .......... 300
I-From an internal corner of the building ........... 300
L-From the ground or from another floor ............ 300
M-Between two terminals vertically ....................1500
N-Between two terminals horizontally .................. 300
Diagram. 8
G
C
N
E
F
M
A
B
D
I
H
L
Ven 060b
9
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