Saunier Duval Themaclassic F30E PLUS Operating manual

11442
Hepworth Heating Ltd.,
Nottingham Road, Belper, Derbyshire. DE56 1JT
General/Sales enquiries:
Tel: [phone] Fax: [phone]
One Contact Local Service
Customer Services:
Tel: [phone]
Fax: [phone]
4000122704-1.05.02
This is a Cat I2H Appliance
To beleftwiththeuser
Instructions for Use
Installation and Servicing
Themaclassic
F30E
Fanned Flue Combination Boiler
G.C. No. 47 - 920 - 36
Guarantee Registration
The instructions consist of three parts, User, Installation and Servicing Instructions, which includes the Guarantee Registration
Card. The instructions are an integral part of the appliance and must, to comply with the current issue of the Gas Safety
(Installation and Use) Regulations, be handed to the user on completion of the installation.
REGISTER YOUR SAUNIER DUVAL APPLIANCE
CALL 0208 247 9857
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 intallation 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 or
manufacture, 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 or record your registration by
telephoning the Heatcall Customer Service number 01773 828100.
Themaclassic
F30E SB
System Boiler
G.C. No. 41 - 920 - 45

2
4000122704-1
Testing and Certification
These boilers are tested and certificated for safety and performance. It is therefore important that no alterations are made to
these boilers, 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 these boilers 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.
Manufacture's instructions supplied. Manufacture's instructions must not be taken as overriding statutory requirements.
Note: The boiler serial number is marked on the label attached to the inside of the drop down door. Refer to the
'Introduction' section for a description of the basic functions of the boiler. The 'Users' section describes how to safely operate the
boiler.
Mandatory warning for CEE countries
Warning: These appliances are designed, approved and inspected to meet the requirements of the 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 your assistance.
CE Mark
These boilers meet the requirements of Statutory Instrument No. 3083 The boiler (Efficiency) Regulations, and therefore are
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 these appliances show 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.
Substances Hazardous to Health
Undersection6oftheHealthandSafetyatWorkAct1974,wearerequiredtoprovideinformationonsubstanceshazardoustohealth.
The adhesives and sealants used in this appliance are cured and give no known hazard in this state.
INSULATION PADS/CERAMIC FIBRE, GLASSYARN, MINERAL WOOL
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.
Spare Parts
REMEMBER, When replacing a part on these appliances, use only spare parts that you can be assured conform to the safety and
performancespecificationthatwerequire. DonotusereconditionedorcopypartsthathavenotbeenclearlyauthorisedbyHepworth
Heating Ltd.
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.
Important Information

34000122704-1
Important Information 2
Introduction 4
Controls and Lighting 4
Programmer Instructions for use F30E Only 6
Draining 8
Safety Devices 8
Servicing and Maintenance 8
Technical Data 1 9
Dimensions 2 10
Heating System Design 3 10
Domestic Hot Water System Design 4 11
Boiler Schematic F30E 5 12
Boiler Schematic F30E SB 5a 13
Boiler Location, Flue and Ventilation 6 14
Fixing Jig Pack 7 15
Piping System Installation 8 16
Boiler Installation 9 17
Horizontal Rear Flue Installation 10 18
Horizontal Telescopic Top Flue Installation 11 21
Horizontal Top Flue Installation 12 22
Electrical Connection 13 24
Commissioning 14 25
Settings 16 27
Routine Cleaning and Inspection 17 27
Fault Finding 18 31
Wiring Diagram F30E 19 38
Wiring Diagram F30E SB 19a 39
Replacement of Parts 20 40
Spare Parts 21 52
CONTENTS DESCRIPTION SECTION PAGE No.
SERVICING
INSTRUCTIONS
INSTALLATION
INSTRUCTIONS
INSTRUCTION
FOR USE
Contents

4
4000122704-1
The Themaclassic F30E boiler is a wall mounted modulating
combination boiler with electronic ignition providing central
heating and instantaneous hot water.
The ThemaclassicF30ESB boilerisawallmountedmodulating
boiler with electronic ignition providing central heating.
These boilers are of the I2H category for use with Natural Gas
(G20) as distributed in the United Kingdom.
These boilers have a fan assisted balanced flue which both
discharges the products of combustion to and draws the
combustion air from the outside of the room.
Theseboilers aresuitable forhorizontal topand rearoutlet flue
connection only and can be fitted with horizontal flue, vertical
flue or twin-pipe flue. Refer to flue options guide for further
information, this is available from your nearest stockist.
The central heating temperature is user adjustable from the
boiler control panel.
Thedomestichotwatertemperatureisuseradjustablefromthe
boiler control panel (F30E Only).
Domestic hot water demand always has priority over heating
demand (F30E Only).
Thepump,expansionvesselandassociatedsafetydevicesare
all fitted within the boiler.
Theseboilerscan beinstalledagainsteither anexternalwallor
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 qualified registered
person in accordance with the relevant requirements of The
Building Regulations, The Water Byelaws, The Building
Standards (Scotland) Regulations and any applicable local
regulations.
Theseinstructionsshouldbecarefullyfollowedforthesafeand
economical use of your boiler.
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
supplyandearthing requirementsshallcomply with thecurrent
IEE Regulations.
Introduction
Connection of the boiler and system controls to the mains
supply must be through a common isolator and must be fused
3A, maximum. This method of connection must be by a fused
doublepoleisolatingswitch,withaminimumcontactseparation
of3mmon both poles. Theswitch shouldbereadilyaccessible
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
usedprovidedthattheyarenotusedinaroomcontainingabath
or shower.
Wiringto theboiler mustbe PVC85oCinsulated cable,not less
than 0.75mm2(24/0.20mm).
Gas safety (Installation and use) Regulations
Inyourinterestsandthatofgassafety,itisthe law thatALLgas
appliances are installed and serviced by a qualified registered
person in accordance with the above regulations.
Gas leak or fault
Ifagasleakorfaultexistsorissuspected,turntheboileroffand
consult the local gas supply company or your installation/
service company.
Air in the heating system
Persistent air in the heating system may indicate leaks in the
systemorcorrosiontakingplace.CallyourInstallation/Servicing
company.
Overheating safety
Intheeventofaproblem,theoverheatingsafetydevicescause
safety shutdown of the boiler. If this happens, call your
Installation/Servicing company.
Boiler controls
Thecontrolpanel,locatedatthelowerfrontoftheboilercasing,
see diagram 1, allows the boiler to be started, shut down,
controlled and monitored during use.
Flue
Do not obstruct the outside terminal of the flue.
Ancillary equipment
A range of flue accessories are available including vertical
flues, twin-pipe flues, bends etc.
For further information contact your supplier.
Controls and lighting
Your Themaclassic F30E or Themaclassic F30E SB boiler
has been factory configured to operate at the heart of an
existing installation. However, because many installations are
speciallydesigned,donothesitatetocontactyourinstallerwho
will be able to ensure that you get the best performance from
your installation, by adjusting the heating circuit's maximum
output or temperature.
Once these settings have been made, you can still adjust the
temperature to suit your needs.
Central heating adjustment
The selector switch enables you to vary the temperature of the
water in the central heating circuit from the minimum setting
(approx. 38˚C) up to the maximum temperature (approx. 87˚C)
setbyyourinstaller. Mostofthetime,themidpositionwillmeet
your needs but the selector should be moved nearer to the
maximum setting in very cold weather when your home is not
reaching the required temperature.
Domestic hot water (F30E Only)
The selector switch can be adjusted from a temperature of
(approx. 34˚C up to 65˚C) or more.
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.

54000122704-1
Controls and Lighting
Diagram 1
11443
1 - ON/OFF switch
2 - Central heating
temperature selector
3 - Domestic hot water
temperature selector
(F30E Only)
4 - Pressure gauge (bar)
and temperature gauge (°C)
5 - Running lamp
illuminated green when
boiler is ON
(fault indicated by a red
flashing light)
6 - Programmer
(F30E Only, optional for
F30E SB)
1. Lighting the boiler :
Make sure that:
• The boiler is connected to the electrical supply.
• The gas service cock is open.
Switch ON ( I )
The running lamp will
illuminate green
2. Stop the boiler :
• Switch to OFF ( 0 ) the electrical
supply is OFF.
• Turn the gas supply OFF at the
gas service cock if the boiler is to
be out of use for a long time.
1
2
3
4
5
6
3. Domestic hot water adjustment
(F30E Only):
• Position ( 0 ): Domestic hot water OFF
• Position ( I ) and ECO: Domestic hot water
between approx. 38˚C and 55˚C
• ECO: Maximum recommended for
constant use
• Between ECO and MAX:
Occasional use for water above
approx. 55˚C
4. Heating temperature adjustment :
• Winter: Set the control knob
between 1 and 5
• Summer: Set the control knob
to
5. If a fault occurs (indicated by red flashing
light) :
• Reset boiler: Switch 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 Heatcall.
(Saunier Duval’s own service organisation) using
the telephone number on the front
cover of this literature.
6. Installation filling (F30E Only):
• If the boiler loses water: the pressure gauge (a)
and fault display (b) will flash. Fill the system by the
filling device (c) at the bottom of the boiler until the
pressure gauge reads 1.5 bar.
• Warning: Take care not to overfill the boiler . At a
pressure of 2.5 bar or above indicating over
pressure, the fault display (b) will flash. The
pressure must be reduced to 1.5 bar by bleeding a
radiator. If the fault continues call your Installation/
Servicing company or Heatcall. (Saunier Duval’s
own service organisation) using the telephone
number on the front cover of this literature.
Diagram 2
➜
(a) (b) (c)
➜
6. Installation filling (F30E SB Only):
• If the boiler loses water: the pressure gauge (a)
and fault display (b) will flash. Fill the system until
the pressure gauge reads 1.5 bar.
11444114451144611447

6
4000122704-1
General description
The Programmer is fitted as standard to the Themaclassic
F30E and is an optional extra for the Themaclassic F30E SB.
The programmer is factory preset which switches the boiler
“ON” and “OFF” up to three times a day as shown below.
Programmer Instructions for Use F30E Only
10205
Diagram 1
1st ON 6.30
1st OFF 8.30
2nd ON 12.00
2nd OFF 12.00
3rd ON 16.30
3rd OFF 22.30
FACTORY PRESET TIMES
NOTE: The 2nd “ON” and “OFF” 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 “advance” feature to manually switch
the boiler “ON” or “OFF” and a holiday feature to able you to
programmetheboilertostartautomaticallywhenreturningfrom
holiday. Detailsonhowtosetthesefeaturearegivenfurtheron
in these instructions.
Setting the Time
Make sure there is an electrical supply to the boiler and the
boiler is switched “ON”.
Place the slide switch to
Press the “RESET” (res) button for a few seconds, using a
pointedobject such asapencil. When releasedthedisplay will
begin to flash, see diagram 1. Using the +and -buttons, set
the display to the correct time in twenty four hour format, for
example, 1300 for 1pm, see diagram 2.
Helpfulhint The+and-buttons are usedto changethe times.
Pressandreleaseforsmall changes, holdthe buttondown and
the time will change quickly.
To use the internal, factory set, programmes place the slide
switch to the 'RUN' position. The display will show the current
time and the “ON” or “OFF” symbol will be displayed according
to whether the programmer has switched the boiler “ON” or
“OFF”.
To Override or Advance the programmer
Toadvance thetimeclock operation,that is, switchthe heating
on when it is off or vice versa, press the “ON/OFF” button. The
programmer will switch the heating on or off and the “ON” or
“OFF” symbol will flash on the display to show that it has been
overridden, see diagram 3.
Note: The boiler will stay “ON” or “OFF”, 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“ON”or“OFF”symbolwillstopflashing. Theoperationofthe
programmer can be overridden in this way at any time.
10302
Diagram 2
10303
Diagram 3
10304
Diagram 4

74000122704-1
Programmer Instructions for Use F30E Only
10305
Diagram 5
10306
Diagram 6
10307
Diagram 7
10308
Diagram 8
ON
To set the programmer ON and OFF times
Note:Theprogrammercanbesettogiveaminimumofoneand
a maximum of three ON and three OFF times.
Place the slide switch to “SET”.
Pressthe“enter” button. Thedisplaywillshow the firstontime,
see diagram 4.
Using the +and -buttons, change the first on time to the time
you require then press the “enter” button twice. This stores the
new time and displays it to confirm it has been stored in the
programmer memory.
Press the “enter“ button again. The display will show the first
OFF time, see diagram 5.
Usingthe+and-buttons,changethefirst“OFF”timetothetime
you require. Press the “enter” button twice. The display will
show the first “ON” time.
Press the “enter” button again. The display will now show the
first “OFF” time you have just entered.
Repeat the above for the remaining “ON” and “OFF” times.
When the “ON” and “OFF” times have been set, place the slide
switch to “RUN”.
Note: Ifall three“ON” and“OFF” timesare notrequired, follow
theaboveinstructionsbutaftersettingthedesiredtimes,setthe
other times to show a series of dashes, using the +and -
buttons, see diagram 6. The series of dashes are between
times 23.59 and 0.00.
Helpful Hint If youget confusedand wish to start again,press
the “Reset” (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
Theprogrammed“ON”and“OFF” timescan be checkedat any
time by moving the slide switch from “RUN” to “SET”.
Successivepressesofthe“enter”buttonwillshowthe“ON”and
“OFF” times.
Alwaysreturntheslideswitchto“RUN”toreturntonormaltimed
working.
To set the 'Holiday' feature
The programmer has a holiday feature which can be set, if
required,tokeepthecentralheating“OFF”foraperiodbetween
onehourandtwentysevendays.Thiscanbeused,forexample,
to keep the central heating “OFF” during a holiday. After the
programmedtimehaselapsed,theboilerwillreturntoitsnormal
programmes and switch on the boiler in time for a return from
holiday.
Placetheslideswitchto“HOL”,theletter“h”willappearonthe
display, see diagram 7.
Using the +and -buttons, set the “Holiday” time required.
Afterthedisplayhasshown“twentythreehours”,the“h”symbol
onthe display willchangeto a“d”.TheHoliday timewillnow be
displayed in days, instead of hours, see diagram 8.
Use the “ON/OFF” button to set the boiler to the required
operation during the “Holiday” period.
Place the slide switch to “RUN”.
After the programmed “Holiday” time, the boiler will return to
normal timed operation.

8
4000122704-1
The boiler incorporates a visual fault display that indicates
certain fault conditions, (red flashing light) should they occur.
Should the boiler fail to operate during Commissioning, the
mostlikely faultisthat thegas supply tothe boilerhasnot been
turnedonorpurgedsufficientlyorthatthereisnopressureinthe
heating system.
General safety devices
Air flow rate safety device
Ifan obstruction, evenpartial,of theflueoccurs, foranyreason
whatsoever, the built in safety system of the boiler will turn the
boilerOFF,theredlightwillflashandthefanwillcontinuetorun.
The boiler will be ready to operate when the fault has been
cleared.
Heating safety valve
CAUTION:Aheatingsafetyvalvewithadischargepipeisfitted
to this boiler.
The valve MUST NOT BE TOUCHED except by a qualified
registeredperson.Ifthevalvedischargesatanytime,switchthe
boiler off and isolate it from the electrical supply. Contact your
installation/service company.
In case of power supply failure
The boiler no longer operates. As soon as power supply is
restored, the boiler will be automatically restarted.
If the gas supply is interrupted
The boiler switches over to safety mode, the red light will flash.
Call a qualified service engineer or Heatcall (Saunier Duval’s
own service organisation) using the telephone number on the
front cover of this literature.
Air in pipes
Important: Acentral heatingsystem cannot operatecorrectly
unlessitisfilledwithwaterandairbledfromthesystem. Ifthese
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. Call a qualified
service engineer or Heatcall (Saunier Duval’s own service
organisation) using the telephone number on the front cover of
this literature.
Frost protection
Theboilerhasabuilt in frostprotection devicethat protects the
boiler from freezing. If the boiler is to be left and there is a risk
of frost, ensure that the gas and electrical supplies are left
connected.The frostprotectiondevice will lightthe boiler when
the temperature of the boiler water falls below 6°C. When the
temperature reaches 16°C, the boiler stops.
Note : This device works irrespective of any room thermostat
setting and will protect the complete heating system.
Servicing and Maintenance
To ensure the continued efficient and safe operation of the
appliance it is recommended that it is checked and serviced as
necessary at regular intervals. The frequency of servicing will
depend upon the particular installation conditions and usage,
but in general once a year should be enough.
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.
Toobtainservice,pleasecallyourinstallerorHeatcall(Saunier
Duval’sownserviceorganisation)usingthetelephonenumber
behind the controls cover door.
Please be advised that the ‘Benchmark’ logbook should be
completed by the installation 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
boilerLogbook. YoucancheckyourinstallerisCORGIregistered
by calling CORGI direct on: 01256 372300.
Cleaning
Theboilercasingcanbecleanedwithadampcloth followedby
a dry cloth to polish.
Do not use abrasive or solvent cleaners.
Boiler casing
CAUTION. Do not remove or adjust the casing in any way, as
incorrectfittingmayresultinfaultyoperation.Ifindoubt,consult
your installation/service company.
Draining
Protection against freezing
The boiler has a built in frost protection programme as long as
the electricity and gas are left switched on.
If the temperature within the appliance falls to 3˚C the burner
and system pump are activated.
When the temperature inside the appliance reaches 10˚C the
burnerwillshutdownandafterashortperiodthepumpwillstop.
This device primarily protects the boiler. Any other exposed
areas of the system should be protected by a seperate frost
thermostat.
Iftheboileristobeoutofuseforanylongperiodsduringsevere
weather conditions, it is recommended that the whole system,
including the boiler, be drained to avoid the risk of freezing.
If in doubt, consult your servicing company.
Draining and filling
Caution:Theboilerisinstalledaspartofasealedsystemwhich
must only be drained and filled by a competent person.
Safety Devices

94000122704-1
0
10
20
30
40
50
60
70
0 200 400 600 800 1000 1200 1400
Flow rate through heating system l/h
Available pressure (kPa) between heating supply and return
1
2
3
4
5
1 Technical Data
Heat input (max) NET Q 32,6 kW
111,231 BTU/H
Heat input (min) NET Q 13,3 kW
45,380 BTU/H
Heat output (max) NET P 29,6 kW
100,995 BTU/H
Heat output (min) NET P 10.8 kW
36,849 BTU/H
Efficiency - Sedbuk D 78,6%
Maximum heating temperature 87°C
Expansion vessel effective capacity 8
Expansion vessel charge pressure 0,5 bar
Maximum system capacity at 75°C156 l
Safety valve, maximum service pressure 3 bar
Ø Burner injector 1,15mm
Inlet pressure 20 mbar
Maxi. Burner pressure 14,2 mbar
Mini. Burner pressure 2,4 mbar
Gas rate maximum 3,45 m3/h
Heating
Heat input (max) NET Q 32,6 kW
111231 BTU/H
Heat input (min) NET Q 13,3 kW
45380 BTU/H
Heat output (max) NET P 29,6 kW
100,995 BTU/H
Heat output (min) NET P 10.8 kW
36,849 BTU/H
Maximum hot water temperature 63 °C
Minimum hot water temperature 38 °C
Specific flow rate (for 30°C temp rise) 14,1 l/min.
Threshold flow rate 1,7 l/min.
Maximum supply pressure 10 bar
Minimum supply pressure 0,5 bar
Hot water F30E Only
Electrical supply 230 V ~ 50Hz
Electrical rating 122 W fused at 3A
Level of protection IPX4D
Fuse rating 1,25mA
Natural Gas (G20)
Electrical
Products outlet diameter 60 mm
Fresh air inlet diameter 100 mm
Combustion products values CO (40 ppm)
CO2 (7,7%)
NOx (81ppm)
Combustion
11357
(10 kPa = 1 m WG)
1
2
3
4
5
Bypass fully shut
Open 1/4 turn
Open 1/2 turn
Open 1 turn
Open 2 turns
Diagram 1.1

10
4000122704-1
• The Themaclassic is for use only 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 1.1). 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 is 500 l/h.
• The system can be fitted with a lockable balancing valve if
necessary in the main flow or return pipes shown as valve 'A'
in diagram 3.1.
• The piping system shall be routed so as to avoid any air
pockets and facilitate permanent venting of the installation.
Bleedfittingsmustbeprovidedateveryhighpointofthesystem
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 3.1.
•Provision shallbemade foradrain valveatthe lowestpointof
the system.
• Where thermostatic radiator valves are fitted, not all radiators
mustbefittedwiththistypeofvalve,andinparticular,wherethe
room thermostat is installed.
•Inthecaseofanexistinginstallation,itisESSENTIALthatthe
system is thoroughly flushed prior to installing the new boiler.
UsingaproprietaryproductsuchasFernoxorSentinel. Contact
the product manufacturers for specific details.
3.1 Bypass
•Theboilerisfittedwithanadjustableautomaticbypass. Ensure
that under no circumstances does the flow rate drop below the
figure specified.
• If the central heating circuit is fitted with thermostatic radiator
valvestoallradiatorsthenanadditionalbypassshouldbefitted
not less than 1.5 metres from the appliance, see diagram 3.1.
3.2 Filling the system F30E
Afilling deviceis fittedto theboiler toinitially fillthe systemand
replace water lost during servicing, see the relevant parts of
diagram 2 controls and lighting and diagram 3.1.
3.3 Filling the system F30E SB
• Provision for filling the system at a low level must be made.
Three methods are shown in diagram 3.2. There must be no
permanentconnectiontothemainswatersupply,eventhrough
a non-return valve.
Note: It is important that fittings used for connection to potable
water comply with the water undertakings requirements.
The Themaclassic is delivered in three
separate packages:
• The boiler
• The fixing jig and hanging bracket
• The flue system
10204
Diagram 2.1
Net lift weight (boiler only)
Themaclassic F30E 37 kg
Themaclassic F30E SB 36 kg
Gross lift weight (boiler and packaging)
Themaclassic F30E 40 kg
Themaclassic F30E SB 39 kg
2 Dimensions
450
798
232
365
3 Heating System Design

11 4000122704-1
4 Domestic Hot Water System Design F30E Only
• Copper tubing or plastic Hep20 may be used for the domestic
hot water system. Unnecessary pressure losses should be
avoided.
• The flow restrictor must be fitted limiting the flow through the
boiler to a maximum of 12 l/min.
• The boiler will operate with a minimum supply pressure of 0,6
bar, but under reduced flow rate.
Best operating comfort 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.
3 Heating System Design
10015
Flow
control valve Drain point
Bypass
valve
Domestic
water
Heating
circuit
Return
Additional
expansion
vessel
(if required)
Boiler
Hot
Cold supply
Filling device
Bypass
(if required)
*
*
BOILER
DRAIN
POINT
'A'
FLOW CONTROL
VALVE
HEATING
CIRCUIT
RETURN
ADDITIONAL
EXPANSION
VESSEL
(if required)
* BYPASS
(if required)
METHOD 1
METHOD 2
METHOD 3
SUPPLY STOP
VALVE
SUPPLY
PIPE
HOSE
UNIONS SERVICING
VALVE
TEMPORARY
HOSE
HEATING
SYSTEM
HEATING
SYSTEM
TEMPORARY
HOSE
HOSE
UNIONS SERVICING
VALVE
SUPPLY
PIPE
SUPPLY STOP
VALVE
DOUBLE CHECK
VALVE ASSEMBLY
HEATING
SYSTEM
SERVICING
VALVE
SUPPLY
STOP VALVE
SUPPLY
PIPE
HOSE
UNIONS DOUBLE CHECK
VALVE ASSEMBLY
OVERFLOW
CISTERN
COMBINED
CHECK VALVE
AND VACUUM
BREAKER
PRESSURE
REDUCING
VALVE
Diagram 3.1
Diagram 3.2
3132
10157
Themaclassic F30E
Themaclassic F30E SB
'A'

12
4000122704-1
5 Boiler Schematic F30E
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.
Diagram 5.1
9720
A - Heating return
B - Cold water inlet
C - Heating flow
D - Domestic hot water outlet
E - Gas
12 - Ignition module.
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

13 4000122704-1
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.
Diagram 5a.1
10294
A-Heating return.
B-Heating flow.
C-Gas.
10 - Pump.
11 - Heating thermistor.
12 - Ignition module.
13 - By-pass.
14 - Gas control valve.
15 - Loss of water sensor.
16 - Heating filter.
17 - Discharge safety valve (3bar).
ABC

14
4000122704-1
If the appliance has to be stored for any length of time before
installation it should be kept in a safe place where it will not be
a hazard to persons or obstruct any access.
6.1 Clearances
The position of the boiler must be such that there is adequate
space for servicing.
The recommended clearances are:
20 mm either side of the boiler.
600 mm at the front of the boiler.
300 mm below the boiler.
25 mm above the flue elbow.
300 mm above the boiler (rear flue only).
Note: The boiler must be mounted on a flat wall which is
sufficiently robust to take its weight when full, that is, 36 kg. If
in doubt, expert advice should be obtained, in the event of the
wall being found not suitable.
Note:Itispermissibletoinstalltheboilerwithsmallerclearances
than those quoted above PROVIDING that adequate
consideration is given for Servicing/Repairs at a later date. If
any doubt exists, contact the Saunier Duval's Technical
Helpline 01773 828400.
The minimum acceptable spacings from the terminal to
obstructions and ventilation openings are shown in diagram
6.1.
The boiler must be installed so that the terminal is exposed to
the external air.
Should any doubt exist as to the permissible position of the
terminal, contact the Saunier Duval's Technical Helpline
01773 828400.
6 Boiler Location, Flue and Ventilation
6.2 Terminal guard
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
aminimumof50mmclearancefromanypartoftheterminaland
to be central over the terminal.
Terminal guard type K3 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 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.
Flue options and accessories.
For detailed information refer to flue options guide. For further
information, 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.
A
A
FGEA
G
G
G
B,C B,C
FF
K
K
K
C
G
LL
UNDER CAR PORT etc.
H,I
JD
F
K
Diagram 6.1
11401
MINIMUM SITING DIMENSIONS FOR THE
POSITIONING OF FLUE TERMINALS MM
ADIRECTLY BELOW, ABOVE OR
HORIZONTALLY TO AN OPENING, AIR
BRICK, OPENING WINDOWS, AIR VENT, OR
ANY OTHER VENTILATION OPENING 300
BBELOW GUTTER, DRAIN/SOIL PIPE 75
CBELOW EAVES 200
DBELOW A BALCONY OR CAR PORT 200
EFROM VERTICAL DRAIN PIPES AND
SOIL PIPES 150
FFROM INTERNAL CORNERS AND
EXTERNAL CORNERS 300
G ABOVE ADJACENT GROUND OR
BALCONY LEVEL 300
HFROM SURFACE OR A BOUNDARY
FACING THE TERMINAL 600
IFACING TERMINALS 1200
JFROM OPENING (DOOR/WINDOW)
IN CAR PORT INTO DWELLING 1200
KVERTICAL FROM A TERMINAL 1500
LHORIZONTALLY FROM A TERMINAL 300

15 4000122704-1
7 Fixing Jig Pack
The fixing jig is made up as follows:
A - Heating return fitting with isolating valve (v).
B (F30E 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 (q).
D (F30E Only) - Domestic hot water outlet.
E - Gas fitting.
Diagram 7.1
AB
C
D
E
COPPER
CONNECTIONS
AND WASHERS
HF
JNOTE:
The fixing jig is
shown assembled
Other components within the fixing jig pack.
F - Hanging bracket
G - wall template
H - copper connections
J - sealing washers and screws
RIGHT
HAND
SUPPORT
BRACKET
LEFT
HAND
SUPPORT
BRACKET
ISOLATING
VALVE
PLATE
SCREW (J)
9716
G
9717
H
v
m
q
1Heating system connections
- Pipe diam. 22mm
2Hot water systemconnections
- Pipe diam. 15mm (F30E Only)
3Gas connection
- Pipe diam. 15mm

16
4000122704-1
8 Piping System Installation
10211
Diagram 8.1
20
min.
440
min.
80 min. Rear top flue outlet
232
8.1 Fixing jig, refer to diagram 7.1
• Note: It is important the hanging bracket and service cock
bracketarefittedtoaflatandtruewallareaforcorrectalignment
withtheboiler. Ifthiscannotbeachieveditisacceptabletopack
out the service cock bracket to obtain the correct alignment.
• Remove the contents of the fixing jig pack.
•Securetheleftandrighthandsupportbracketstotheisolating
valve plate with the securing screws (2 OFF) supplied.
• Connect the copper connections and sealing washers to the
isolating valves.
1Heating system connections - Pipe diam. 22mm
2Hot water system connections - Pipe diam. 15mm (F30E
Only)
3Gas connection - Pipe diam. 15mm
8.2 Cutting the flue hole
•Removethewalltemplate,followthe instructionsgivenon the
wall template.
• Determine the flue application, length and terminal position
beforestarting. NOTE: Ifyouhavechoosenastandardrearflue
application the flue and adapter must be fitted before the boiler
is hung onto the wall.
• 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 Rear or Top Rear flue outlet hole from
template.
• 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.
•Making allowancefor theslopeof theflue, cuthole in external
wall, preferably using a core drill. For installations with internal
and external access use a 105 mm diameter core drill.
For installations with internal access only use a 125 mm
diameter core drill.
Important
When cutting the flue hole and when extending the flue centre
line to a side wall, remember that the flue system must have a
fallofabout 35 mmpermetreof flue DOWNWARDtowardsthe
terminal. There must NEVER be a downward incline towards
the boiler.
• Reposition the wall template over hole in wall.
• Mark the hanging bracket and jig position holes.
•Drill,plugandfixthehangingbrackettothewallusingsuitable
screws (not supplied).
• Check that the hanging bracket is level.
• Drill plug and fix the fixing jig to the wall.
Rear
flue outlet
Side
clearance
F30E shown
8.3 Water connection
Connectthesystempipeworktothecopperconnectionsonthe
fixing jig observing the correct flow and return format as shown
in diagram 3.1. Do not subject the isolating valves to heat.
8.4 Gas connection
•Thesupplyfrom the governedgas metermust beof adequate
size to provide a constant inlet working pressure of 20 mbar (8
in w.g.).
Toavoidlowgaspressureproblems,itisrecommendedthatthe
15 mm gas supply on the boiler is connected to using 22 mm
pipe (as close as possible to the boiler within 1 metre).
• 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
Inyourinterestsandthatofgassafety,itisthe law thatALLgas
appliancesareinstalledandservicedbyacompetentpersonin
accordance with the above regulations.

17 4000122704-1
9 Boiler Installation
Diagram 9.3
10213
Diagram 9.2
10314
SECURING SCREW (2 OFF)
FLUE
BLANKING
PLATE AND
GASKET
9.1 Statutory requirements
The installation of this boiler must be carried out by a qualified
registeredpersoninaccordancewiththerelevantrequirements
of the current issue of:
The Gas Safety (Installation and Use) Regulations
The Building Regulations
The local water company Byelaws
The Building Standards Regulations (Scotland)
The Health and Safety at Work Act
9.2 Sheet metal parts
WARNING.Wheninstalling or servicingthisboiler,careshould
betakenwhenhandlingtheedgesofsheet metal partstoavoid
the possibility of personal injury.
9.3 Installing the boiler
Prior to starting work, the system must be thoroughly flushed
using a propriety cleanser such as Sentinel X300 to eliminate
any foreign matter and contamination e.g. metal filings, solder
particles, oil, grease etc.
Note. Solvent products could cause damage to the system.
Theboilerpackconsistsoftheboilerandadocumentenvelope/
fittings pack which contain, literature, self adhesive wiring
diagram label, magnetic user instruction label, mains voltage
externalcontrolsconnectionplug,guaranteereturnform,sealing
washers,screws,fluerestrictor,coldwaterinletrestrictor(F30E
Only), filling loop extension (F30E Only), discharge safety
valve pipe.
• Stand the boiler upright.
• Remove all packaging from around the boiler.
• 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.
• Remove the self adhesive wiring diagram label from 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.
• Ensure the plastic plugs are removed from water and gas
pipes. NOTE: There will be some spillage of water.
• F30E Only Fit water flow restrictor into cold water inlet
isolating valve, see diagram 20.4.
Important Note. For Rear flueing option ONLY. Remove
thefan,seediagram9.1. Removetheflueoutletblankingplate
andgasketsecured withtwoscrewsfromthebackoftheboiler,
seediagram9.2. Refittheflueoutletblankingplateandgasket
over the top flue outlet and secure with the two screws, see
diagram 9.3.
Important Note. With regards to the manual handling
operations, 1992 regulations, the following operation exceeds
the recommended weight for one man lift.
ImportantNote.Ifyouhavechoosenarearflueapplicationthe
flue and interface must be fitted before the boiler, refer to
Section 10.
•Lifttheboilerupandengageboilerupperpartontothehanging
bracket.
• Fit the washers between the boiler pipes and the inlet and
outletfittingsonthefixing jig andconnect thevarious couplings
between the boiler and jig.
SECURING
SCREW (2
OFF)
FLUE
BLANKING
PLATE AND
GASKET
Diagram 9.1
9741
POWER
SUPPLY
LEADS
EARTH
LEAD FAN RETAINING
BOLTS

18
4000122704-1
Diagram 9.4
9770
DISCHARGE
SAFETY
VALVE (3 bar)
DISCHARGE
SAFETY
VALVE PIPE
Diagram 9.5
10087
FILLING LOOP
EXTENSION
FILLING
DEVICE
9.4 Discharge safety valve, refer to diagram
9.4.
WARNING.Itmustnotdischargeaboveanentranceorwindow
or any type of public access area.
Ashortdischargepipeissuppliedinthefittingspack,whenfitted
to the safety valve it will end below the boiler. The discharge
pipe must be extended using not less than 15 mm o.d. pipe, to
discharge in a visible position outside the building, facing
downward preferably over a drain.
Note: Fit a compression fitting to facilitate service of the
appliance.
Thepipemusthaveacontinuousfallandberoutedtoaposition
sothatanydischargeofwater,possiblyboilingorsteam,cannot
create any danger to persons, damage to property or external
electrical components and wiring. Tighten all pipe connection
joints.
9.5 Filling loop extension F30E Only
Remove the filling loop extension knob from the fittings kit. Fit
to the filling device on/off knob this is a push fit, see diagram
9.5.
9 Boiler Installation
10 Horizontal Rear Flue Installation
The Horizontal Rear flue - kit No A20097 is
suitable for installations that require a flue
length from 300 minimum to 930 maximum. If
longer flueing is required extensions and
bends are available, see note below. If a
shorter flue length is required the flue can be
cut to suit, see diagram 10.2 for minimum flue
length.
Important Note:Additional 1 metre extentions, 90°and 45°
bendsareavailable. Themaximumextendedflueis3.5m. The
useoffluebendsrequiresthefluelengthstobereducedby1m.
for 90°and 0.5m. for 45°.
10.1 Horizontal Rear Flue kit of parts, refer to
diagram 10.1.
10.2 Cutting Rear Flue, refer to diagram 10.2.
Important Notes: After cutting ensure that there are no burrs.
10.3 Installation of Rear Flue assembly
•Fitrubber sealing collar(C) into grooveattheouter endof the
flue assembly (A) and (B), see diagram 10.3.
• Fit flue assembly with attached rubber sealing collar into wall
from the outside with rubber sealing collar to the outside. Pull
assemblyinwardstobringrubbersealingcollarhardupagainst
external wall. The oposite end must exit the inner wall face by
30mm. see diagram 10.4. (1.)
• Fit the plastic internal flange (H) over the flue, push along the
pipeuntilengagedagainstinternalwall,seediagram10.4.(2.)
• Remove the backing from the wrap around self adhesive seal
(E) and carefully fit seal around the back end of the flue and
internal flange thats extending 30mm. from the inner wall face,
see diagram 10.4. (2.)
•Removethebackingfromthewraparoundselfadhesive semi
rounded seal (D) and carefully fit seal around the front end of
the flue thats extending 30mm. from the inner wall face, see
diagram 10.4. (2.)
• Fit the ‘O’ ring (I) into the interface (G), apply a small amount
of silicone grease to the ‘O’ ring when fitting.
•Ease theinterface (G) overthe seals,see diagrams 10.4 (3.)
and 10.5.
• Important: Ensure that the flue if cut has no burrs that could
damagethe‘O’ring. Ifthefluelengthislessthan500mm.fitthe
flue restrictor (a) into the fan outlet, see diagram 10.6.
• Fit the interface sealing gasket (F) to the interface.
Preparing the boiler
•Lifttheboilerupandengageboilerupperpartontothehanging
bracket.
• Fit the washers between the boiler pipes and the inlet and
outletfittingsonthefixing jig andconnect thevarious couplings
between the boiler and jig.
Now the boiler is on the wall, slide forward the interface about
20mm.secure it ontothe backofthe boiler withthetwo screws
previously removed, see diagram 10.7.
• Engage the fan outlet into the interface, refit the fan, see
diagram 10.8.
F30E Only
F30E shown

19 4000122704-1
Diagram 10.2
10310
70mm. plus X = wall thickness 75 min.
plus 30mm. = cutting length
X30mm70mm
Outside
wall face Boiler
mounting
wall face
Pho 087
Diagram 10.3
10313
Diagram 10.1
Horizontal Rear flue kit
B
C
IH
F
G
A
D
The combined kits A20097 include
- Flue duct pipe ....................................................... A
- Air duct pipe ........................................................... B
- External rubber sealing collar .............................. C
- Self adhesive semi rounded seal ........................ D
- Self adhesive seal ................................................... E
-Interface sealing gasket ....................................... F
- Interface ................................................................. G
- Internal flange ....................................................... H
- 'O' rings ...................................................................... I
E
10 Horizontal Rear Flue Installation
INNER
WALL
PLASTIC
INTERNAL
FLANGE
SELF
ADHESIVE
SEAL
INTERFACE
SEAL
FLUE
PIPE
SEAL
INTERFACE
SEMI
ROUNDED
SEAL
RUBBER
SEALING
COLLAR
STANDARD
FLUE
ASSEMBLY
30mm
10311
Diagram 10.4
(1.)
(3.)
(2.)

20
4000122704-1
10 Horizontal Rear Flue Installation
10234
Diagram 10.5
INTERFACE
SELF
ADHESIVE
GASKET
STANDARD
FLUE
ASSEMBLY
INNER
WALL
SELF
ADHESIVE
SEAL SAMPLE
POINT
PLASTIC
INTERNAL
FLANGE
SELF
ADHESIVE
SEMI
ROUND
SEAL
10316
Diagram 10.6
10315
Diagram 10.7
SECURING
SCREW (2
OFF) INTERFACE
SELF
ADHESIVE
GASKET
RESTRICTOR
FAN
Diagram 10.8
10312
POWER SUPPLY LEAD
EARTH
LEAD FAN RETAINING
BOLT (2 OFF)