Saunier Duval ThemaClassicPlus F 24 E User manual

MEMO

2
Descriptions ThemaClassicPlus F
1-Air pressure switch (Pr) (Themafast F)
2-Fan (Ex) (Themafast F)
3-Main heat exchanger
4-Overheat safety thermostat (K4)
5-Combustion chamber
6-Expansion vessel
7-Flame sense electrode (FL)
8-Burner
9-Ignition electrode (FA)
10 - Pump (P)
11 - Heating/DHW thermistor NTC (CTN2)
12 - Ignition module (AL)
13 - By-pass
14 - Gas mechanism (EV)
15 - Loss of water sensor (Cp)
16 - DHW heat exchanger
17 - Three way valve (V3V)
18 - Domestic water flow sensor (Db)
19 - Domestic water filter
20 - Filling system
21 - Heating safety valve 3 bar
22 - Boiler drain valve
23 - Central heating filter
24 - Micro-accumulation sensor (CTN3)
25 - Warm resistor
26 - Micro-accu.
27 - DHW safety valve 10 bar
A-Heating return
B-Cold water
C-Heating flow
D-Hot water outlet
E-Gas
AB C DE
1
13
15
20
21
11 12
6
3
2
4 5
16
18
14
22
17
10
19
23
24
27
79
8
25
26

3
Wiring diagram ThemaClassicPlus F
+18V
rpm S
rpm
Ex
EVS
Cp
H7.2 H7.1
H7.2 H7.1
+5V
S
+18V
s
Db
INTERFACE
CTN 2
Pr K4
FA
V
3
V
N
CH
SAN
Opt.
Vm
M
AL
FL
P
1
2
3
Th. 2 input
(Frost stat)
Th. 1 input = Thermostat 1 input (Room stat)
Th. 2 input = Thermostat 2 input (Frost stat)
Voltage free
heatings controls
connection plug
Mains voltage external
controls connection plug
Th. 1 input
(Room stat)
4
5
6
7
8
9
10
11
12
34
56
7
8
9
10
1
2
3
4
5
6
12
13
2
1
2
1
1
3
1
3
1
2
H2
H8
H5
H4
H1
H3
H6
2
1
H7
J1
J13
J12
J4
J2
J7
213456
R
CTN 3
L
M/A
L
N
F1
230 Vac
Opt.
12
34
TRA
CTN 4
J15 J11
342114
5
23
2.0
bar
45
°C
1
3
5
8
7
6
1
2
3
4
5
6
7
8
9
10
11
12
13
b
S1
2
1
SW
230V control
board
connected to 230V control board
M/A - On/Off switch
P-Pump
V3V - 3-way valve
AL - Ignition unit
FA - Ignition electrodes
FL - Ionisation rod
INTERFACE - Interface board
b-Voltage free roomstat
CTN2- (NTC2) thermistance chauffage
CTN3- (NTC3) thermistance micro-accu.
Cp - Water pressure sensor
Pr - Pressostat sécurité air
SW - not used
EVS - Gas mechanism safety valve
K4 - Overheating safety device
Vm - Gas mechanism modulatingvalve
(step motor)
Db - Hot water flow
Ex - Modulating fan
R-Micro-accu. warm resistance
rpm - module vitesse extracteur
Accessories
Opt - Option board
CTN4- (NTC4) Capteur de sonde extérieure
S1 - flue valve (to remove if no valve)

4
Characteristics ThemaClassicPlus
Gas characteristics F 24 E
F 30 E
Natural gas G 20 (20 mbar)
Ø diaphragm (mm) 5,65 6,9
Ø burner injector (mm) 1,2 1,2
Maximum gas output (m3/h) 2,74 3,45
Gas flow rate adjusted from factory (m3 /h)* 1,7 2,2
Minimum gas output (m3 /h) 1,16 1,32
Maximum burner pressure (mbar) 12,25 13,33
Gas pressure for factory setting (mbar)* 5,1 3,5
Minimum burner pressure (mbar) 2,35 2,15
Butane G 30 (29 mbar)
Ø diaphragm (mm) 4,8 6,1
Ø burner injector (mm) 0,73 0,73
Maximum gas output (kg /h) 2,03 2,57
Gas flow rate adjusted from factory (kg /h)* 1,3 1,6
Minimum gas output (kg /h) 0,87 0,985
Maximum burner pressure (mbar) 23,23 25,5
Gas pressure for factory setting (mbar)* 9,6 6,7
Minimum burner pressure (mbar) 4,5 3,73
Propane G 31 (37 mbar)
Ø diaphragm (mm) 4,8 6,1
Ø burner injector (mm) 0,73 0,73
Maximum gas output (kg /h) 2,01 2,532
Gas flow rate adjusted from factory (kg /h)* 1,3 1,6
Minimum gas output (kg /h) 0,85 0,97
Maximum burner pressure (mbar) 29,8 32,5
Gas pressure for factory setting (mbar)* 12,3 8,5
Minimum burner pressure (mbar) 5,7 4,7
Number of injectors 14 17
Hot water characteristics F 24 E
F 30 E
Maximum temperature of domestic hot water (°C) 38 to 65 38 to 65
Ignition flow rate (l/mn) 1,7 1,7
Specific output (∆ of 30°C) (l/mn) 11,3 14,1
Calibration pressure of DHW safety valve (bar) 10 10
Minimum hot water pressure (bar) 0,5 0,5
Max pressure of hot water supply (bar) 10 10
* In the factory the heating output is adjusted at 15 kW for F24 and 20 kW for F30.
Heating characteristics F 24 E
F 30 E
Heating control (modulating) (kW)
Heating outlet temperature (C°)
Adjustable heating power (kW)
Minimum heating flow (l/h) 500 500
Max pressure in service of expansion cylinder (bar) 3 3
Max working pressure of boiler when heating (bar) 2,9 2,9
Capacity of expansion (l) 6,5 8
Maximum capacity of installation (l) 125 156
Pre-expansion pressure of expansion cylinder (bar) 0,5 0,5
Calibration pressure of heating circuit safety valve (bar) 3 3
modulating
38 to 50 or 38 to 73 or 38 to
80 or 38 to 87°C
ajustable from mini to maxi.

5
User interface ThemaClassicPlus
How to display data menu ?
The display has a hidden menu which is accessible via a code.
This code can be used by two levels of professionals :
- The installer who needs to configure the device for commissioning
- The after sales service which may be required to change parts,
and consequently reconfigure them for the device.
To avoid any error in manipulation, different codes are attributed :
- so-called "installer" code = 96. With this code, data 1 to 9 can be changed,
10 and 11 are not used and 12 to 36 are in read-only mode.
- After sales service code = 35. By entering this code, the display goes directly to line 23.
Data 23 to 28 can be changed (which was not the case with code 96).
The following data are in read-only mode.
- If another code is entered, the display goes directly to the fault log
(line 31, but without numbered data).
To access the data menu :
- Press the mode button (ref. 1) for about 10 seconds ;
the display then changes configuration ;
- Use + or – (2 or 3) to display code 96 or 35.
- Confirm by pressing the mode button (1).
The display then indicates line 1 (for code 96) or 23 (for code 35) in the data menu.
The figure on the left is the data, the one on the right is the setting for this data.
To change a figure :
- Scroll through the data using + or – until you reach the data to be changed.
- Press the mode button (1) : the figure on the right begins to flash. Change it using + or -.
- Press the mode button to confirm.
NB : Some figures cannot be changed because they are in read-only mode,
or are not valid for the device concerned (reserved for future models).
11 45
°C
13
2

Data Data figures

6
Data menu ThemaClassicPlus
Data Function description Valid range Observations
1Heating power limitation (in kW) P. min to P max Factory setting = 15 kW
2configuration relative to flue length 0 to 10 see table 1
3
Selection of minimum heating reference value
(°C)
38 ou 50°C
4
Selection of maximum heating reference value
(°C)
50, 73, 80
or 87°C
5
Selection of pump operation
1, 2 or 3
1 = with Roomstat,
2 = with burner,
3 = continuous in winter
6Outdoor sensor curve 0 to 15 see table 3
7Outdoor sensor offset -9 to +10 see table 3
8
Forcing the burner at Pmin or Pmax in central
heating. No more modulation.
Nota : after 15 min, the forcing function stops
by itself.
0, 1 or 2
0 = normal,
1 = forcing at P min,
2 = forcing at P max.
see table 5
9Hoter water tank 0or 1 Keep 0
10 & 11 Not used
12 Measured heating flow temperature (°C) 0 to 100°C reading only
13 Not used 0 to 100°C
14 Not used 0 to 100°C
15 Measured hot water storage temperature (°C) 0 to 100°C reading only
16 Measured domestic water flow rate (L/mn) x 10 0 to 19,9 reading only
17 Fan speed (rpm) / 100 0 to 199 reading only
18 Instantaneous thermal power (kW) 0 to 24 reading only
19 Not used 0 to 44
20 Outdoor sensor set point (°C) 0 à 100 reading only
21 Measured outdoor temperature (CTN4) (°C) - 32 to +40°C reading only
22 Interface revision code 0 to 100 reading only
23 Boiler code 0 to 199 reading only
24 Minimum output of gas mecanism 0 to 199 see p.7
25 Maximum output of gas mecanism 0 to -199 see p.7
27 Not used
28 Not used
29
Time meter :
number of blocs of 10 hours
0 to 99 ex : 2 means 20 hours
30
Time meter :
number of blocs of 1000 hours
0 to 199 ex : 1 means 1000 hours
31 to 35 Last fault history see table 4
36 Reset of fault history
press + et - at the same
time to reset the memory
Note : - Underlined datas are factory settings.
- Data 26 never appears.
- Datas not used are displayed but not significant.

7
Gas meccanism adjustment
Table 5 :
Point 8 :
This data is intended to lock the boiler at minimum or maximum power for a fixed time
(maximum 15 minutes). During this time, the boiler runs in all or nothing mode ;
there is no burner modulation, so that the following can be performed :
- settings (e.g. reducing the power setting)
- checking the installation (e.g. combustion check).
Setting reduced power : via point 24.
Point 24 is used to adjust burner pressure to reduce power.
The value to be set is given on page 4
(e.g. 2.16 mbar for a C 24 E with natural gas).
To make this setting, lock the boiler at reduced pressure
by setting point 8 to 1.
The factory set value is noted on a label stuck
on the electrical control box.
If changing the gas mechanism, or changing the type
of gas, this setting must be checked.
Setting maximum power : via point 25.
Point 25 is used only to reduce burner pressure at maximum setting,
if the network pressure is constantly higher than normal pressure.
The burner pressure to set is given on page 4
(e.g. 11.76 mbar for a C 24 E with natural gas).
To make this setting, lock the boiler at maximum power
by setting point 8 to 2. 1990
dato 25
0 199
dato 24

8
Details data menu ThemaClassicPlus
Table 2 : codici prodotti
ThemaClassicPlus F 24 E Plus . . . . .equipped with natural gas . . . . . . . . . . . .code : .. . . . . . . . . . .66
ThemaClassicPlus F 30 E Plus . . . . .equipped with natural gas . . . . . . . . . . . .code : .. . . . . . . . . . .72
-20 -15 -10 -5 0 5 10
38
43
48
53
58
63
68
73
OFFSET
78
83
87
38
41
45
48,6
52,2
55,8
59,3
63
66,5
70,1
73
38
39,3
40,6
41,3
42,6
43,8
45,1
46,4
47,7
49
50
15 20 25
(°C)
(°C)
5 7 9
11 13
15
3
1
0
2
46 8 10
12 14
Heating setting
outdoor temperature
Table 1 : aeraulic configuration
This adjustment changes the maximum speed of the fan : if the flue suffers a heavy fall in pressure, you
must increase the speed to compensate. The following table defines the coefficient to enter in the menu,
depending on the length of the evacuation duct.
Table 3 : Outdoor sensor
The ThemaClassicPlus display includes the outdoor sensor module :
consequently, only the sensor (CTN4) has to be added to the device to ensure operation.
The outdoor sensor is set via 3 parameters :
- The maximum heating setting (point 4 on the installer menu).This value depends on the type of heating
(under floor heating, radiators, etc.).
- The slope of the probe. 16 slopes are available (point 6 on the installer menu).
To know which slope to select, you must know the regional minimum temperature used to calculate
the installation. Choose the slope which gives the maximum heating setting for the regional minimum
temperature.
- The zero point,
i.e. the outdoor
temperature
on which the heating
is based (point 7
on the installer menu).
Horizontal concentric Vertical concentric Twin pipes
flue system (C12) flue system (C32) (C52)
parameter flue lenght (L) parameter flue lenght (L) parameter flue lenght
(L1+L2)
top rear
outlet outlet
F24E F30E F30E F24E F30E F24E F30E
00,3 m 0 1,2 m 0 1,2 m
10,7 m 1 2,6 m 1 4 m
21,2 m 2 3,9 m 2 7,6 m
31,6 m 0,3 m 0,3 m 3 5 m 1,0 m 3 11 m 1,0 m
42m 0,8 m 0,6 m 4 6,1 m 2,0 m 4 14 m 5,1 m
52,3 m 1,2 m 0,9 m 5 7,1 m 3,0 m 5 17 m 9,3 m
62,7 m 1,7 m 1,2 m 6 8,2 m 4,0 m 6 19,8 m 13,4 m
73,1 m 2,1 m 1,5 m 7 9,3 m 5,0 m 7 22,8 m 17,6 m
83,3 m 2,6 m 8 10,4 m 6,0 m 8 25,4 m 21,7 m
93,8 m 3 m 9 11,5 m 7,0 m 9 28,4 m 25,9 m
10 4 m 3,5 m 10 12 m 8 m 10 30 m 30 m

code Fault type indication
01 or 04
Ignition failure (no gas or no flame detection)
02
Air failure (SRC or pressure switch) automatic reset
after 15 mn
03
Recurrent air failure
05
Failure on the overheating safety loop
06
Fault on heating sensor loop CTN2
07
not used
08
Fault on vessel sensor loop CTN3
09
Fault on water pressure sensor loop
10
not used
11
No reception from the main PCB
12 User’s interface or distant control panel fault
13
Main circuit fault
14
Heating feed temperature maximum limit overstepped
(or CTN2 out of function)
15
Step-motor fault (gas mechanism)
16
Gas safety valve failure
17
Network voltage insufficient (<170V)
18
Failure on user's interface
19
CTN2 is not stuck on the pipe while DHW demand
20
User’s interface not compatible with the boiler
21
Lack of water (less than 0.5 bar)
22
Too much water pressure(over 2,7 bar)
01 or 04 The grey codes are not visible on the screen.
07 or 10 The black codes are not used on this boiler.
9
Failure codes list ThemaClassicPlus

10
Diagnostic aid ThemaClassicPlus
Code Fault type Display Checks to be performed
02
04
05
air flow safety
No ignition
note : maximum ignition time
= 7 seconds
Overheating loop
➢This symbol is not instantaneously
displayed, but if it becomes displayed
after 40 s, check :
➥the sucker or exhaust system
(clogged or too long)
➥the pressure switch
➥the electrical connections
➢If the burner ignites
and turns OFF after 7 s:
➥check the ionizing electrode
and/or its proper connection
➥verify the configuration code
(23 in boiler data menu)
➥Make sure that more than 40 V
are present between phase and earth.
Otherwise, add a no-earth kit.
➢If the burner fails to ignite :
➥Make sure that the gas valve is open.
➥Check the gas mechanism
➥Inspect the ignition electrodes
➢If no spark train is present:
➥Check the igniter for proper connection,
or check the igniter itself.
➥Pump seized or its capacitor has failed
➥Plate or installation valves shut
➥Overheating thermostat failed
➥Perform air bleeding
➥Check the electrical connections.

11
➢circuits open or in short-circuit. Check :
➥Sensor resistance
(12500 Ωat 20 °C, 1750 Ωat 70 °C)
➥Disconnect the sensor from the pipe:
if the boiler starts, then the NTC
is in contact with the earth: change
the sensor.
➥NTC possibly wet: dry it
➥ Sensor in short-circuit
or sensor insulation fault.
➥Check the electrical connections
➥ Interface possibly wet. Dry it or replace it.
➥Poor connection to the card
➢This fault may be occasional :
➥Switch OFF the boiler. Wait for 5 s
or so and try to turn it ON.
➥If the fault persists,
change the main circuit board.
➥ Hot water NTC disconnected
➥3-way valve seized
in heating configuration when the boiler
is set on domestic water
➥Pump failed
➥Low heating flow rate (radiators closed)
➥Motor connection or motor failure
➥ Check the safety electric valve
➥ Minimum ignition voltage = 175V
➢This fault may be occasional
and transient
➥Otherwise, check the card.
➥ Check the position of CTN2
➥ Perform water topping-up
➥ Check the expansion vessel,
the filling cock (may be open),
the pressure sensore,
the capacity of water of the installation.
Code Fault type Display Checks to be performed
06
08
09
11 or 12
13
14
15
16
17
18 or 20
19
21
22
Heating sensor loop (NTC 2)
Microfast sensor loop (NTC 3).
note : a mini-accumulator NTC
fault will not lock the boiler.
Pressure sensor loop (Cp)
User’s interface
Main card
Temperature limiter
(ensured by heating
feed NTC: (CTN2)
Step-motor failure
Gas leak through the safety
electric valves
Network voltage too low
Communication fault
CTN2 not at the right place
Lack of water in primary circuit
Too much water pressure

09/02 - AM28 - TMCLPLUS - UK
Some spare parts ThemaClassicPlus
Main heat exchanger : F 24: S10030 F 30 : S10065
DHW heat exchanger :F 24 : S10166 F 30: S10060
Pump : F 24 : S10052 F 30 : S10055
Main board: F 24 : S10155 F 30 : S10200
Fan (F) : F 24 : S10114 F 30 : S 10192
Interface PCB : F 24/F 30 : S10172
Domestic water flow sensor (Db) : S57202
Loss of water sensor (Cp) : S57205
Heating/DHW thermistor NTC2 (CTN2) : S57398
Ignition electrode: S10038
Flame sense electrode: S10037
Ignition module : S57427
Hydraulic characteristics ThemaClassicPlus F
ThemaClassicPlus F 24 E
ThemaClassicPlus F 30 E
50
40
30
20
10
0 500 1000
1
2
3
4
5
Flow rate in the heating circuit (l/h)
Available pressure (mcw) between heating outlet and return
50
40
60
30
20
10
0 1000 1200200 400 600 800
1
2
3
4
5
Flow rate in the heating circuit (l/h)
Available pressure (mcw) between heating outlet and return