Saunier Duval Thema Classic Plus Memo Boiler … By spares.co Tel. 0161 620 6677 4 Characteristics...

Supplied By www.heating spares.co Tel. 0161 620 6677

MEMO


2

Descriptions ThemaClassicPlus F

1 - Air pressure switch (Pr) (Themafast F)2 - Fan (Ex) (Themafast F)3 - Main heat exchanger4 - Overheat safety thermostat (K4)5 - Combustion chamber6 - Expansion vessel7 - Flame sense electrode (FL)8 - Burner9 - Ignition electrode (FA)

10 - Pump (P)11 - Heating/DHW thermistor NTC (CTN2)12 - Ignition module (AL)13 - By-pass14 - Gas mechanism (EV)15 - Loss of water sensor (Cp)16 - DHW heat exchanger17 - Three way valve (V3V)18 - Domestic water flow sensor (Db)19 - Domestic water filter

20 - Filling system21 - Heating safety valve 3 bar22 - Boiler drain valve23 - Central heating filter24 - Micro-accumulation sensor (CTN3)25 - Warm resistor26 - Micro-accu.27 - DHW safety valve 10 bar

A - Heating returnB - Cold waterC - Heating flowD - Hot water outletE - Gas

A B C D E

1

13

15

20

21

11 12

6

3

2

4 5

16

18

14

22

17

10

1923

24

27

7 98

25

26


3

Wiring diagram ThemaClassicPlus F

+18V

rpm S

rpm

Ex

EVS

Cp

H7.2 H7.1

H7.2H7.1

+5V

S

+18Vs

Db

INTERFACE

CTN 2

PrK4

FAV3V

NCHSAN

Opt.

Vm

M

AL

FL

P

123

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)

4567891011

1 23

45

67

8910

123456

1213

21

2

1

1

3

1

3

1

2

H2

H8

H5

H4

H1

H3

H6

21H7

J1

J13

J12

J4

J2

J7

21 3 4 5 6

R

CTN 3

L

M/A

L

N

F1

230 Vac

Opt.1

234

TRA

CTN 4

J15 J11

34 2 11 4 52 3

2.0bar 45°C

1

3

5

876

12345678910111213

b

S12

1

SW

230V control board

connected to 230V control board

M/A - On/Off switchP - PumpV3V - 3-way valveAL - Ignition unitFA - Ignition electrodesFL - Ionisation rodINTERFACE - Interface boardb - Voltage free roomstatCTN2- (NTC2) thermistance chauffageCTN3- (NTC3) thermistance micro-accu.Cp - Water pressure sensorPr - Pressostat sécurité airSW - not usedEVS - Gas mechanism safety valve

K4 - Overheating safety deviceVm - Gas mechanism modulatingvalve

(step motor)Db - Hot water flowEx - Modulating fanR - Micro-accu. warm resistancerpm - module vitesse extracteur

AccessoriesOpt - Option boardCTN4- (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)



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




Propane G 31 (37 mbar)



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




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 to80 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

1 32

Data Data figures


6

Data menu ThemaClassicPlus

Data Function description Valid range Observations1 Heating power limitation (in kW) P. min to P max Factory setting = 15 kW2 configuration relative to flue length 0 to 10 see table 1

3Selection of minimum heating reference value(°C) 38 ou 50°C

4 Selection of maximum heating reference value(°C)

50, 73, 80or 87°C

5

Selection of pump operation

1, 2 or 31 = with Roomstat,2 = with burner,3 = continuous in winter

6 Outdoor sensor curve 0 to 15 see table 37 Outdoor sensor offset -9 to +10 see table 3

8

Forcing the burner at Pmin or Pmax in centralheating. No more modulation.Nota : after 15 min, the forcing function stopsby itself.

0, 1 or 2

0 = normal,1 = forcing at P min,2 = forcing at P max.see table 5

9 Hoter water tank 0 or 1 Keep 010 & 11 Not used

12 Measured heating flow temperature (°C) 0 to 100°C reading only13 Not used 0 to 100°C14 Not used 0 to 100°C15 Measured hot water storage temperature (°C) 0 to 100°C reading only16 Measured domestic water flow rate (L/mn) x 10 0 to 19,9 reading only

17 Fan speed (rpm) / 100 0 to 199reading only

18 Instantaneous thermal power (kW) 0 to 24 reading only19 Not used 0 to 4420 Outdoor sensor set point (°C) 0 à 100 reading only21 Measured outdoor temperature (CTN4) (°C) - 32 to +40°C reading only22 Interface revision code 0 to 100 reading only23 Boiler code 0 to 199 reading only24 Minimum output of gas mecanism 0 to 199 see p.725 Maximum output of gas mecanism 0 to -199 see p.727 Not used28 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 sametime 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 prodottiThemaClassicPlus F 24 E Plus . . . . .equipped with natural gas . . . . . . . . . . . .code : . . . . . . . . . . . .66ThemaClassicPlus 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 configurationThis adjustment changes the maximum speed of the fan : if the flue suffers a heavy fall in pressure, youmust 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 sensorThe 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 pipesflue system (C12) flue system (C32) (C52)

parameter flue lenght (L) parameter flue lenght (L) parameter flue lenght(L1+L2)

top rearoutlet outletF24E F30E F30E F24E F30E F24E F30E

0 0,3 m 0 1,2 m 0 1,2 m1 0,7 m 1 2,6 m 1 4 m2 1,2 m 2 3,9 m 2 7,6 m3 1,6 m 0,3 m 0,3 m 3 5 m 1,0 m 3 11 m 1,0 m4 2 m 0,8 m 0,6 m 4 6,1 m 2,0 m 4 14 m 5,1 m5 2,3 m 1,2 m 0,9 m 5 7,1 m 3,0 m 5 17 m 9,3 m6 2,7 m 1,7 m 1,2 m 6 8,2 m 4,0 m 6 19,8 m 13,4 m7 3,1 m 2,1 m 1,5 m 7 9,3 m 5,0 m 7 22,8 m 17,6 m8 3,3 m 2,6 m 8 10,4 m 6,0 m 8 25,4 m 21,7 m9 3,8 m 3 m 9 11,5 m 7,0 m 9 28,4 m 25,9 m10 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 resetafter 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 ignitionnote : maximum ignition time = 7 seconds

Overheating loop

This symbol is not instantaneouslydisplayed, but if it becomes displayedafter 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 Ω at 20 °C, 1750 Ω at 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 NTCfault 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 safetyelectric valves

Network voltage too low

Communication fault

CTN2 not at the right place

Lack of water in primary circuit

Too much water pressure


09/0

2 -

AM

28 -

TM

CLP

LUS

- U

K

Some spare parts ThemaClassicPlus

Main heat exchanger : F 24 : S10030 F 30 : S10065DHW heat exchanger :F 24 : S10166 F 30 : S10060Pump: F 24 : S10052 F 30 : S10055Main board : F 24 : S10155 F 30 : S10200Fan (F) : F 24 : S10114 F 30: S 10192Interface PCB: F 24/F 30 : S10172

Domestic water flow sensor (Db) : S57202Loss of water sensor (Cp) : S57205Heating/DHW thermistor NTC2 (CTN2) : S57398Ignition electrode : S10038Flame sense electrode : S10037Ignition module : S57427

Hydraulic characteristics ThemaClassicPlus F

ThemaClassicPlus F 24 E

ThemaClassicPlus F 30 E

50

40

30

20

10

0 500 1000

1

23

4

5

Flow rate in the heating circuit (l/h)

Ava

ilabl

e pr

essu

re (m

cw)

betw

een

heat

ing

outle

t and

retu

rn

50

40

60

30

20

10

0 1000 1200200 400 600 800

1

2

34

5

Flow rate in the heating circuit (l/h)

Ava

ilabl

e pr

essu

re (m

cw)

betw

een

heat

ing

outle

t and

retu

rn

Saunier Duval Thema Classic Plus Memo Boiler … By spares.co Tel. 0161 620 6677 4 Characteristics...

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Transcript of Saunier Duval Thema Classic Plus Memo Boiler … By spares.co Tel. 0161 620 6677 4 Characteristics...