Sime ALU HE Series, ALU HE 80, ALU HE 160, ALU HE 116, ALU HE 200 User, Installation And Servicing Instructions
...
Cod. 6316191 - 08/2013
BRAVA DGT HE
25 - 30 - 35
199838
ENSURE THAT THESE
INSTRUCTIONS ARE LEFT
FOR THE USER AFTER
COMPLETION OF THE
BENCHMARK SECTION
PLEASE READ THE
IMPORTANT NOTICE
WITHIN THIS GUIDE
REGARDING YOUR BOILER
WARRANTY
Cod. 6316191 - 08/2013
UK
Cod. 6316191 - 08/2013
199839
Authorised User No. 02285
6328465 - 09/2019 - R7
Aluminium condensation boilers
USER, INSTALLATION AND SERVICING INSTRUCTIONS
ALU HE
ENSURE THAT THESE
INSTRUCTIONS ARE LEFT
FOR THE USER AFTER
COMPLETION OF THE
BENCHMARK SECTION
PLEASE READ THE
IMPORTANT NOTICE
WITHIN THIS GUIDE
REGARDING YOUR BOILER
WARRANTY
BOILER DETAILS
please position here a sticker
from installation pack
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
changes
IMPORTANT NOTICE
For the first year all of our appliances are protected by our manufacturer’s guarantee which covers both parts and
labour.
As you would expect from Sime Ltd, it is our aim to provide our valued customers with the best in after sales and
service.
To take advantage of any extended warranty offered, all you have to do is to adhere to these 3 simple conditions:
The installation must be carried out to Manufacturers/Benchmark Standards by a Gas Safe Registered
Engineer, and recorded in the installation manual.
The appliance must be registered with both Sime Ltd and Gas Safe within 30 days of installation.
The appliance must be serviced every 12 months, within 30 days of the anniversary of the installation date, by either
Sime Ltd or a Gas Safe registered engineer- ensuring that the Benchmark service record in the installation
manual
Failure to comply with the above will result in only the 12 month warranty being offered.In the absence of any proof
of purchase, the 12 month warranty period will commence from the date of manufacture of the boiler as shown on the
appliance data plate.
is completed.
SAFE HANDLING
This boiler may require 2 or more operatives to move it into its installation site, remove it from its packaging and
during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve
lifting pushing and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered:
– Grip the boiler at the base
– Be physically capable
– Use personal protective equipment as appropriate e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.
– Keep back straight
– Avoid twisting at the waist
– Always grip with the palm of the hand
– Keep load as close to the body as possible
– Alway
WARNING
Caution should be exercised when performing any work on this appliance.
Protective gloves and safety glasses are recommended.
– Avoid direct contact with sharp edges.
– Avoid contact with any hot surfaces.
s use assistance
NOTICE
Please be aware that due to the wet testing of the appliance, there may some residual water in the hydraulic circuit.
– Protect any surfaces, carpets or floorings.
– Use a suitable container to catch any water that escape when removing the protective caps from the connections.
All descriptions and illustrations provided in this manual have been carefully prepared but we reserve the right to make
and improvements in our products that may affect the accuracy of the information contained in this manual.
2
3
The Benchmark Scheme
Sime is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and com
missioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimise
safety, efficiency and performance.
Benchmark is managed and promoted by the Heating and Hotwater Industry Council.
For more information visit www.centralheating.co.uk.
Please ensure that the installer has fully completed the Benchmark Checklist in the use and maintenance section of
the installation instructions supplied with the product and that you have signed it to say that you have received a full
and clear explanation of its operation.
The installer is legally required to complete a commissioning checklist as a means of complyng with the appropriate
Building Regulations (England and Wales).
All installations must be notified to Local Area Building Control either directly or through a Competent Persons
Scheme.
A Building Regulations Compliance Certificate will then be issued to the customer who should, on receipt, write the
Notification Number on the Benchmark Checklist.
This product should be serviced regularly to optimise its safety, efficiency and performance.
The service engineer should complete the relevant Service Record on the Benchmark Checklist after each service.
The Benchmark Checklist may be required in the event of any warranty work and as supporting documentation
relating to home improvements in the optional documents section of the Home Information Pack.
I
IT
IN
manu
wi
N
G
Y
AND
ON
080
mportant Information
IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS,
ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). The
facturer’s instructions must not be taken as overriding any statutory requirements, and failure to comply
th these regulations may lead to prosecution.
o modifications to the appliance should be made unless they are fully approved by the manufacturer.
AS LEAKS: DO NOT OPERATE ANY ELECTRICAL SWITCH, OR USE A NAKED FLAME. TURN OFF THE GAS SUPPL
VENTILATE THE AREA BY OPENING DOORS AND WINDOWS CONTACT THE GAS EMERGENCY SERVICE
0111999.
-
Please refer to commissioning instructions for filling in the checklist at the back of this installation guide.
Note: All Gas Safe registered installers carry a ID Card.
You can check your installer is Gas Safe Registered by calling 0800 408 5577
SIME COMBINATION BOILERS
Installer checklist
Please remember to carry out the following checks after installation. This will achieve complete customer
satisfaction, and avoid unnecessary service calls. A charge will be made for a service visit where the fault is not
due to a manufacturing defect.
Has a correct by-pass been fitted and adjusted?
Has the system and boiler been flushed?
Is the system and boiler full of water, and the correct pressure showing on the pressure gauge?
Is the Auto Air Vent open?
Has the pump been rotated manually?
Is the gas supply working pressure correct?
Is the boiler wired correctly? (See installation manual).
Has the D.H.W. flow rate been set to the customer requirements?
Has the customer been fully advised on the correct use of the boiler, system and controls?
Has the Benchmark Checklist in the use and maintenance section of this manual, been completed?
––
4
SAFETY WARNINGS AND REGULATIONS
m
WARNINGS
– After having unpacked the boiler en-
sure that it is undamaged and complete including the valve pack, hanging
bracket and template.
– The appliance must be used as in-
tended.
for any injury or damage to persons,
animals,or property as a result of improper installation, adjustment, maintenance or use.
In the event of water leaks, disconnect
–
the appliance from the mains power
supply, close the water mains and seek
help from a qualified engineer.
– Periodically check that the operating
pressure of the water heating system
when cold be included in the range
6.0 bar
the pressure or contact professionally
qualified personnel.
– If the appliance is not used for a long
period of time, the following operations
must be carried out:
-
set the main isolation switch to "OFF";
-
close the gas and water valves for the
water heating system.
Sime
declines all responsible
0.8-
. If this is not the case, increase
m
WARNINGS
–
It is recommended that all operators
read this manual carefully in order to
use the appliance in a safe and rational
manner.
–
This manual
appliance. It must therefore be kept for
future reference and must always accompany the appliance in the event of
the appliance being tr
other Owner or System Manager or being installed on another system.
–
Installation and maintenance
pliance must be carried out by a qualified company or by a professionally
qualified technician in accordance with
the instructions contained in the manual. Once the work is complete, the
company or technician will issue a declaration of conformity with national and
local technical standards and legislation in force in the country where the
appliance will be used.
is an integral part of the
ansferred to an-
of this ap-
– In order to ensure optimal appliance
operations
maintenance and checks are carried
out at least
to the
specific legal provisions
Sime
recommends that
ONCE A YEAR
or according
.
5
RESTRICTIONS
d
DO NOT
– To allow children under the age of 8 to
use the appliance. The appliance can
be used by children no younger than
8 years old, by people with physical
or cognitive disabilities, and by people
lacking experience or the necessary
knowledge, provided that they are supervised or have been instructed on
how to use the appliance safely and
that they understand the risks associated with it.
– To allow children to play with the ap-
pliance.
–
To allow unsupervised children to per-
form user maintenance and cleaning.
–
Do not use electrical devices or appli-
ances such as switches, electrical appliances etc if you can smell gas. If this
should happen:
-
open the doors and windows to ventilate the room;
-
turn the gas off at the meter;
-
call the emergency service 0800
111999.
– Do not touch the appliance with bare
feet or with any wet part of the body.
– Do not carry out any repair, mainte-
nance or cleaning operation before
having disconnect
from the mains power by setting the
main switch to "OFF", and closing the
gas supply.
– Do not modify the safety or adjustment
devices without authorization and instructions from the manufacturer.
ed the appliance
d
DO NOT
– Do not block the condensate drain.
– Do not pull, detach or twist the electri-
cal cables coming out of the appliance
ev
en if the appliance is disconnected
from the mains power supply.
– Do not expose the boiler to atmospher-
ic agents. These boilers can also be
inst
alled in partially covered areas, as
per EN 15502, with a maximum ambient temperature of 60 °C and a minimum ambient temperature of 0 °C. It
is generally advisable to install the
boilers below weathered roofs, on the
balcony or in a protected niche, to protect them from exposure to weathering
agents (rain, hail and snow). All boilers
provide a standard antifreeze function.
– Do not block or reduce the size of the
ventilation openings of the room where
the appliance is installed, if present.
– Remove the mains power and gas sup
ply from the appliance if the external
temper
(risk of freezing).
– Do not leave containers with flamma-
ble substances in the room where the
appliance is ins
– Do not dispose of the packaging ma-
terial irresponsibly as it could be dangerous. Packaging must be disposed of
as specified by the legislation in f
in the country where the appliance will
be used.
ature could fall below ZERO
talled.
-
orce
6
RANGE
MODEL CODE
ALU HE 80 8115701
ALU HE 116 8115710
ALU HE 160 8115720
ALU HE 200 8115730
ALU HE 240 8115740
ALU HE 280 8115751
MANUAL STRUCTURE
This manual is organized as follows.
USER INSTRUCTIONS
TABLE OF CONTENTS 9
COMPLIANCE
Our company declares that
lowing directives:
Gas Appliances EU Regulation 2016/426
–
– Low Voltage Directive 2014/35/UUE
– Electromagnetic Compatibility Directive 2014/30/EU
– Ecodesign Directive 2009/125/EC
– Regulation (EU) No. 813/2013 - 811/2013
– Boiler Efficiency Directive 92/42/EEC
ALU HE
boilers comply with the fol-
SYMBOLS
a
f
d
WARNING
To indicate actions which, if not carried out correctly,
can result in injury of a general nature or may damage
or cause the appliance to malfunction; these actions
therefore require particular caution and adequate
preparation.
ELECTRICAL HAZARD
To indicate actions which, if not carried out correctly,
could lead to injury of an electrical nature; these actions therefore require particular caution and adequate preparation.
DO NOT
To indicate actions which MUST NOT BE carried out.
DESCRIPTION OF THE APPLIANCE
TABLE OF CONTENTS 15
INSTALLATION AND SERVICING
INSTRUCTIONS
TABLE OF CONTENTS 27
CASCADING SYSTEMS
TABLE OF CONTENTS 53
m
CAUTION
To indicate particularly important and useful information.
7
8
TABLE OF CONTENTS
USER INSTRUCTIONS
1 USING THE BOILER ALU HE 10
1.1 Control panel ..................................10
1.2 Start-up ......................................11
1.2.1 Preliminary checks.................... 11
1.2.2 Ignition.............................. 11
1.3 Adjusting the delivery temperature ................11
1.4 Malfunctions ..................................11
1.5 Fault / malfunction codes........................12
1.6 SIME remote control connection (optional accessory) 12
2 MAINTENANCE 13
2.1 Servicing......................................13
2.2 External cleaning...............................13
2.2.1 Cleaning the case ..................... 13
3 DISPOSAL 13
3.1 Disposal of the equipment (European Directive
2012/19/EU) ...................................13
VERY IMPORTANT!
PLEASE MAKE SURE YOUR COMMISSIONING CHECKLIST AND THE SERVICE INTERVAL RECORDS ENCLOSED
ARE FILLED IN CORRECTLY.
ALL GAS SAFE REGISTERED INSTALLERS CARRY A GAS SAFE ID CARD.
BOTH SHOULD BE RECORDED IN YOUR COMMISSIONING CHECKLIST AND A SERVICE INTERVAL RECORDS.
YOU CAN CHECK YOUR INSTALLER IS GAS SAFE REGISTERED
BY CALLING ON 0800 408 5500 OR ALTERNATIVELY WWW.GASSAFEREGISTER.CO.UK
9
1 USING THE BOILER ALU HE
3
1
2
4
5
1.1 Control panel
The control panel allows all operators to make all adjustments
necessary to manage
tems.
Sime ALU HE
boilers and connected sys-
Fig. 1
2
DESCRIPTION OF COMMANDS
T
ON = Boiler has electric power.
OFF = Boiler has electric power but is not available
U
V
W
X
Y
J
Q
ON/OFF BUTTON
for operation. The protection functions are on, how
ever.
SUMMER MODE BUTTON
boiler operates only on demand for domestic hot wa-
(function not available)
ter
WINTER MODE BUTTON
boiler operates for heating and domestic hot water.
SET DHW BUTTON
perature of the domestic hot water is displayed
(function not available)
SET HEATING BUTTON
ton the temperature of heating circuit 1 is displayed.
With the second pr
of heating circuit 2 is displayed. With the third press
of this button the temperature of heating circuit 3 is
displayed.
RESET BUTTON
erating error.
INCREASE BUTTON
set is increased.
REDUCE BUTTON
set is reduced.
.
. By pressing this button the
.
. By pressing this button the
. By pressing this button the tem-
.
. With the first press of this but-
ess of this button the temperature
. Lets you reset operation after an op-
. By pressing this button the value
. By pressing this button the value
-
1
DISPLAY ICONS DESCRIPTION
l
n
r
u
v
f
h
z
i
j
E
SUMMER MODE ICON
WINTER MODE ICON
DHW MODE ICON
HEATING MODE ICON
GRADUATED OUTPUT SCALE
bar light up in proportion to the output delivered by
the boiler.
BURNER OPERATION AND BLOCKING ICON
RESET REQUIRED ICON
CHIMNEY SWEEP FUNCTION ICON
SECONDARY DIGITS
pressure value.
MAIN DIGITS
status and outdoor temperature.
SUPPLEMENTARY SOURCES PRESENT ICON
. The boiler displays the values set, fault
.
.
.
.
. The segments of the
.
.
. The boiler displays the system's
.
.
3
BUTTONS RESERVED FOR INSTALLER (access to INST parameters and CASCADE parameters)
c
w
L
M
N
Z
4
LIGHT BAR
Blue = Operation.
Red = Operating error.
5
TIMER (optional)
Mechanical timer (code 8092228) or digital timer (code 8092229)
for programming heating/dhw.
CONNECTION THROUGH PC
Sime
the
personnel. Do not connect other electronic devices
(cameras, phones, MP3s etc.). Use a tool to remove
the cap and replace it after use.
WARNING: Communication port sensitive to static
electricity
earthed metal surface to get rid of static electricity.
INFORMATION BUTTON
times to scroll through the parameters.
CHIMNEY SWEEP FUNCTION BUTTON
ton several times to scroll through the parameters.
REDUCE BUTTON
set.
INCREASE BUTTON
set.
programming kit and only by authorised
. Before use, it is advisable to touch an
. For changing the default values
. For changing the default values
. To be used only with
. Press the button several
. Press the but-
10
1.2 Start-up
1.2.1 Preliminary checks
a
Commissioning of the
fessionally qualified personnel after which the boiler can operate automatically. It may, however, be necessary for the system manager to start the appliance autonomously after having
turned it off, without inv
holiday.
In such cases it must first be checked that the fuel and water
system isolation valves are open.
1.2.2 Ignition
After having carried out the preliminary checks, proceed as follows:
set the main system switch to "ON"
–
– the blue bar (4) comes on and the screen saved by the elec
Example: winter; delivery temperature (40°C); system pressure
(1.3 bar).
WARNING
Should it be necessary to access the areas in the bottom part of the appliance, make sure that the system
components and pipes ar
ALU HE
olving a technician: for example, after a
tronic circuit board before the appliance was turned off is
shown on the display.
e not hot (risk of burning).
boiler must be carried out by pro-
-
1.3 Adjusting the delivery temperature
The control panel on
delivery temperature on two temperature levels by choosing the
best ones for the systems managed (e.g. 80°C and 50°C).
To adjust the delivery temperature on the first of the two levels:
– press button
will be shown on the display
u
– press buttons
(e.g. 80°C)
– press button X again. The symbol x will be shown on the
display
– press buttons
(e.g. 50°C)
ALU HE
boilers lets you manually adjust the
(twice if the display isn't backlit). The symbol
X
or Q until the desired value is displayed
J
or Q until the desired value is displayed
J
ON
Fig. 2
When heat is requested from the systems the boiler automatically carries out:
the operational checks
–
– ignition and starts automatic operation.
m
CAUTION
– When the display is not backlit (off), the first press
on each function button serves to backlight it (turn
it on).
– To manually stop the boiler press button
– The display will show the following screen.
T
.
Once the settings are completed, to go back to the starting
screen press button
touching any buttons.
or wait for approx. 60 seconds without
X
1.4 Malfunctions
In the event of a fault/malfunction the message
pear on the display with the alarm number and the light bar (4)
will turn red.
e: “ALL 02” (Low System Pressure Error: less than 0.8
Exampl
bar).
NOTE:
in the case of
when cold, without disconnecting the power supply to be able to
see when the pressure reaches the correct value (be included
in the range 0.8-6.0 bar). The warning disappears when normal
conditions are reset and the boiler starts up again automatically.
"ALL 02"
, the system can be reintegrated,
"ALL"
will ap-
11
In the case of all other errors, before repairing the fault, it is
OFF
recommended, as a precautionary measure, that you:
– disconnect the appliance from the mains power by setting the
main switch to "OFF"
– close the fuel isolation valve.
Fig. 3
NOTE:
When, in addition to the message
also appears on the display, after having repaired the
h
fault, button
must be pressed for approx. 3 seconds, and
Y
"ALL ..."
the symbol
then released. The boiler starts up again normally.
Type No. Description
ALL 31 Cascade delivery probe (SMC) fault
ALL 32 Three zone system configuration fault
ALL 35 Communication fault RS485 board
ALL 36 Number of boilers connected in cascade fault
ALL 45
ALL 70 Cascade stop general fault
ALL 71 General fault with a boiler in the cascade
ALL 72 Delivery probe (SMC) disconnected error
ALL 80 Gas valve control circuit hardware fault
ALL 89 Gas valve control circuit hardware fault
ALL 98 Maximum number of software errors reached
ALL 99 Generic board software error
NOTE:
If one of the faults listed above occurs, press button T
Manual release performed more than 6 consecutive
times in the last hour
to pause the boiler and contact Qualified Technical Personnel.
1.6 SIME remote control connection (optional
accessory)
The boiler is ready for connection to a
the remote control is connected or, alternatively, when a remote
supervision device is connected, the boiler display shows:
SIME
remote control. When
1.5 Fault / malfunction codes
If a fault/malfunction is detected during boiler operation, the
"ALL"
message
code and the light bar (4) will go red.
Possible errors are reported below.
Type No. Description
ALL 01 Air pressure switch fault
ALL 02 Low water pressure in system
ALL 03 High water pressure in system
ALL 05 Boiler delivery probe fault
ALL 06 No flame detection
ALL 07 Safety thermostat or siphon pressure switch triggered
ALL 08 Fault in flame detection circuit
ALL 09 No water circulating in primary system
ALL 10 Hot water tank sensor/anti-freeze faulty
ALL 11 Modulator disconnected error
ALL 13 Smoke probe triggered
ALL 14 Smoke probe fault
ALL 15 Fan fault
ALL 18 Boiler delivery probe temperature above 117°C
ALL 19 External sensor fault (flashing warning)
ALL 20 Mix 1 zone safety thermostat triggered
ALL 21 Mix 1 Zone valve delivery probe fault
ALL 22 Mix 2 zone safety thermostat triggered
ALL 23 Mix 2 Zone valve delivery probe fault
ALL 24 S1 solar delivery probe fault
ALL 25 S2 solar exchanger probe fault (tank)
ALL 26 S3 2nd solar system delivery probe fault
ALL 27
ALL 29 Number of expansion boar
ALL 30 Return sensor fault
will appear on the display followed by the fault
Solar application coherence fault – hydraulic configu
ration
ds connected fault
-
For set-up and use of the remote control, follow the instructions supplied with the device.
m
CAUTION
A
Sime
remote control and a remote supervision device
cannot be connected at the same time.
12
2 MAINTENANCE
3 DISPOSAL
2.1 Servicing
For the appliance to operate correctly and efficiently it is recommended that the system manager calls upon the services of a
essionally Qualified Technician to carry out
Prof
tenance.
m
CAUTION
Maintenance must ONLY be carried out by qualified
professionals who follow the indications provided in
the INSTALLATION AND MAINTENANCE INSTRUC
TIONS.
ANNUAL
main-
-
2.2 External cleaning
a
2.2.1 Cleaning the case
When cleaning the cladding, use a cloth dampened with soap
and water or alcohol for stubborn marks.
d
WARNING
– Should it be necessary to access the areas in the bot-
tom part of the appliance, make sure that the system
components and pipes ar
– Before performing any maintenance, put on protec
tive gloves.
DO NOT
Do not use abrasive products.
e not hot (risk of burning).
-
3.1 Disposal of the equipment (European Di-
rective 2012/19/EU)
Boilers and electrical and electronic appliances
used professionally or classified as professional waste must not be disposed of as unsorted
t
municipal was
stead, they must be disposed of as per Directive 2012/19/EU and Italian Legislative Decree
49/2014. Pl
regarding returning or replacing your appli
ance, should your product be replaced by another identical product. Your product has been
designed and manufactur
to reduce its impact on the environment and
human health as much as possible. However,
it contains components which may be hazard
ous if not disposed of correctly. Your role as
pr
oduct purchaser handling the appliance
the
at the end of its life is very important when it
comes to reducing the impact of waste on the
environment and human health, and promoting
recycling. The crossed-out wheeled bin sym
bol found on your appliance, and shown here,
means that at the end of your product’s lifecycle, it must not be disposed of with unsorted
municipal was
of, in accordance with the law, as electrical and
electronic waste. Individual countries may also
define specific rules on how to handle electrical
and electronic waste. Before disposing of your
appliance, please check the rules in force in
your country.
e at the end of their life. In-
ease speak with your local retailer
ed in such a way as
t
e. Instead, it must be disposed
-
-
-
d
DO NOT
dispose of the product with urban waste.
13
14
TABLE OF CONTENTS
DESCRIPTION OF THE APPLIANCE
4 DESCRIPTION OF THE APPLIANCE 16
4.1 Characteristics ................................16
4.1.1 Operation............................ 16
4.1.2 Domestic Hot Water (DHW) ............. 17
4.2 Check and safety devices ........................17
4.3 Identification ..................................17
4.3.1 Technical Data Plate................... 18
4.4 Structure .....................................19
4.5 Technical features..............................20
4.6 Main water circuit ..............................21
4.7 Sensors ......................................22
4.8 Minimum water flow rate ........................22
4.9 Load losses ...................................22
4.10 Control panel ..................................23
4.11 Wiring diagram ................................24
4.11.1 RS 485 board......................... 25
15
4 DESCRIPTION OF THE APPLIANCE
4.1 Characteristics
ALU HE
aluminium boilers generate heat through condensation
and are designed to heat rooms and produce domestic hot water,
if the system contains a storage tank. They are composed of:
– an aluminium body, with low water content and high exchange
surface, to maximise energy efficiency and heat yields
– a total pre-mix microflame burner in stainless steel that al
lows high modulation ratios, combustion stability and low
emissions of pollutants (Class NOx = 6), to be achieved
– a variable speed fan required for modulation and air/gas mix
ing
– a combustion circuit which can be "Type C" (sealed) or "Type
B" (open) with respect to the place where the boiler is in
stalled, depending on the configuration of the combustion air
inlet adopted during installation
– a control panel which. if equipped with an external sensor,
allows the delivery temperature to be adjusted according to
the outdoor temperature (sliding temperature operation).
The boiler therefore provides only the heat the User actually
needs, avoiding energy being wasted and the associated costs.
If there are malfunctions or faults, the specific error codes are
displayed, which simplifies the work of Technical Service.
During planning solutions have been adopted to:
– constantly achieve the best air/gas mixture
– reduce heat dispersion
– reduce noise.
Sime ALU HE
cade composed of between two and eight appliances with the
same heating output.
When boiler
ONLY with the master boiler, treating the cascade as a single
heat generator where:
Cascade output = Boiler output x no. of boilers installed
Sime ALU HE
auxiliary sensor and to the
controls. They can manage direct systems or direct systems and
two mixed systems (or two groups of mixed systems connect
ed in parallel), if the optional kits "mix 1 kit-code 8092275" and
"mix 2 kit-code 8092276" are installed. A solar system can also
be installed using the “solar kit-code 8092277” and the “MOD
BUS interface code 8092278” to communicate via MODBUS with
remote devices. All kits are optional accessories to be ordered
separately. After each stoppage, whether automatic or manual,
post-ventilation and post-circulation are performed. The system
should include an INAIL safety device 8101595, which is man
datory for ITALY ONLY, and a plate heat exchanger or hydraulic
separ
boilers can be installed as single units or in a cas-
s are connected in a cascade, they communicate
boilers can be connected to 0-10 V DC controls, to an
Sime Home
at
or, depending on the system characteristics.
or
Sime Home Plus
-
-
-
remote
-
-
-
Sime ALU HE
– anti-freeze function, which is activated automatically if the
temperature of the water inside the boiler falls below the val
ue set under “PAR 35” and if the outdoor temperature falls
below the value set under “PAR 36”
– antiblocking function for the pump and any diverter valve,
which is activated automatically every 24 hours if there have
been no requests for heat
– the chimney sweep function lasts 15 minutes and makes the
job of the qualified technician easier when measuring the pa
rameters and combustion efficiency
anti-legionella function when a storage tank is used
–
– automatic adjustment of the ignition output and minimum and
maximum heating output. The outputs are managed automat
ically by the electronic circuit board to ensure maximum system usage flexibility
dispersal function, so that if the delivery probe detects a tem-
–
perature of 90°C, the fan runs until it falls to 89°C
screed drying function, to keep the floor at a pre-set tempera-
–
ture profile with the help of the mixer valve
"External sensor value correction" function.
–
boilers also have the following functions:
-
-
-
4.1.1 Operation
When the general switch is activated the boiler is powered with
electricity. The blue bar (4) on the control panel lights up. The
symbols, "- -" message and the system pressure are shown cor
rectly on the screen. To turn the boiler on or off press button T
then button
"SUMMER mode". The value of the delivery sensor detected at
that moment appears on the display.
m
When heat is requested from the systems or the storage tank,
if there is one, the control panel automatically carries out the
functional checks, and electrically powers the gas valve and igni
tion transformer to turn on the flame. This is how automatic operation of the boiler begins. When the request for heat is fulfilled
the flame goes out, but the f
in operation to carry out post-ventilation and post-circulation at
the end of which they stop and wait for the next request for heat.
to select "WINTER mode" or button U to select
V
CAUTION
When the display is not backlit (off), the first press on
each function button serves to backlight it (turn it on);
the second press to carry out the command.
an and the cir
culation pump remain
-
-
16
4.1.2 Domestic Hot Water (DHW)
Domestic hot water can be produced if the system has a dhw
circuit with a storage tank. The dhw system can be created either
upstream or downstream of the water shut-off valve. The instal
lation company is responsible for choosing and paying for all the
systems' components and devices.
m
CAUTION
The installation company is responsible for choosing
and paying for all the systems' components and devices.
4.2 Check and safety devices
The
ALU HE
boilers are equipped with the following check and
safety devices:
– thermal safety thermostat 98°C with automatic reset
– system water pressure transducer
– delivery sensor (SM)
– return sensor (SR)
– exhaust sensor (SF)
– air pressure switch
– siphon pressure switch.
4.3 Identification
The
ALU HE
boilers can be identified by means of:
1 Packaging label:
ing and provides a code, the serial number of the boiler and
the bar code
2 Technical Data Plate:
the boiler and provides the technical data, appliance performance information and any other information required by
law in the c
1
ALU HE
this is located on the outside of the packag-
this is located inside the front panel of
ountry wher
e the appliance will be used.
1
d
a
DO NOT
Do not commission or operate the appliance with safety devices which do not work or which have been tampered with.
WARNING
Safety device may only be replaced by professional
Sime
qualified personnel using
original spare parts.
2
2
Fig. 4
17
4.3.1 Technical Data Plate
ELECTRICAL PROTECTION DEGREE
ELECTRICAL PROTECTION DEGREE
CALDAIA
A
GASBRENNWERTKESSEL
160,0
156,1
CALDAIA
A
GASBRENNWERTKESSEL
168,2
160,0
156,1
168,2
ALU 80-116-160-200 HE
ALU 240-280 HE
YEAR OF MANUFACTURE
WATER CONTENT IN BOILER
MAX USEFUL OUTPUT (80-60°C)
MAX USEFUL OUTPUT (50-30°C)
MAX OPERATING PRESSURE
ELECTRICAL SUPPLY
MAXIMUM ABSORBED POWER
GAS AND PRESSURE TEST
COUNTRY OF INTENDED INSTALLTION
APPLIANCE CATEGORY
IF THE GAS IS CHANGED
NAME
SERIAL NUMBER
TYPE OF GAS
MAX HEAT INPUT
GAS CHANGE
BOX TO BE MARKED
Fonderie SIME S.p.A.
Legnago - VR (Italy) - Tel. +39 0442 631111
A CONDENSAZIONE - CONDENSING BOILER - CALDERA DE COND ENSACION - CALDEIRA
CONDENSACAO - CHAUDIERE A CONDENSATION - COND ENSATIEKETEL -
KONDENZAþ1I KOTEL - CONDENSARE CAZAN - KOCIOL KONDENSACYJNY - KONDENZÁCIÓS
Q max = Q min =
P max 80-60°C = P min 80-60°C =
n
P max 50-30°C = P min 50-30°C =
AT-CH-CZ-ES-FR-GB-GR- IE-
DK-EE-FI-LV-NL-NO-SE
G31 37 mbar
- ȂǽǻǿȊǺ ȉȋȃȇȋȁȄȎȉǿȉ - KOND ENZACIJSKI KOTEL - PLYNOVÝ
ALU HE 160 8115720
9999999999
18,00
G20 G31 G2 0 G31
n
IT-LT-PT-RO-SI-SK
kW
kW
kW 34,3 kWnn
6 bar 0,6 MPa
230V~ - 50Hz - 230W
G20 20 mbar
BE-PL
L
2018
kW
kW
n
kW
G20/G31 20/37 mbar
G20 20 mbar (2 kPa)
G31 37 mbar (3,7 kPa)
T max =PMS =
IP X0D
1312CS6214
PIN n.
1312
32,0
30,6
B23P-C43-C53-C63-C83II2H3P
B23P-C43-C53-C63-C83I2HHUG20 25 mbar (2,5 kPa)
B23P-C43-C53-C63-C83I2H
B23P-C43-C53-C63-C83I3P
kW
32,0 kW
kW
30,6 kW
34,3 kW
85
°C
NOx class 6
n
APPLIANCE TYPE
CODE
N° PIN
TYPE OF GAS
MIN HEAT INPUT
MIN USEFUL OUTPUT (80-60°C)
MIN USEFUL INPUT (50-30°C)
MAX OPERATING TEMPERATURE
NOx CLASS
GAS COUNCIL NUMBER CODE (UK)
WRAS CERTIFICATION (UK)
APPLIANCE CLASSIFICATION
TYPE OF GAS
SUPPLY PRESSURE
MAX USEFUL OUTPUT (50-30°C)
MAXIMUM ABSORBED POWER
COUNTRY OF INTENDED INSTALLTION
MAX USEFUL OUTPUT (80-60°C)
NAME
SERIAL NUMBER
YEAR OF MANUFACTURE
WATER CONTENT IN BOILER
MAX HEAT INPUT
MAX OPERATING PRESSURE
ELECTRICAL SUPPLY
GAS AND PRESSURE TEST
APPLIANCE CATEGORY
GAS CHANGE
BOX TO BE MARKED
IF THE GAS IS CHANGED
MADE IN ITALY
Fonderie SIME S.p.A.
Via Garbo, 27 - 37045 Legnago - VR (Italy) - Tel. +39 0442 631111
A CONDENSAZIONE - CONDENSING BOILER - CALDERA DE COND ENSACION - CALDEIRA
CONDENSACAO - CHAUDIERE A CONDENSATION - COND ENSATIEKETEL -
KONDENZAþ1I KOTEL - CONDENSARE CAZAN - KOCIOL KONDENSACYJNY - KONDENZÁCIÓS
Q max = Q min =
P max 80-60°C = P min 80-60°C =
n
P max 50-30°C = P min 50-30°C =
AT-ES-FR-
GB-GR-IT-PT
- ȂǽǻǿȊǺ ȉȋȃȇȋȁȄȎȉǿȉ - KOND ENZACIJSKI KOTEL - PLYNOVÝ
ALU PLUS HE 1100 8115781
9999999999
n
400 V 3N~ - 50 Hz - 2134W
91,00
1053,0 k W 211,0 k Wnn
bar6 0,6 MPa
G20 20 mbar
I2H
I2EDE G20 20 mbar (2 kPa) B23P
I2E(S)BE G20 20 mbar (2 kPa) B23P
2018
L
kW
kW
n
G20 20 mbar (2 kPa) B23P
n
T max =PMS =
IP X0D
1312CS6203
PIN n.
1312
200,01000,0
kW
196,4980,0
kW
85
°C
NOx class 6
APPLIANCE TYPE
CODE
N° PIN
MIN HEAT INPUT
MIN USEFUL OUTPUT (80-60°C)
MIN USEFUL INPUT (50-30°C)
MAX OPERATING TEMPERATURE
NOx CLASS
GAS COUNCIL NUMBER CODE (UK)
WRAS CERTIFICATION (UK)
APPLIANCE CLASSIFICATION
TYPE OF GAS
SUPPLY PRESSURE
18
m
MADE IN ITALY
Fig. 5
CAUTION
Tampering with, removing or failing to display the identification plate or carrying out any other operation which does not allow
safe identification of the product or which may hinder installation and maintenance operations.
4.4 Structure
24
13
20
18
17
13
18 26251920
17
16
1
21
22
2
15
14
23
3
4
13
12
5
6
24
7
11
10
9
8
12
1
Front panel
2
Gas valve
3
Pressure transducer
4
Pressure gauge fitting
5
Return sensor (SR)
6
Return manifold
7
Boiler drain valve
8
Foot
9
Condensate siphon outlet
10
Condensate collection tank
11
Boiler return
12
Smoke outlet fitting
13
Combustion air inlet
14
Boiler body
15
Gas supply pipe
16
Boiler delivery
17
Delivery sensor
18
System delivery manifold
19
Top panel
20
Fan
21
Control panel
22
Min. gas pressure switch
23
Inspection and cleaning doors
24
Side panels
25
Ignition electrodes unit
26
Flame detection electrode
27
Burner
28
Electrical wiring terminal board
14
27
22
28
Fig. 6
19
4.5 Technical features
DESCRIPTION
80 116 160 200 240 280
CERTIFICATIONS
Country of intended installation
AT - BE - CH - CY - CZ - DK - EE - ES - FI - FR - GB - GR - HU
IE - IT - LT - LV - NL - NO - PT - RO - SE - SI - SK
Fuel G20 / G31 G20
PIN number 1312CS6214
Category II2H3P I2H
Appliance classification B23P - C43 - C53 - C63 - C83
Class NO
x
(*) 6 (< 56 mg/kWh)
HEATING PERFORMANCE
HEAT INPUT (**)
Nominal flow (Q
Minimum flow (Q
n
max) kW 80 115,5 160 200 240 280
nw
min) G20 / G31 kW 20 / 20 21 / 28,8 32 / 32 40 / 50 48 62
HEAT OUTPUT
Nominal (80-60°C) (P
Nominal (50-30°C) (P
Minimum G20 (80-60°C) (P
Minimum G20 (50-30°C) (P
Minimum G31 (80-60°C) (P
Minimum G31 (50-30°C) (P
n
max) kW 77,8 112,3 156,1 195,7 234,4 275,4
n
max) kW 83,8 122 168,2 208,6 251,8 295,3
n
min) kW 19,2 20,1 30,6 37,8 46,5 60,4
n
min) kW 21,6 22,8 34,3 42,5 52 66,0
n
min) kW 19,2 27,5 30,6 47,2 - -
n
min) kW 21,6 31,2 34,3 53,1 - -
EFFICIENCY
Max useful efficiency (80-60°C) % 97,3 97,2 97,5 97,8 97,7 98,3
Min useful efficiency (80-60°C) % 95,9 95,6 95,6 94,4 96,8 97,4
Max useful efficiency (50-30°C) % 104,7 105,6 105,1 104,3 104,9 105,4
Min useful efficiency (50-30°C) % 108,2 108,5 107,1 106,2 108,4 106,4
Useful efficiency at 30% of load (40-30°C) % 108,2 108,1 108,1 108,0 108,1 108,3
Losses after shutdown at 50°C W 251 276 301 327 352 377
ELECTRICAL SPECIFICATIONS
Power supply voltage V 230
Frequency Hz 50
Absorbed electrical power (Q
Absorbed electrical power at (Q
n
max) W 211 263 230 360 408 438
n
min)30% W 41 25 24 50 52 165
Absorbed electrical power in stand-by W 6 6 6 6 6 6
Electrical protection degree IP XOD
COMBUSTION DATA
Smoke temperature at Max/Min flow (8060°C)
Smoke temperature at Max/Min flow (5030°C)
°C 66 / 57 65,1 / 56 61,9 / 58,1 69,6 / 58,1 70,7 / 58,3 69,2 / 61,5
°C 51 / 32 46,4 / 30,4 52,3 / 34,5 50,6 / 31,0 50,2 / 30,3 49,6 / 35,9
Smoke flow Max/Min g/s 37,6 / 9,6 54,3 / 10,1 75,2 / 15,3 94,0 / 19,2 112,8 / 23 129,2 / 30
CO
2
at Max/Min flow rate (G20) % 9,3 / 9,1 9,3 / 9,1 9,3 / 9,1 9,3 / 9,1 9,3 / 9,1 9,5 / 9,0
CO
2
at Max/Min flow rate (G31) % 10,6 / 10,3 10,6 / 10,3 10,5 / 10,3 10,0 / 9,7 - -
NOx measured mg/kWh 50 47 48 40 33 37
NOZZLES GAS
Gas consumption at Max/Min flow rate
(G20)
Gas consumption at Max/Min flow rate
(G31)
Gas supply pressure (G20/G31)
3
m
/h 8,28 / 2,08 12,08 / 2,21 17,01 / 3,38 21,16 / 4,23 25,39 / 5,08 29,6 / 6,55
kg/h 6.25 / 1,55 8,98 / 2,19 12,41 / 3,14 15,55 / 3,8 - -
mbar 20 / 37 20 / 37 20 / 37 20 / 37 20 20
kPa 2 / 3,7 2 / 3,7 2 / 3,7 2 / 3,7 2 2
TEMPERATURE PRESSURE
Max operating temperature (T max) °C 85
Heating adjustment range °C 20÷80
Min/Max operating pressure
bar 0,8 / 6
kPa 80 / 600
Water content in boiler l 12,5 15,3 18,0 22,9 25,6 28,4
Loss of load water side T nom (20°C) mbar 65 80 80 90 90 100
Max. T at min./max. power °C 35 / 25 35 / 25 35 / 25 35 / 25 35 / 25 35 / 25
Water flow rate T 20°C m
Water flow rate T 10°C m
3
/h 3,34 4,83 6,67 8,41 10,08 11,84
3
/h 6,69 9,66 13,34 16,82 20,16 23,7
Total residual head (outlet + inlet) Pa 250 250 200 200 200 100
ALU HE
(*) NOx class according to UNI EN 15502-1:2015
(**) Heat input calculated using the lower heat output (Hi)
G20 Hi.
9.45 kW/m3 (15°C, 1013 mbar) -
20
G31 Hi.
12.87 kW/kg (15°C, 1013 mbar)
4.6 Main water circuit
2
1
M
9
8
3
G
4
5
R
6
Sc
7
KEY:
M Boiler delivery
R Boiler return
G Gas supply
Sc Condensate outlet
1
Delivery sensor
2
Fan
3
Gas valve
4
Water pressure transducer
5
Return sensor (SR)
6
Boiler drain valve
7
Condensate siphon outlet
8
Min. gas pressure switch
9
Safety thermostat
Fig. 7
21
4.7 Sensors
TR
0
200
240
160
120
2 4 6 8 10 12 14 16 18 20 22 24
280
320
The sensors installed have the following characteristics:
– boiler delivery, boiler return and flue gas probes NTC R25°C;
10kΩ β25°-85°C: 3435
– domestic hot water sensor NTC R25°C; 10kΩ β25°-85°C: 3435
(optional accessory)
– external sensor NTC R25°C; 10kΩ β25°-85°C: 3435
0°C 1°C 2°C 3°C 4°C 5°C 6°C 7°C 8°C 9°C
0°C
27279
26135
25044
24004
23014
22069
21168
20309
19489
18706
17959
17245
16563
15912
15289
14694
14126
13582
13062
8945
6247
4444
3216
2365
1766
1336
1024
12565
8622
6033
4300
3116
2296
1717
1300
998
Resistance R (Ω)
10°C
20°C
30°C
40°C
50°C
60°C
70°C
80°C
90°C
100°C
12090
8313
5828
4161
3021
2229
1669
1266
973
11634
8016
5630
4026
2928
2164
1622
1232
11199
7731
5440
3897
2839
2101
1577
1199
10781
7458
5258
3773
2753
2040
1534
1168
10382
7196
5082
3653
2669
1982
1491
1137
9999
6944
4913
3538
2589
1925
1451
1108
9633
6702
4751
3426
2512
1870
1411
1079
9281
6470
4595
3319
2437
1817
1373
1051
4.9 Load losses
The graph shows the curves for the load losses of the boilers,
necessary for the correct circulation pump to be chosen.
LOAD LOSS (mbar)
80
40
80
116
160
200
280
240
Correspondence of Temperature Detected/Resistance
Examples of reading:
TR=75°C → R=1925Ω
TR=80°C → R=1669Ω.
4.8 Minimum water flow rate
To protect the heat exchanger from overheating, a sufficient water flow rate must be maintained.
By observing the water flo
maximum ΔT of 35°C is guaranteed at the minimum heat input,
and a maximum ΔT of 25°C at maximum heat input.
The table below shows the minimum water flow rate required
for each boiler.
DESCRIPTION
Minimum water flow
rate
(at Qmin ∆T 35°C)
Minimum water flow
rate
(at Qmax ∆T 25°C)
Water flow rate ∆T 20
(at Qmax)
Water flow rate ∆T 10
(at Qmax)
w rates shown in the table below, a
ALU HE
80 116 160 200 240 280
m3/h 0,5 0,55 0,7 1,1 1,2 1,3
3
m
/h 2,7 4,1 5,5 6,9 8,2 9,6
3
/h 3,3 4,8 6,7 8,4 10,1 11,8
m
3
/h 6,7 9,7 13,4 16,8 20,2 23,7
m
0
m
FLOW RATE (m3/h)
Fig. 8
WARNINGS
– Not respecting the recommended water flow rates
could cause the appliance to malfunction.
– At first start-up it is useful to check the rotation of
the pumps' shafts.
– DO NOT operate the pumps without any water.
– The pumps chosen must have a consumption suit
able for the fuse installed on the electrical panel
(4AT).
-
22
4.10 Control panel
3
1
2
4
5
The control panel allows all operators to make all adjustments
necessary to manage
tems.
1
DISPLAY ICONS DESCRIPTION
l
n
r
u
v
f
h
z
i
j
E
SUMMER MODE ICON
WINTER MODE ICON
DHW MODE ICON
HEATING MODE ICON
GRADUATED OUTPUT SCALE
bar light up in proportion to the output delivered by
the boiler.
BURNER OPERATION AND BLOCKING ICON
RESET REQUIRED ICON
CHIMNEY SWEEP FUNCTION ICON
SECONDARY DIGITS
pressure value.
MAIN DIGITS
status and outdoor temperature.
SUPPLEMENTARY SOURCES PRESENT ICON
Sime ALU HE
. The boiler displays the values set, fault
boilers and connected sys-
.
.
.
.
. The segments of the
.
.
.
. The boiler displays the system's
.
Fig. 9
2
DESCRIPTION OF COMMANDS
T
ON = Boiler has electric power.
OFF = Boiler has electric power but is not available
U
V
W
X
Y
J
Q
3
BUTTONS RESERVED FOR INSTALLER (access to INST parameters and CASCADE parameters)
c
w
L
M
N
Z
4
LIGHT BAR
Blue = Operation.
Red = Operating error.
5
TIMER (optional)
Mechanical timer (code 8092228) or digital timer (code 8092229)
for programming heating/dhw.
ON/OFF BUTTON
for operation. The protection functions are on, how
ever.
SUMMER MODE BUTTON
boiler operates only on demand for domestic hot wa-
(function not available)
ter
WINTER MODE BUTTON
boiler operates for heating and domestic hot water.
SET DHW BUTTON
perature of the domestic hot water is displayed
(function not available)
SET HEATING BUTTON
ton the temperature of heating circuit 1 is displayed.
With the second pr
of heating circuit 2 is displayed. With the third press
of this button the temperature of heating circuit 3 is
displayed.
RESET BUTTON
erating error.
INCREASE BUTTON
set is increased.
REDUCE BUTTON
set is reduced.
CONNECTION THROUGH PC
Sime
the
personnel. Do not connect other electronic devices
(cameras, phones, MP3s etc.). Use a tool to remove
the cap and replace it after use.
WARNING: Communication port sensitive to static
electricity
earthed metal surface to get rid of static electricity.
INFORMATION BUTTON
times to scroll through the parameters.
CHIMNEY SWEEP FUNCTION BUTTON
ton several times to scroll through the parameters.
REDUCE BUTTON
set.
INCREASE BUTTON
set.
.
. By pressing this button the
.
. By pressing this button the
. By pressing this button the tem-
.
. With the first press of this but-
ess of this button the temperature
. Lets you reset operation after an op-
. By pressing this button the value
. By pressing this button the value
. To be used only with
programming kit and only by authorised
. Before use, it is advisable to touch an
. Press the button several
. Press the but-
. For changing the default values
. For changing the default values
-
23
4.11 Wiring diagram
GREEN
SR
CR
L 2
V
N
BLUE
BROWN
QU4 KAEV
OP
5
4
1
BLUE
BLACK
GREEN
RED
6
RS485
CD. 63228900
1
45
23
CN18CN10CN11
A21242631 C
BROWN
KAPI
BLUE
KAEV
BLUE
TPA
5V
GND
OUT
RED
GREEN
ORANGE
CN1 CN2 CN3
35
32 36 49 50 58
BROWN
BLUE
BROWN
68
BLACK
ER
20
BLACK
6972
CN12
64
CN9
BROWN
CN13
18
BLUE
KAVD2
F1
F2
KAVD1
EA
N
69
CN14
72
CN7
N
AUXLAUX
TRA
L
L
VZ
RED
RED
10
1117
N
AR
VZ
TA1 230V
BLUE
BROWN
GREEN
BLACK
BLACK
BLUE
BLUE
GREEN
BLUE
1 1
CN4
4
5
CN5
6
7
CN6
JP1
11121314151617
AR
10
2
3
4
5
6
7
8
9
BROWN
TS
BLUE
SF2
SM
C
SB/SA
0...10VDC
P
NA
BLUE
NC
BROWN
P
NA
SE
TZ1
TZ2
APS
NC
C
Pm
C
P
EV
SPS
NC
NA
QU1
QU2KAVD1
QU3
KAPI
KAPI
KAVD2
MC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
L
N
PE
N
PE
Pcp
N2
ACS
RISc
N3
SF
SF1
PC
PC1
L N
230 V - 50 Hz Pcp
Connections to be made by the installer
L
Live
N
Neutral
MCP
Primary circuit pump
PB
Storage tank pump
PM
Primary circuit modulat-
PB
ing pump(*)
PM VD
VD
Diverter valve
PWM-GND
F1-F2
TRA
V
Fan
Modulating pump signal (if
present)
Fuses (4 AT)
Ignition transformer
GND
PWM
ER
Flame detection electrode
EA
Electrode on
Pm
Min. gas pressure switch
EV
Gas solenoid valve
TPA
Pressure transducer
SM
Delivery sensor (SM)
SR
Return Sensor (SR)
SF2
Exhaust sensor (SF)
SB/SA
Storage tank sensor or auxiliary sensor
(e.g. system delivery sensor, SMi)
JP1
Dial jumper or 0...10V DC or TA2 (**)
OP
Mechanical timer
SPS
Siphon pressure switch
SE
PM
VG1
External sensor (Obligatory)
CR
Remote control or, alternatively, a MOD-
BUS interface kit
TS
Safety thermostat
TZ1÷TZ2
TA1 (230V)
VZ
AR
AUX
QU1..QU4
KAPI
KAEV
KAVD1
KAVD2
APS
RS485
Room thermostat for the zone
Room Thermostat
Zone valve
Remote alarm
Auxiliary connection
Thermal fuses (4 A)
Pump relay
Fan relay
Domestic hot water relay
Heating relay
Air pressure switch
Cascade board
(*) The
PM
pump (modulating) can be installed instead of the
Pcp
pump
(**) JP1 engaged = TZ2 usable; 0 ... 10V DC not usable; JP1 disengaged = TZ2 not usable; 0 ... 10V DC usable
Fig. 10
24
4.11.1 RS 485 board
BOILER BOARD
Connection for communication with
other boilers in the cascade
The RS485 board is provided as standard and is factory installed on every boiler. It is positioned in the cover of the control panel and
fixed in place with two screws.
It is needed for communication between boilers, when they are installed in a cascade (see the specific diagrams under “Electrical
connections for the cascade”).
BLACK
GND
GND
+
–
3 4 5
6
+
–
2
1
GREEN
BLUE
RED
BOARD RS-485
m
CAUTION
Installer must:
– Connect the boiler to a 230v -50Hz single phase
power supply through a fused mains switch, with
at least 3mm spacing between contacts, fused at
which ensures complete cut-off in overvoltage
3amps
category III conditions (i.e. where there is at least 3
mm between the open contacts)
– Respect the connections L (Live) - N (Neutral).
– Ensure that the special power cable is only replaced
with a cable ordered as a spare part and connected
by professionally qualified personnel.
Fig. 11
m
.
d
CAUTION
Installer must:
– Connect the earth wire to an effective earthing sys-
Sime
tem.
damage to persons, animals,or property as a result
of failure to provide adequate earthing of the appli
ance.
declines all responsible for any injury or
DO NOT
Do not use water pipes for earthing the appliance.
-
25
The Benchmark Scheme
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
Benchmark places responsibilities on both manufacturers and installers.
The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations.
The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the
customer for future reference.
Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme.
26
INSTALLATION AND SERVICING INSTRUCTIONS
Installer Checklist
Please remember to carry out the following checks after installation. This will achieve complete customer
satisfaction, and avoid unnecessary service calls. A charge will be made for a service visit where the fault is not
due to a manufacturing defect.
Has a correct by-pass been fitted and adjusted?
Has the system and boiler been flushed?
Is the system and boiler full of water, and the correct pressure showing on the pressure gauge?
Is the Auto Air Vent open?
Has the pump been rotated manually?
Is the gas supply working pressure correct?
Is the boiler wired correctly? (See installation manual).
Has the D.H.W. flow rate been set to the customer requirements?
Has the customer been fully advised on the correct use of the boiler, system and controls?
Has the Benchmark Checklist in the use and maintenance section of this manual, been completed?
TABLE OF CONTENTS
5 INSTALLATION 28
5.1 Receiving the product ...........................28
5.1.1 Optional accessories .................. 28
5.2 Dimensions and weight..........................28
5.3 Handling ......................................28
5.4 Ventilation requirements ........................29
5.5 New installation or installation of a replacement
appliance .....................................29
5.6 Cleaning the system ............................29
5.7 Characteristics of feedwater and system treatment . . 29
5.8 Plumbing connections ..........................30
5.9 Condensate outlet/collection .....................30
5.10 Gas supply ....................................30
5.11 Smoke outlet and combustion air inlet .............31
5.11.1 Maximum duct lengths................. 32
5.12 Electrical connections and External controls........33
5.12.1 External sensor....................... 34
5.13 Systems that can be controlled ...................35
5.13.1 Main hydraulic diagrams ............... 35
5.14 Refilling or emptying............................39
5.14.1 Method of filling a sealed system ........ 39
5.14.2 SYSTEM Filling ....................... 39
5.14.3 EMPTYING operations ................. 39
6 COMMISSIONING 40
6.1 Preliminary operations ..........................40
6.2 Before commissioning ..........................40
6.3 Parameter setting and display ....................40
6.4 List of parameters..............................41
6.5 Configuring the auxiliary sensor ..................42
6.6 Fault/error message............................43
6.7 Fault / malfunction codes........................43
6.8 Gas calibration.................................44
6.8.1 Chimney sweep function and calibration .. 44
6.9 Operating data display ..........................45
6.10 Gas conversion ................................47
7 MAINTENANCE 48
7.1 Servicing......................................48
7.2 External cleaning...............................48
7.2.1 Cleaning the case ..................... 48
7.3 Burner Inspection ..............................48
7.3.1 Burner access........................ 48
7.3.2 Cleaning the burner ................... 48
7.3.3 Cleaning boiler body ................... 49
7.3.4 Dismantling and cleaning siphons and
condensate collection tank ............. 49
7.3.5 Check of electrodes and flame detection
sensor .............................. 49
7.3.6 Connecting the air pressure switch and
siphon .............................. 50
7.5 Possible faults and solutions .....................50
7.4 Circuit Board Replacement ......................50
27
5 INSTALLATION
2
3
m
CAUTION
The appliance must only be installed by the
nical Service or by qualified professionals
wear
suitable protective safety equipment.
5.1 Receiving the product
Appliances
tected by a nylon cover, placed on wooden pallets.
Sime ALU HE
are supplied in a single package, pro-
Sime
Tech-
who MUST
Fig. 12
5.2 Dimensions and weight
H
D
W
Fig. 13
Description
W (mm) 600 600 600 600 600 600
D (mm) 1116 1116 1116 1317 1317 1317
H (mm) 1200 1200 1200 1200 1200 1200
Net weight (kg) 140 160 180 210 227 245
80 116 160 200 240 280
ALU HE
The plastic bag found inside the packaging contains the following:
Installation, use and maintenance manual
–
– Certificate of warranty
– Hydrostatic test certificate
– Control unit manual
d
DO NOT
Do not leave packaging material around or near children since it could be dangerous. Dispose of it as prescribed by legislation in force.
5.1.1 Optional accessories
Description Code
NTR 1500 condensate neutralising kit 8105330
NTR 1500 P condensate neutralising kit 8105335
NTR 300 condensate neutralising kit 8105340
NTR 300 P condensate neutralising kit 8105345
25 kg NTR granule refill 8105350
Sime Home 8092280
Sime Home Plus 8092281
Hot water tank sensor L=2000 6231331
Contact delivery sensor 6277122
MODBUS interface kit 8092278
st
1
mixed zone kit 8092275
st
2
mixed zone kit 8092276
Solar kit 8092277
INAIL safety device (Italy only) 8101595
Digital timer (weekly 24V) 8092229
Mechanical timer (daily 24V) 8092228
Board housing kit 8092236
Boiler body rod 6077930
Motorised damper kit Ø150 mm 8093350
Motorised damper kit Ø200 mm 8093360
Coupling for vertical duct Ø160 mm 8092830
Coupling for vertical duct Ø200 mm 8092840
5.3 Handling
Once the packaging is removed, moving the appliance is as follows:
remove the front panel (1) to make it easier to grip and move
–
– insert two 1" tubes (2) into the relevant housings or slot the
forks of the fork-lift (3) under the structure
– lift the appliance and move it with suitable equipment.
1
Fig. 14
a
WARNING
Use suitable tools and personal protection when removing the packaging and when handling the appliance. Observe the maximum weight that can be lifted
son.
per per
28
5.4 Ventilation requirements
The location where the appliance is to be installed must comply
with the Technical Regulations and Legislation in force. It must
be equipped with suitably sized air vents for "TYPE B" installa
tions.
APPROXIMATE MINIMUM DISTANCES
-
m
CAUTION
It is a condition of the warranty that the boiler is installed in accordance with the instructions in this
manual. The boiler mus
Register, the Benchmark record must be completed
and the boiler is serviced annually and recorded in this
manual.
t be registered with Gas Safe
m
d
≥ 1,2 m
≥ 1,2 m
≥ 0,1 m
WARNINGS
– Before assembling the appliance, the installer
make sure that the floor can support the weight.
– Observe the required clearances.
– The installation room must have an appropriate
height for the installed power, according to the local
and national legislation in force.
– When the installation is in a cascade, the minimum
space between the boilers is 1 m.
DO NOT
– To install
protected from the weather.
ALU HE
appliances outside if not suitably
≥ 1 m
Fig. 15
MUST
5.5 New installation or installation of a replacement appliance
The boiler must be installed in a fixed location and only by specialized and qualified person in compliance with all instructions
ained in this manual.
cont
The installation of this boiler must be in accordance with the rel
evant requirements of the current Gas Safety (installation and
use), the local building regulations and I.E.E. wiring regulations.
Detailed recommendations for air supply and fluing are given in
BS5440.
The following notes are for general guidance: it is not necessary
to have a purpose provided air vent in the room or compartment
in which the appliance is installed.
-
m
CAUTION
If the domestic water supply is metered or should a
water meter be added at a later time, a small expansion vessel should be included in the domestic water
w
ork.
pipe
5.6 Cleaning the system
Before connecting the boiler it is recommended that the system
be flushed in accordance to BS 7593, to eliminate any foreign
bodies that may be detrimental to the operating efficiency of the
appliance.
m
CAUTION
Failure to flush and add inhibiter to the system may
invalidate the warranty.
5.7 Characteristics of feedwater and system
treatment
– All recirculatory systems will be subject to corrosion unless an
appropriate water treatment is applied. This means that the
efficiency of the system will deteriorate as corrosion sludge
accumulates within the system, risking damage to pump and
valves, boiler noise and circulation problems.
– Before connecting the boiler the associated central heating
system must be flushed in accordance with the guidelines
given in BS 7593 “Treatment of water in domestic hot water
central heating systems”.
Sime
recommends only the use of FERNOX products for the
–
flushing and final treatment of the system water. This is particularly important in hard water areas. Failure to flush and
inhibit
add
ranty. Artificially softened water must not be used to fill the
heating sys
minium heat exchangers. Adding Fernox F1 or Mb-1 will guard
agains
Sime
–
er installation.
It is important to check the inhibitor concentration after in-
–
stallation, system modification and annually on a service visit
in ac
benchmark service record this has been complete). Test kits
are available from inhibitor stockists; the return of the Fer
nox test report should be kept with the Benchmark to validate
warranty
– Where Central heating systems are susceptible to freezing a
mixture of inhibitor and anti-freeze should be added in accord
ance with the DWTA code of practice and the Manufactures instructions.
The addition of sealing agents to system water is not recom-
–
mended because deposits can be left in heat exchanger causing circulation issues.
or to the system may invalidate the appliance war-
t
em. Naturally soft water areas can corrode alu-
t c
orrosion.
promote the fitting of TF1 System filter with any new boil-
c
ordance with the manufacturer’s instructions. (Note on
.
-
-
29
5.8 Plumbing connections
BA C D
BA C D
The dimensions of the water fittings of
given below.
Sime ALU HE
boilers are
m
CAUTION
– It is recommended that a condensate neutralising
unit be provided and the pipework should have a
downward angle of at least 3%.
– Before commissioning the appliance, fill the siphon
with water.
M
M
E
R
R
F
As
Fig. 16
PN10
DN50
PN10
DN50
ALU HE
PN10
DN50
PN10
DN50
PN10
DN50
PN10
DN50
PN10
DN50
PN10
DN50
mm
Description
A (mm) 838 838 838 1089 1089 1089
B (mm) 180 180 180 238 238 238
C (mm) 175,5 175,5 175,5 175,5 175,5 175,5
D (mm) 424,5 424,5 424,5 424,5 424,5 424,5
E (mm) 678 678 678 678 678 678
F (mm) 384 384 384 384 384 384
M - Boiler
delivery
R - Boiler
return
As - Siphon
fitting
80 116 160 200 240 280
PN10
DN50
PN10
DN50
PN10
DN50
PN10
DN50
Ø15 mmØ15 mmØ15 mmØ15 mmØ15 mmØ15
5.10 Gas supply
The gas connection must be made using seamless steel or copper tube.
Where the piping has t
sleeve must be provided.
When sizing gas piping, from the meter to the boiler, take into
account both the volume flow rates (consumption) in m3/h and
the relative density of the gas in question.
The sections of the piping making up the system must be such
as to guarantee a supply of gas sufficient to cover the maximum
output available from the boiler, limiting pressure loss between
the gas meter and any apparatus being used to not greater than
1.0 mbar for family II gases (natural gas).
An adhesive data badge is sited inside the front panel; it contains
all the technical data identifying the boiler and the type of gas for
which the boiler is arranged.
The gas supply line must be sized by an expert, and implemented
during installation in compliance with the installation standards
in force. The size of the line must take into account the pressure
of the gas line used and the maximum heat input of the single
appliance or of the appliances that make up the cascade.
Before making the gas duct, check that::
– the type of gas is correct for the appliance
– the pipes are clean
– the gas supply pipe is the same size as or larger than the one
on the boiler fitting (G 1”)
– there is a suitable filter installed on the gas line.
o pass through walls, a suitable insulating
5.9 Condensate outlet/collection
NC
m
CAUTION
– The condensate outlet duct must be airtight, suitably
sized to that of the siphon and must not be restricted
at any point.
– The condensate outlet must be constructed in full com-
pliance of the National or Local regulations in force.
Fig. 17
G G
E
Fig. 18
Description
A (mm) 838 838 838 1089 1089 1089
B (mm) 85 85 85 158 158 158
C (mm) 529 529 529 524,5 524,5 524,5
D (mm) 71 71 71 75,5 75,5 75,5
E (mm) 872 872 872 870,5 870,5 870,5
G - Gas cock con
nection
a
m
WARNING
Once installation has been completed, check that
the joints are air tight as indicated in the installation
Standards.
CAUTION
It is recommended that the gas line has a suitable filte r.
80 116 160 200 240 280
Ø 1" G Ø 1" G Ø 1" G Ø 1" G Ø 1" G Ø 1" G
ALU HE
30
m
X
D
A B
CAUTION
If the gas supply is changed from G20 to G31, mark the
box on the TECHNICAL DATA PLATE.
Marking is
116, 160
and
G31 - 37 mbar
OBLIGATORY
200
.
only for models
ALU HE 80
5.11 Smoke outlet and combustion air inlet
Sime ALU HE
(C43 - C 53 - C63 - C 83) depending on the type of installation.
The smoke outlet and combustion air inlet systems that can be
created for single boilers are shown below. Information regarding cascading boiler systems is provided in the relevant section
of this manual.
boilers are "Type B" (B23P) or "Type C", sealed,
B23P
,
NC
Fig. 20
C
G
Øi
E
Description
A (mm) 330 330 330 330 330 330
B (mm) 270 270 270 270 270 270
C (mm) 80 80 80 80 80 80
D (mm) 598 598 598 598 598 598
E (mm) 595 595 595 510 510 510
F (mm) 93 118
G (mm) 80 100
Øi (internal diameter) 160 200
d
DO NOT
– Do not block or reduce the size of the air vents of the
place of installation or the appliance.
80 116 160 200 240 280
ALU HE
F
Fig. 19
m
WARNINGS
– When the
from the place of installation it MUST BE EQUIPPED
with air vents created as described by the regula
tions in force in the destination country.
Sime ALU HE
–
upstream from the smoke duct, which safely stops
the boilers if the temperature of the smoke becomes
too high.
– We recommend using a smoke duct made from al
uminium, plastic or stainless steel, provided that it
omplies with the r
c
should be suitably resistant to high temperatures
and condensation. The condensation liquid from
the flue pipe must be drained before it enters the
aluminium boiler body so as to avoid corrosion or
blockages.
– Outlet ducts which are not isolated are a potential
source of danger.
– The flue pipe must be provided with a condensate
outlet and must ensure the minimum drop in pres
sure set by current regulations, considering pressure to be "zero" at the connection with the duct.
It is recommended that a condensate neutraliser be
–
installed before discharging it into the waste water
drain.
– The flue pipe must be of the correct size for conden
sation thermal units. Flue pipes and smoke ducts
that ar
problems with the combustion parameters and gen
erate noise.
– Ensure that the duct and condensate outlet pipes
have an angle of at least 3% towards the neutraliser
or the drain.
– Install a suitable filter on the combustion air inlet
duct to prevent dust or dirt from being aspirated.
Sime ALU HE
boilers use a smoke detector, located
e inadequat
boiler takes in combustion air
egulations in form. The material
e or of the wrong size can cause
-
-
-
-
-
31
C43/63
C53
NC
Fig. 21
5.11.1 Maximum duct lengths
The table shows the maximum permitted lengths for the smoke
outlet and combustion air inlet ducts, expressed in metres.
ALU HE
Øi 80 mm
80
116
160
200
240
280
Load loss - Equivalent lengths
ALU HE
80
116
160
ALU HE
200
240
280
45° Ø 80
mm curve
45° Ø 100
mm curve
Maximum permitted length (m)
Inlet
10 25 - -
9 25 - 8 25 - -
- - 10 25
- - 9 25
- - 8 25
0,5 1 0,5 1
0,75 1,5 0,75 1,5
1 2 1 2
0,5 1 0,5 1
0,75 1,5 0,75 1,5
1 2 1 2
Outlet
Øi 160 mm
Leq (linear metres)
Inlet Outlet
90° Ø 80
mm curve
Leq (linear metres)
Inlet Outlet
90° Ø 100
mm curve
Inlet
Øi 100 mm
45° Ø 160
mm curve
45° Ø 200
mm curve
Outlet
Øi 200 mm
90° Ø 160
mm curve
90° Ø 200
mm curve
C83
NC
Fig. 22
Inlet optional accessories
Description
90° curve M-F (6 pieces) 8077410
90° curve M-F (with take-
off point)
90° curve M-F (insulated) 8077408
Extension W. 1000 mm (6
pieces)
Extension W. 1000 mm
(insulated)
Extension W. 500 mm (6
pieces)
Internal and external ring
nut kit
Inlet terminal 8089500
45° curve M-F (6 pieces) 8077411
ALU HE 80-116-160
Diameter Ø 80 mm
8077407
8077309
8077306
8077308
8091500
Outlet optional accessories
200-240
Description
Extension Ø 160 mm L.
1000 mm
Extension Ø 160 mm L.
500mm
90° elbow Ø 160 mm 8102521 45° elbow Ø 160 mm 8102520 -
Extension Ø 200 mm L.
1000 mm
90° elbow Ø 200 mm - 8102526
ALU HE 80-116-160
Diameter Ø 160 mmDiameter Ø 200
8102523 -
8102522 -
- 8102525
ALU HE
280
mm
-
NC
Fig. 23
32
5.12 Electrical connections and External con-
MC
TS
KAVD2
trols
Sime ALU HE
must be carried out by the installer or by professionally qualified
personnel. Some of the cabling is to the MC terminal board and
some to the electronic circuit board connectors.
To connect the electrics:
– remove the top panel (1) and front panel (2) to access the MC
terminal board
– undo the screws (3) that attach the control panel and rotate it
forward
– undo the screws on the back of the control panel and take off
the cover (4) to access the electronic board.
The cables must go into the back of the boiler and must be
locked when the job is completed with the tear-proof cable clip
that's already fitted. Once the connections have been made, re
assemble what was previously dismantled.
boilers require the connections given below which
-
Connections to electronic circuit board
The connections shown below MUST be made for single boilers
or for the master boiler in a cascade.
CN3
49 50 58
N
F1
F2
L
69
CN14
72
CN7
1 1
CN4
4
5
CN5
6
7
CN6
10
JP1
1117
2
3
4
5
6
7
8
9
10
SE
CR
SB/SA
TZ1
TZ2
4
d
1
b
3
2
a
c
Fig. 24
Connections to be made by the installer
The connections shown below MUST be made for single boilers
or for the master boiler in a cascade.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
L
N
PE
N
PE
Pcp
N2
ACS
RISc
N3
SF
SF1
PC
PC1
GND
PWM
PM
VG1
L N
230 V
Pcp
PB
PM VD
SRF
50 Hz
Fig. 25
KEY:
MCP Primary circuit pump (4A - 230V)
L Live
N Neutral
PB Tank pump (4A - 230V)
PM Modulating pump (4A - 230V)
VD Diverter valve
PWM-GND Modulation for modulating pump (if present)
SF-SF1 Flue gas damper consent (Max 4A - 230V)
PC-PC1 Connections for pump operating signal
SRF Flue gas damper
N
AUXLAUX
L
VZ
TA1 230V
11121314151617
N
AR
AR
VZ
MARRONE
0...10VDC
BLU
Fig. 26
KEY:
L Live
N Neutral
SE External sensor
CR Remote control or, alternatively, a MODBUS interface
kit
SB/SA Storage tank sensor or auxiliary sensor (e.g. system
delivery sensor, SMi)
TZ1÷TZ2 Room thermostat for the zone
JP1 Dial jumper or 0...10V DC or TA2 (**)
AUX Auxiliary connection
VZ Zone valve
TA1 (230V) Room Thermostat
AR Remote alarm
(**) JP1 engaged = TA2 usable; 0 ... 10V DC not usable; JP1 dis
engaged = TA2 not usable; 0 ... 10V DC usable
m
WARNINGS
It is compulsory:
– to use an omnipolar cut-off switch, disconnect
switch, in compliance with EN standards (contact
opening of at least 3 mm)
– to respect connection L (Live) - N (Neutral)
– to refer to the electrical diagrams in this manual for
any electrical intervention
– to connect the earth wire to an effective earthing
system (*).
d
DO NOT
– to use cables with a cross-section of less than 1 mm
2
– to use the water pipes to earth the appliance.
(*)
Sime
declines all responsible for any injury or damage to
persons, animals,or property as a result of failure to provide
adequate earthing of the appliance.
-
33
5.12.1 External sensor
°C
100
110
The boiler is designed for connection to an external temperature
sensor code 8094101, which will automatically regulate the central heating delivery temperature.
ery t
This means that the deliv
on the basis of the external temperature depending on the cli
matic curve selected from those shown in the diagram (Fig. 27).
Climatic curve
Delivery temperature
90
80
70
60
50
40
30
20
20 10 0 -10 -20 -30
emperature of the boiler can vary
35 30 27,5 25 22,5
40
20
17,5
15
12,5
10
7,5
5
2,5
°C
External temperature
When fitting the sensor on the outside of the building:
– remove the cover
– attach the sensor to the wall using 2 plugs
– make the electrical connections.
-
1
3
F
NOTE:
Minimum cross-section of cables 1 mm2; maximum length
of connection 50 m; unpolarised connection terminals.
2
Fig. 28
Fig. 27
m
CAUTION
If there is an external sensor, in order to select the optimal climatic curve for the system and therefore the
delivery t
emperature based on the external tempera-
ture:
select parameter “PAR 22” or “PAR 25” or “PAR 28”
–
(see List of parameters) corresponding to zone 1, 2
or 3 as relevant
– press the
or Q button to select the curve suita-
J
ble for reaching the desired room temperature.
20
” curve is factory set to reach a room temper-
The “
ature of 20°C.
ernal sensor must be installed outside the building, on a
The ext
flat surface, in a north or north-west position (coldest side) and
well away from flue pipes, doors, windows and areas in direct
sunlight.
34
5.13 Systems that can be controlled
PS
Sime ALU HE
some system diagrams, by way of example, in which the boiler
can be a single appliance or a group of cascading boilers which
can considered as a single appliance in terms of heat output,
where
5.13.1 Main hydraulic diagrams
Full hydraulic diagram
boilers can control many types of systems. Here are
Cascade output = Boiler output x no. of boilers installed
.
m
CAUTION
When systems using
are managed by MODBUS systems,
be used to manage mixed circuits or the solar circuit.
You MUST use external devices.
ALU HE
single or cascade boilers
Sime
kits CANNOT
S1
Solar kit
code 8092277
Mix 2 Zone kit
code 8092276
Mix 1 Zone kit
code 8092275
EU
PB
VMIX 2
VMIX 1
SB
BR
P MIX 2
Smz2
P MIX 1
Smz1
P1
S2
KEY:
SE External sensor
TA Room thermostat for boiler acti
vation
M Boiler delivery
R Boiler return
GS INAIL safety unit (Italy only)
Vsic Relief valve
SP Hydraulic separator
MCP Primary circuit pump
NC Condensate neutraliser
TZ1 Zone ambient thermostat
RL1 Zone relays
Ts2
Ts1
P1 Direct zone pump
Mix 1 Zone pump
(only for installations with a SINGLE boiler)
VMIX 1 MIX 1 system mixer valve
PMIX 1 MIX 1 system pump
Ts1 MIX 1 system safety thermostat
Smz1 Zone 1 delivery probe
Mix 2 Zone pump
(only for installations with a SINGLE boiler)
VMIX 2 MIX 2 system mixer valve
PMIX 2 MIX 2 system pump
Ts2 MIX 2 system safety thermostat
Smz2 Zone 2 delivery probe
-
TZ1
Italy only
GS
SE
RL1
Vsic
PB Storage tank pump
BR DHW cylinder
SB Hot water tank sensor (SB)
SP
Pcp
NC
M
TA
R
U Domestic hot water output
E Domestic hot water inlet
Solar kit
S1 Solar delivery probe
S 2 Solar exchanger probe (tank)
PS Solar pump
35
Heating hydraulic diagram
SE
Italy only
GS
Vsic
TZ1
RL1
Mix 1 Zone kit
code 8092275
Mix 2 Zone kit
code 8092276
TA
M
P1
SA
SP
R
Pcp
Smz1
Ts1
VMIX 1
P MIX 1
P MIX 2
Smz2
Ts2
NC
NOTE:
For installations with a SINGLE BOILER, up to two MIX systems, or two groups of MIX systems, can be managed by installing
the optional accessories MIX 1 ZONE KIT (code 8092275) and MIX 2 ZONE KIT (code 8092276).
When systems using
single or cascade boilers are managed by MODBUS systems,
Sime
kits CANNOT be used to manage
ALU HE
mixed circuits or the solar circuit. You MUST use external devices.
Hydraulic diagram with zone valves
Italy only
GS
TZ1
TZ2
TZ3
SE
VMIX 2
TA
M
R
NC
KEY:
SE External sensor
TA Room thermostat for boiler
activation
M Boiler delivery
R Boiler return
GS INAIL safety unit (Italy only)
Vsic Relief valve
SP Hydraulic separator
MCP Primary circuit pump
NC Condensate neutraliser
SA Auxiliary sensor (system
delivery sensor, SMi)
Vsic
VZ1
SA
SP
Pcp
TZ1 Zone ambient thermostat
RL1 Zone relays
P1 Direct zone pump
TZ1÷TZ3 Room thermostat for the zone
VZ1-VZ3 Zone valves
Mix 1 Zone pump
(only for installations with a SINGLE boil-
er)
VMIX 1 MIX 1 system mixer valve
PMIX 1 MIX 1 system pump
VZ2
VZ3
Ts1 MIX 1 system safety thermostat
Smz1 Zone 1 delivery probe
Mix 2 Zone pump
(only for installations with a SINGLE boiler)
VMIX 2 MIX 2 system mixer valve
PMIX 2 MIX 2 system pump
Ts2 MIX 2 system safety thermostat
Smz2 Zone 2 delivery probe
36
Hydraulic diagram with tank after hydraulic separator
SB
SB
Italy only
GS
TZ1
SE
Vsic
TA
Hydraulic diagram with tank before hydraulic separator
SE
M
R
NC
Italy only
SP
Pcp
GS
RL1
TZ1
RL1
Mix 1 Zone kit
code 8092275
P1
P MIX 1
Smz1
Ts1
Mix 1 Zone kit
code 8092275
PB
VMIX 1
EU
BR
TA
KEY:
SE External sensor
TA Room thermostat for boiler
activation
M Boiler delivery
R Boiler return
GS INAIL safety unit (Italy only)
Vsic Relief valve
SP Hydraulic separator
MCP Primary circuit pump
NC Condensate neutraliser
TZ1 Zone ambient thermostat
M
R
NC
Vsic
P1
VD
SP
RL1 Zone relays
P1 Direct zone pump
VD Heating/dhw diverter valve
Mix 1 Zone pump
(only for installations with a SINGLE boiler)
VMIX 1 MIX 1 system mixer valve
PMIX 1 MIX 1 system pump
Ts1 MIX 1 system safety thermostat
Smz1 Zone 1 delivery probe
PB
VMIX 1
PMIX 1
Smz1
Ts1
PB Storage tank pump
BR DHW cylinder
SB Hot water tank sensor (SB)
U Domestic hot water output
E Domestic hot water inlet
m
CAUTION
When the tank is connected as
shown in the diagram, "PAR 02"
MUST BE SET TO 3.
BRPcp
EU
37
Underfloor heating hydraulic diagram
Italy only
SE
GS
Vsic
Mix 1 Zone kit
code 8092275
TZ1
TZ2
TA
KEY:
SE External sensor
TA Room thermostat for boiler
activation
M Boiler delivery
R Boiler return
GS INAIL safety unit (Italy only)
Vsic Relief valve
M
R
NC
VMX1
SA
SP
Pcp
SP Hydraulic separator
MCP Primary circuit pump
NC Condensate neutraliser
SA Auxiliary sensor (system deliv
ery sensor, SMi)
Zone relays
RL1
P1 Direct zone pump
TZ1÷TZ2 Room thermostat for the zone
VZ1÷VZ2 Zone valves
PMIX 1
Smz1
Ts1
VZ 1
Mix 1 Zone pump
(only for installations with a SINGLE boiler)
VMIX 1 MIX 1 system mixer valve
-
PMIX 1 MIX 1 system pump
Ts1 MIX 1 system safety thermostat
Smz1 Zone 1 delivery probe
VZ 2
m
38
CAUTION
The system designer is responsible for choosing and sizing up the system components and MUST follow the best practice
technical guidelines, as well as complying with the local and national legislation in force in the destination country.
5.14 Refilling or emptying
Mains
water supply
Heating
cicuit return
Before carrying out the operation described below, isolate the
boiler power supply.
Ensure that the inhibiter concentration is correct on refilling.
5.14.1 Method of filling a sealed system
A sealed system must only be filled by a competent person using
a method similar to that shown in figure below.
Hose
unions
Double chech
valve assembly
5.14.3 EMPTYING operations
– check that the water system isolation devices are closed
– connect a funnelling pipe to the system drain valve and open it.
When it has fully emptied, close the valve.
Stop
valve
Test cock
Filling loop
temporarily connected
Stop
valve
Fig. 29
5.14.2 SYSTEM Filling
Sime ALU HE
tem and an emptying tap. Therefore these must be provided,
during inst
the installer.
Before carrying out the operations described below, make sure
that the main system switch is set to "ON" in order for the display
to show the pressure level in the system during refilling.
– there are no requests for heat
– the main system switch is set to "ON"
– the display shows the system pressure value
– the outlet valve is closed
ON
boilers DO NOT have a device to fill the boiler/sys-
allation, assembled in the most convenient places for
Fig. 30
– open the isolation and air bleeding valves in the highest points
of the system
– open the heating circuit isolation valves
– activate the filling system "Method of filling a sealed system,
and fill the heating system until a pressure of
shown on the display
– stop the filling system
– check that there is no air in the system by bleeding all the radi
ators and the circuit on the high points of the system
check the pressure on the display and if necessary top up until
–
the correct pressure reading appears
– it is recommended that the condensate trap is filled prior to
fitting the flue, by carefully pouring water into the exhaust
connection.
0,8-6,0bar
is
-
39
6 COMMISSIONING
6.1 Preliminary operations
a
Before commissioning the appliance, check that:
– the type of gas is correct for the appliance
– the gas isolation valves for the heating system and the water
– the pump impeller rotates freely
– the siphon has been filled.
WARNING
Should it be necessary to access the areas in the bottom part of the appliance, make sure that the system
components and pipes ar
system are open
e not hot (risk of burning).
6.2 Before commissioning
After having carried out the preliminary operations, proceed as
follows:
– set the main system switch to "ON"
ON
When heat is requested from the systems the boiler or the cascade automatically carries out:
the operational checks
–
– ignition and starts automatic operation.
m
If there is a fault, the message
sage "RESET" (e.g.
sage
CAUTION
– When the display is not backlit (off), the first press
on each function button serves to backlight it (turn
it on).
– To manually stop the boiler press button
– The display will show the following screen.
"ALL"
, the fault code, the mes-
"ALL 06"
will appear on the display.
h
- no flame detected) and the mes-
T
.
Fig. 31
– The blue bar (4) on the control panel lights up. The symbols,
"- -" message and the system pressure are shown correctly
on the display
– check that the system pressure as shown on the display when
0.8
and
the system is cold is as required, between
– press button V on the single boiler or the master boiler in the
case of a cascade. The value of the delivery probe detected at
that moment will appear on the display.
6.0 bar
NOTE:
To restart the boiler press button Y, for about 3 seconds,
and then release it. The boiler repeats the ignition cycle and
works normally until the temperatures requested are reached.
6.3 Parameter setting and display
The
parameters
) or in operation.
by (
T
To go into the parameter menu:
– press buttons
same time until
"--"
set
– to scroll through the parameters press buttons L and
– to change the value set press buttons N and Z.
can be displayed and set with the boiler in stand-
and M (for approximately 2 seconds) at the
L
"PAR --"
appears on the display
(parameter number) and the value
M
PROCEDURE TO BE CARRIED OUT ONLY FOR CASCADE INSTALLATIONS
Disconnect the power supply by turning the main system
–
switch to "OFF" and then on "ON"
– wait for approximately 3 seconds to allow the electronic board
to run the necessary checks.
40
To exit the menu and go back to the first screen, press one of
the function buttons, excluding Y, or wait approx. 60 seconds
without pressing any button.
6.4 List of parameters
The parameters PAR 01 and PAR 02 are factory set according to
table “A” and automatically generate the settings for parameters
PAR 04, PAR 08, PAR 18 and PAR 31 as shown in the table.
d
TABLE “A”
Type of
gas
Boiler
power
(kW)
PAR 01 1 2 3 4 5 6 50 51 52 53
PAR 02 5 5 5 5 5 5 5 5 5 5
PAR 04 5 5 5 5 5 5 5 5 5 5
PAR 08 33 33 33 33 45 25 28 33 41 40
PAR 18 30 30 30 72 72 72 30 30 30 72
PAR 31 100 100 100 100 100 100 100 100 100 100
DO NOT
Use settings other than those shown in the table “A” as
this could generate a serious boiler malfunction.
G20 G31
80 116 160 200 240 280 80 116
160 200
TABLE “B”
No. Description
1 Instant monothermal – 3-way electric – DHW flowmeter
Instant monothermal – 3-way electric – DHW flowmeter – solar
2
input
Remote storage tank – 3-way electric – storage tank sensor –
3
low inertia
On-board storage tank – 3-way electric – DHW sensor – low
4
inertia
Storage tank – 3-way electric – storage tank thermostat – low
5
inertia (or heating only)
Remote storage tank – dual pump – storage tank sensor – low
6
inertia
7 On-board storage tank – dual pump – DHW sensor – low inertia
Remote storage tank – dual pump – storage tank thermostat –
8
low inertia (or heating only)
9 Heating only – anti-freeze sensor – low inertia
Storage tank – 3-way electric – storage tank sensor – high
10
inertia
11 Storage tank – dual pump – storage tank sensor – high inertia
Storage tank – 3-way electric – storage tank thermostat – high
12
inertia or heating only high inertia
Storage tank – dual pump – storage tank thermostat – high
13
inertia
14 Heating only – anti-freeze sensor – high inertia
Type No. Description Range U/M Step Default
CONFIGURATION
PAR 01 Combustion configuration
PAR 02 Hydraulic configuration
PAR 03 Assigning Timed Programmer 2
PAR 04 Disabling Pressure Transducer
PAR 05 Assigning Auxiliary Relay
PAR 06 Disabling Light Bar
PAR 07 Assigning Channels QAA73
PAR 08 No. of Ignition Step Fan Revs 0,0 …. 81 rpmx100
PAR 09 Long chimney 0 … 40 % 1 0
PAR 10 Opentherm device
PAR 11 External Sensor Value Correction -5...+5 °C - 0
PAR 12 Duration of Backlighting
PAR 13 Modulating Pump Speed
1 = DHW+Recirculation Pump
3 = Enabled 0…4 bar NO ALARM
4 = Enabled 0…6 bar NO ALARM
– = ND
1 .. 53
– = ND
1 .. 14 (see table “A”)
2 = DHW
3 = Recirculation Pump
0 = Disabled
1 = Enabled 0…4 bar
2 = Enabled 0…6 bar
5 = Enabled 0.8…5.8 bar
6 = Enabled 0.3…5.8 bar
1 = Remote alarm
2 = Recirculation Pump
3 = automatic filling
4 = N.C. remote alarm
5 = Heat pump
6 = Zone 2 valve
0 = Disabled
1 = Enabled
0 = Not assigned
1 = Circuit 1
2 = 3-zone system
1 = QAA73
2 = QAA53
3 = RVS43.143
4 = RVS46.530
5 = RVS61.843
- - = always
0 = never
1…199
- - = no modul.
AU = AUTO
30...100
- -
- -
- - 1
- -
- - 1
- - 1
- - 1
0.1 from
0.1 to
1 from
20 to 81
- - 1
seconds
x 10
% 10 AU
See table
See table
See table
See table
19.9
1 3
“A”
“B”
“A”
“A”
41
Type No. Description Range U/M Step Default
49 50 58
PAR 15 Boiler address (specific to boilers in a cascade)
PAR 16 Not used
PAR 17 Not used 1…30 - 1 25
PAR 18 Post-ventilation time 1...180
PAR 19 System type
DOMESTIC HOT WATER - HEATING
PAR 20 Minimum Tset Zone 1 Heating Par 64 OEM .. Par 21 °C 1 20
PAR 21 Maximum Tset Zone 1 Heating Par 20 .. Par 65 OEM °C 1 80
PAR 22 Heating Curve Grade Zone 1 3...40 - 1 20
PAR 23 Minimum Tset Zone 2 Heating Par 64 OEM .. Par 24 °C 1 20
PAR 24 Maximum Tset Zone 2 Heating Par 23 .. Par 65 OEM °C 1 80
PAR 25 Heating Curve Grade Zone 2 3...40 - 1 20
PAR 26 Minimum Tset Zone 3 Heating
PAR 27 Maximum Tset Zone 3 Heating Par 26 .. Par 65 OEM °C 1 80
PAR 28 Heating Curve Grade Zone 3 3...40 - 1 20
PAR 29 ∆T heating 10…40 °C 1 20
PAR 30 Heating Post-Circulation Time 0 .. 199 Sec 10 30
PAR 31 Heating Maximum Output 30 ..100 % 1
PAR 32 Pump Activation Delay Zone 1 0 .. 199 10 Sec 1 1
PAR 33 Re-ignition Delay 0 ..10 Min 1 3
PAR 34 Supplementary sources activation threshold
PAR 35 Boiler Antifreeze Threshold 0…+20 °C 1 3
PAR 36 External Sensor Antifreeze Threshold -5…+5 °C 1 -2
PAR 37 Flow meter Modulation Saturation Band -- = Disabled 0….100 % 1 100
PAR 38 DHW Post-Circulation Time 0…199 Sec 1 0
PAR 39 Anti-legionella Function (Only hot water tank)
EXPANSION BOARD
PAR 40 No. of expansion boards 0….3 - 1 0
PAR 41 Mix Valve Motion Time 0 .. 199 10 sec 1 12
PAR 42 DHW Priority on Mixed Zone
PAR 43 Screed Drying
PAR 44 Solar thermal system type 1….8 -- 1 1
PAR 45 ∆Ton Solar Pump Manifold 1
PAR 46 Delay to solar integration “- -“, 0….199 min 1 0
PAR 47 Tmin Solar Manifold “- -“, -30….0 °C 1 -10
PAR 48 Tmax Solar Manifold “- -“, 80….199 °C 1 120
RESET
PAR 49 Reset default parameters (Par 01 – Par 02 equal to “—”) - , 1 - - -
-- = not enabled
0 = master
1…7 = slaves
-- = not enabled
1…31 = slaves
0 = 2 zones
1 = 3 zones
Par 64 OEM ..
.. Par 27
--,
-10…40
0 = Disabled
1 = Enabled
0 = Parallel
1 = Absolute
0 = Off
1 = Curve A
2 = Curve B
3 = Curve A+B
Par74OEM+1
….50
- 1 "- -"
- 1 "- -"
seconds
x 10
- - 0
°C 1 20
°C 1 -
- - 0
- - 1
- - 0
°C 1 8
1
See table
“A”
See table
“A”
6.5 Configuring the auxiliary sensor
Below is the procedure for configuring the storage tank sensor
(SB) or the auxiliary sensor (e.g. system delivery sensor, SMi).
– press buttons
rameter menu shows
press buttons
–
“--”
appears on the display
– to access the OEM parameters, enter the following key combi-
nation:
L
– press the L and M buttons to select the “OEM 52” parameter
– to change the “OEM 52” parameter settings and set the value
to “5”, press the
– to exit the menu and go back to the first screen, press one
of the function buttons, excluding RESET, or wait approx. 60
seconds without pressing any buttons.
42
and M (~ 2s) at the same time until the pa-
L
and M (~ 2s) at the same time again until
L
M Z N
Z
Z
and N buttons
F1
F2
Type No.
OEM 52
N
10
Description
Assigning
AUX sensor
1 1
4
5
6
7
2
CN4
3
4
5
CN5
6
7
8
CN6
9
10
0 = not used
1 = DHW inlet sensor
2 = hot water tank sensor
3 = antifreeze sensor
4 = hot water tank thermost.
5 = System delivery sensor
Range
CR
SB/SA
Fig. 32
Default
2
6.6 Fault/error message
OFF
In the event of a fault/malfunction the message
pear on the display with the alarm number and the light bar (4)
will turn red.
e: “ALL 02” (Low System Pressure Error: less than 0.8
Exampl
bar).
Before repairing the fault:
– disconnect the appliance from the mains power by setting the
main switch to "OFF"
– as a precautionary measure, close the gas isolation valve.
Resolve the problem and start-up the boiler again.
"ALL"
will ap-
Fig. 33
NOTE:
When, in addition to the message
also appears on the display, after having repaired the
h
fault, button
must be pressed for approx. 3 seconds, and
Y
"ALL ..."
then released. The boiler starts up again normally.
6.7 Fault / malfunction codes
Type No. Description
ALL 01 Air pressure switch fault
ALL 02 Low water pressure in system
ALL 03 High water pressure in system
ALL 05 Boiler delivery probe fault
ALL 06 No flame detection
ALL 07
ALL 08 Fault in flame det
ALL 09 No water circulating in primary system
ALL 10 Hot water tank sensor/anti-freeze faulty
ALL 11 Modulator disconnected error
ALL 13 Smoke probe triggered
ALL 14 Smoke probe fault
ALL 15 Fan fault
ALL 18 Boiler delivery probe temperature above 117°C
ALL 19 External sensor fault (flashing warning)
ALL 20 Mix 1 zone safety thermostat triggered
ALL 21 Mix 1 Zone valve delivery probe fault
ALL 22 Mix 2 zone safety thermostat triggered
ALL 23 Mix 2 Zone valve delivery probe fault
ALL 24 S1 solar delivery probe fault
ALL 25 S2 solar exchanger probe fault (tank)
ALL 26 S3 2nd solar system delivery probe fault
ALL 27
ALL 29 Number of expansion boar
ALL 30 Return sensor fault
ALL 31 Cascade delivery probe (SMC) fault
ALL 32 Three zone system configuration fault
ALL 35 Communication fault RS485 board
ALL 36 Number of boilers connected in cascade fault
ALL 45
ALL 70 Cascade stop general fault
ALL 71 General fault with a boiler in the cascade
ALL 72 Delivery probe (SMC) disconnected error
ALL 80 Gas valve control circuit hardware fault
ALL 89 Gas valve control circuit hardware fault
ALL 98 Maximum number of software errors reached
ALL 99 Generic board software error
Safety thermostat or siphon pressure switch trig
gered
ection circuit
Solar application coherence fault – hydraulic config
uration
ds connected fault
Manual release performed more than 6 consecutive
times in the last hour
the symbol
-
-
43
6.8 Gas calibration
ALU HE 80
ALU HE 116
1
ALU HE 80
ALU HE 116
After checking that the boiler is operating correctly, you must
take combustion readings as well as maximum and minimum
power readings, and check the combustion efficiency by activat
ing the
chimney sweeper function
.
6.8.1 Chimney sweep function and calibration
The chimney sweeper function is used by the qualified maintenance technician to check the gas pressure, detect the combustion parameters and measure the combustion efficiency when
equir
ed by the legislation in force.
r
This function lasts 15 minutes and is activated by proceeding as
follows:
– with the boiler inactive, loosen the screw on the mains tapping
point (1) on the gas valve and connect a pressure gauge
GAS VALVE
-
2
– measure the CO
in the table. If it does not correspond, adjust the "maximum
power adjustment screw" (2) on the gas valve until you obtain
2
the CO
readings.
m
Once any necessary adjustments and readings have been made:
– press the
(Qmin) as indicated on the display with
– measure the CO2 and check that it corresponds to the value
in the table. If it does not correspond, adjust the "minimum
power adjustment screw" (4) on the gas valve until you obtain
the CO
GAS VALVE
value shown in the table. Take any other necessary
IMPORTANT
The gas valve on the
screws to adjust the maximum power
– screw (2) for an approximate adjustment
– screw (3) for a finely tuned adjustment.
We recommend adjusting the two screws alternately.
2
value shown in the table.
and check that it corresponds to the value
ALU HE 80
button to operate the boiler on minimum power
N
is equipped with
:
G
3
TWO
1
ALU HE 160-200-240-280
1
Fig. 34
– activate a heat request
– press button
Leave the appliance to stabilise, then:
– press and hold the M button for a few seconds, until you see
figure flashing
the
z
– press the
(Qmax) as indicated on the display with
– check that the gas supply pressure is: G20=20 mbar -
G31=37mbar
or n to activate the boiler.
s
button to operate the boiler on maximum power
Z
v
4
ALU HE
80
116
160
200
240
280
2
ALU HE 160-200-240-280
CO2 (G20) CO2 (G31)
Qmax
(% ± 0,2)
9,3 9,1 10,6 10,3
9,3 9,1 10,6 10,3
9,3 9,1 10,5 10,3
9,3 9,1 10 9,7
9,3 9,1 - 9,5 9 - -
Qmin
(% ± 0,2)
4
2
4
Qmax
(% ± 0,2)
2
Fig. 35
Qmin
(% ± 0,2)
m
44
CAUTION
This procedure MUST BE PERFORMED after:
– gas conversion
– changing the gas valve following a fault.
6.9 Operating data display
1. External temperature, only when external sensor
Once the boiler is operating, a qualified technician can view the operating data.
To access the information, press the
the next piece of information is shown.
If the
button is not pressed, the system exits the function automatically.
L
If there are expansion boards (Mix 1 or Mix 2 Zone or solar), the relative information cannot be shown.
button. The first piece of information is shown on the display. Each time this button is pressed,
L
is connected
2. Heating delivery sensor temperature (SM)
3. Not used
4. Auxiliary sensor or hot water tanksensor
temperature (SB)
9. Fan revs in rpm x 100 (e.g. 4,800 and 1,850 rpm)
10. Burner operating hours in h x 100 (e.g. 14,000 and 10)
11. No. of times burner switched on x 1,000 (e.g. 97,000 and 500)
12. Total no. of faults
5. Smoke probe temperature (SF)
6. Heating temperature for primary circuit
7. Heating temperature for secondary circuit
8. Ionisation current in µA 16. Not used
13. No. of times parameters accessed (e.g. accessed 140 times)
14. No. of times OEM parameters accessed (e.g. accessed 48 times)
15. Not used
45
29. Valve close command with MIX 2 ZONE board, respectively ON and OFF
18. Heating return sensor value (SR)
19. Cascade manifold sensor value
30. Solar sensor temperature with solar board
20. Mixed system delivery probe value with
MIX 1 ZONE board
21. MIX ZONE safety thermostat, respectively ON and OFF
22. Pump with MIX 1 ZONE board, respectively ON and OFF
23. Valve open command with MIX 1 ZONE board,
respectively ON and OFF
24. Valve close command with MIX 1 ZONE board,
respectively ON and OFF
31. Solar sensor temperature with solar board
32. Solar sensor temperature with solar board
33. R1 solar relay with solar board, respectively ON and OFF
34. R2 solar relay with solar board, respectively ON and OFF
35. R3 solar relay with solar board, respectively ON and OFF
25. Mixed system delivery probe value with
MIX 2 ZONE board
26. Safety thermostat with MIX 2 ZONE board (input S1),
respectively ON and OFF
27. Pump with MIX 2 ZONE board, respectively
ON and OFF
28. Valve open command with MIX 2 ZONE board,
respectively ON and OFF
90. Software version on RS-485
(e.g. version 01)
36. Solar flow switch status, respectively ON and OFF
40. Pump command % PWM
60. Last fault error code
45. Heating temperature for third circuit
61. Second-to-last fault
error code
91. Software version on EXP
board (config. MIX ZONE)
92. Software version on 2nd EXP
board (config. MIX ZONE)
46
6.10 Gas conversion
OFF
ALU HE 80
ALU HE 116
1
X
m
CAUTION
Conversion may ONLY be carried out by Professionally
Qualified Personnel.
– set the parameter “PAR 01” appropriately, as well as any other
parameters where necessary
– start the boiler, proceeding as described under Commission
ing in this manual
– activate the Chimney sweep function and calibration, follow-
ing the procedure described in the relevant paragraph.
-
Sime ALU HE
plied to operate with G20 gas, but can also function using G31
gas.
If changing the type of useable gas:
set the main system switch to "OFF"
–
– isolate the gas cock
– avoid contact with any hot surfaces
– connect the gas line to the fuel tank
– loosen the screw on the mains tapping point (1) on the gas
valve and connect a pressure gauge
GAS VALVE
boilers in the 80,
116, 160
and
200
models are sup-
Fig. 36
m
CAUTION
If the gas supply is changed from G20 to G31, mark the
box on the TECHNICAL DATA PLATE.
Marking is
116, 160
and
G31 - 37 mbar
OBLIGATORY
200
.
only for models
ALU HE 80
,
1
ALU HE 160-200-240-280
1
Fig. 37
47
7 MAINTENANCE
OFF
3
4
5
7.1 Servicing
For the appliance to operate safely, correctly and efficiently, current legislation requires that the system manager call upon the
services of a pr
ular maintenance, at least
legal provisions
m
m
ofessionally qualified technician to carry out reg-
annually
.
or according to the
specific
CAUTION
– Only qualified persons in compliance with the in-
structions contained in this manual are permitted to
all, commission and maintain this boiler. Suita-
inst
ble protective safety equipment
installation of this boiler must be in accordance with
the relevant requirements of the current Gas Safety
(installation and use), the local building regulations,
and I.E.E. wiring regulations.
– Make sure that the system components and pipes
are not hot (risk of burning).
MUST be worn
. The
CAUTION
Before carrying out the interventions described below:
– set the main system switch to "OFF"
– isolate the gas cock
– avoid contact with any hot surfaces
– if components are replaced, use ONLY original spare
parts.
2
6
1
Fig. 39
7.3.2 Cleaning the burner
To clean the burner:
– disconnect the connectors for the fan, gas valve, electrodes
and flame detection sensor
– carefully remove the electrode unit and the flame detection
sensor
– unscrew the joint between the pieces (7) of the gas line
– undo the four fixing screws (8) and remove the fan-gas valve
unit (9) from the boiler body, taking care not to damage the
gasket (10)
– carefully take out the burner (11) and clean it using com
pressed air or a soft brush to remove any obstructions
-
7.2 External cleaning
7.2.1 Cleaning the case
When cleaning the cladding, use a cloth dampened with soap
and water, or water and alcohol for stubborn marks, or with special products.
e cl
eaning is completed, dry the appliance.
Onc
d
DO NOT
Do not use abrasive products.
7.3 Burner Inspection
7.3.1 Burner access
To access the internal parts of the boiler:
– remove the front panel (1)
– remove the top panel (2).
To improve accessibility to the internal parts:
– remove the two screws (3) fixing the support for the electrical
parts (4)
– release the connection cables from the clip (5)
– move the support (4) to the right and release it from the two
catches
– move the support (4) down and, via the slots, hook it into the
two clasps (6) on the left side panel.
48
Fig. 38
9
7
8
Fig. 40
11
10
After cleaning has been completed, reassemble all the compo-
19
4 ±0,5
WARNING:
the rounded corner of the
plate must be positioned at
the top right
nents previously removed, putting in new seals where necessary.
In the ev
the diagrams in this manual.
m
ent of possible detached electrical connections, refer to
CAUTION
A test must be carried out on the gas line seal, as required by legislation.
7.3.3 Cleaning boiler body
– Unscrew the nuts (12) and remove the inspection doors (13)
and seals (14)
– Use a rod suitable for mechanically cleaning the boiler body
ducts (e.g. Sime accessory (15) code 6077930). A chemical
product can be used provided it is suitable for aluminium bod
ies working by condensation (e.g. Bekaert TAB 2/2000).
-
7.3.5 Check of electrodes and flame detection sensor
It is recommended that the regulation of the ignition electrodes
unit (23) and their wear, is always checked, along with that of the
flame detection sensor (24).
If necessary replace them, taking care that gaskets (21) and (22)
are not damaged during their extraction.
23
21
22
24
13
12
At the end of the cleaning operations, check the state of the
seals (14) and if necessary replace them.
Refit the (13) doors and retighten the nuts (12) using a 7 Nm
tightening torque.
14
15
Fig. 41
7.3.4 Dismantling and cleaning siphons and conden-
sate collection tank
– Unscrew the nuts (16) and remove the inspection doors (17).
Check and clean the condensate collection tank. When clean-
ing has been completed, reassemble the door, checking the
seal and r
– retighten the nuts (16) using a 7 Nm tightening torque
– undo the ring nuts (18) and (19) and remove the siphon, watch
ing out for any possible leaks of condensate
undo the ring nut (20) and thoroughly clean the internal parts
–
of the siphon
– retighten the ferrules (18), (19) and (20) carefully.
eplacing it if nec
essary
-
Fig. 43
NOTE:
When you insert the flame detection sensor, for example
following maintenance, make sure that the sensor faston (24) is
angled as shown in the figure.
16
17
18
20
Fig. 42
49
7.3.6 Connecting the air pressure switch and siphon
The silicon tubes on the air pressure switches (1) and siphon
(2) MUST be reconnected, where it was necessary to disconnect
them, as shown in the figure:
– Outlet P1 on the air pressure switch (1) to the fan (3)
– Outlet P2 on the air pressure switch (1)and outlet P1 on the
siphon pressure switch (2) to the boiler body (4).
3
1
P1
P2
2
P1 P2
7.4 Circuit Board Replacement
If you replace the
SET THE PARAMETERS as described under "Parameter setting
and display".
electronic circuit board or gas valve
YOU MUST
4
NOTE:
Outlet P2 on the siphon pressure switch (2) remains free.
7.5 Possible faults and solutions
LIST OF MALFUNCTION/FAULT ALARMS
Shown on display
Type of malfunction or
fault
Air pressure switch fault
Low water pressure in
system (< 0,8 bar)
Cause Solution
Incorrect wiring on air pressure
switch
Tubes from air pressure switch
disconnected or damaged
Air duct clogged
Smoke duct clogged
System pressure is lower than 0.8
bar (78 kPa) and the boiler has
stopped
Fig. 44
- Check correct wiring and air pressure switch tubes
- Check that the air duct is free of obstructions
- Check that the smoke duct is free of obstructions
- Carry out system refilling/filling until the pressure is
reset at 0,8 - 5,8 bar (80 - 568 kPa)
- If this error happens again, it is advisable to check that
the system is sealed
High water pressure in
system (> 5,8 bar)
Boiler delivery sensor fault
No flame detection
50
System pressure is higher than 5.8
bar (568 kPa) and the boiler has
stopped
The delivery sensor (SM) is open or
has short-circuited
The flame is not detected at the end
of an ignition sequence
- Empty the system until the pressure is reset at 0,8 - 5,8
bar (80 - 568 kPa)
- Check the pressure transducer
- Check the sensor and its connections
- Check the flame detection sensor and its connections
- Check the electronic circuit board
- Ensure correct gas supply pressure
Shown on display
Type of malfunction or
fault
Safety thermostat or
siphon pressure switch
triggered
Cause Solution
- Check whether there is little water in the system
The boiler stops due to activation of
the safety thermostat or the siphon
pressure switch. The system pump
stays on for one minute
- Check the primary circulation pump
- Check for possible obstruction of condensate drain
- Check the electrical wiring and connections of the
siphon pressure switch tubes
- Once the fault is repaired, press the (reset) button to
start the boiler again
Fault in flame detection
circuit
No water circulating in
primary system
Tank/anti-freeze sensor
fault
Modulator disconnected
error
Exhaust sensor (SF) inter-
vention
Smoke probe fault
Fan fault
Detection of a non-real flame signal,
normally before ignition phase
Faulty components
Poor circulation of water in the
primary water circuit is caused by
the ∆T between the delivery sensor
(SM) and return sensor (SR) and may
occur on start-up or during operation
The sensor connected to the AUX terminals is open or has short-circuited
The gas valve is disconnected from
the electrics
The smoke detector (SF) has detected a too high temperature
The smoke detector (SF) is open or
has short-circuited
The fan speed is outside the pre-set
range. If the anomaly activation
condition continues for two minutes,
the boiler carries out a forced stop
for thirty minutes. At the end of the
forced stop, the boiler will try to
ignite again
- Check the detection electrode and its connections
- Check the electronic circuit board
- Check system pressure and whether the water level in
the system is low
- Check the primary circulation pump
- Check the delivery sensor (SM) and return sensor (SR)
- Check settings of parameter PAR 02
- Check the sensor and its connections
- Check the electrical connection to the gas valve
- Check that the smoke duct, the flue pipe and the chimney have no obstructions
- Once the fault is repaired, press the (reset) button to
start the boiler again
- Check the sensor and its connections
- Check the fan rpm
- Check the electronic circuit board
Boiler delivery probe tem-
perature above 117°C
External sensor fault
(flashing warning)
Mix 1 zone safety thermo-
stat triggered
Mix 1 Zone valve delivery
probe fault
Mix 2 zone safety thermo-
stat triggered
Mix 2 Zone valve delivery
probe fault
S1 solar delivery probe
fault
Other safety devices were not tripped
earlier to limit the temperature of
the boiler body
The external sensor (SE) has
short-circuited. The boiler continues
normal operation
The Mix 1 system's delivery probe is
faulty
The mixer valve has failed
The board has failed
The Mix system's delivery probe is
open or has short-circuited
The Mix 2 system's delivery probe is
faulty
The mixer valve has failed
The board has failed
The Mix system's delivery probe is
open or has short-circuited
The solar system's delivery probe is
open or has short-circuited
- Check that the delivery probe, safety thermostat and
smoke probe are working correctly
- Check the sensor and its connections
- Check the delivery probe
- Check the mixer valve
- Check operation of the board
- Check the electrical connections of all components
- Check the sensor and its board connections
- Check operation of the board
- Check the delivery probe
- Check the mixer valve
- Check operation of the board
- Check the electrical connections of all components
- Check the sensor and its board connections
- Check operation of the board
- Check the sensor and its board connections
- Check operation of the board
51
Shown on display
Type of malfunction or
fault
Cause Solution
S2 solar exchanger probe
fault (tank)
S3 2nd solar system deliv-
ery probe fault
Solar application coher-
ence fault – hydraulic
configuration
Number of expansion
boards connected fault
Return sensor fault
Cascade delivery probe
(SMC) fault (shown on slave
no. 1 only)
Communication fault
RS485 board
The probe on the solar exchanger is
open or has short-circuited
The delivery probe on the 2nd sys
tem, where applicable, is open or has
short-cir
cuit
ed
- Check the sensor and its board connections
- Check operation of the board
-
- Check the sensor and its board connections
- Check operation of the board
Incorrect wiring on the solar board
probes for the type of installation
- Check the wiring and the selected configuration
selected
Parameters not set correctly - Check PAR 40
The return sensor (SR) is open or has
short-circuited. The boiler continues
- Check the sensor and its connections
normal operation
The cascade delivery probe (SMC) is
open or has short-circuited, or is not
connected to the slave 1 boiler
The RS485 board is faulty
Electrical connections incorrect or
interrupted
- Check the probe and its connections to the slave 1
boiler
- Check operation of RS485 board
- Check the electrical connections
Number of boilers connect-
ed in cascade fault
Manual release performed
more than 6 consecutive
times in the last hour
Cascade delivery probe
(SMC) fault (shown on
master only)
General fault with a boiler
in the cascade (shown on
master only)
Delivery probe (SMC) dis-
connected error
Gas valve control circuit
hardware fault
Gas valve control circuit
hardware fault
Number of cascading boilers does
not correspond to setting for PAR A1
(CASCADE)
A alarm repeats continuously and
has been reset more than 6 consecutive times in the last hour.
The cascade delivery probe (SMC) is
open or has short-circuited or is not
connected to the slave 1 boiler
There is a fault on one of the slave
boilers
The boiler delivery probe is disconnected and/or damaged
- Check the setting for PAR A1 (CASCADE) against the
number of boilers in the cascade
- Check what the recurring alarm refers to and find the
solution. Then turn the boiler off and on again, then
reset the alarm.
- The cascade delivery probe (SMC) is open or has
short-circuited, or is not connected to the slave 1 boiler
- Resolve the problem according to the alarm on the
display of the slave boiler showing a fault
- Check the wiring and replace the probe if necessary
Circuit board components damaged - Replace the board
Circuit board components damaged - Replace the board
Maximum number of soft-
ware errors reached
Generic board software
error
52
The software does not work properly - Replace the board
The software does not work properly - Replace the board
TABLE OF CONTENTS
CASCADING SYSTEMS
8 CASCADING SYSTEMS 54
8.1 Cascade characteristics .........................54
8.2 Characteristics of cascading boilers ...............54
8.3 Approximate clearance measurements ............54
8.4 Main primary circuit ............................55
8.5 Technical features..............................56
8.6 Smoke outlet and combustion air inlet .............57
8.7 Gas line.......................................57
8.8 Evacuating condensate ..........................57
8.9 Electrical connections for the cascade . . . . . . . . . . . . . 58
8.10 Master boiler wiring diagram.....................59
8.11 Wiring diagram for slave 1 boiler..................60
8.12 Wiring diagram for slave 2-7 boilers ...............61
8.13 Displaying and setting cascade parameters.........62
8.13.1 Routing the cascading boilers ........... 62
8.13.2 CASCADE parameters for the master boiler 62
8.14 Fault / malfunction codes........................62
9 EXPLODED VIEWS 67
10 APPENDIX 1 (GUIDANCE HHIC) 77
11 APPENDIX 2 91
53
8 CASCADING SYSTEMS
8.1 Cascade characteristics
Each boiler connected in a cascade must be identified with a
specific address than can be set under the relevant parameter
(PAR 15), which determines how it behaves.
m
WARNINGS
For the cascade to function correctly, the external sensor (SE) must be installed.
8.2 Characteristics of cascading boilers
Master boiler
master
The
control units must be connected, as well as all of the system
components such as pumps, zone valves and external sensors.
It is the only one that communicates with the other slave boilers
in the cascade.
The heat requests are then sent to the master boiler and man
aged according to an algorithm that controls the cascade by
turning the slave boilers on and off, and activating the pumps
and necessary valves, etc.
As well as controlling the specific boiler parameters, it also con
trols the main cascade parameters.
Slave boil
Slave
The cascade delivery probe (SMC) MUST be connected to connector CN4 on the electronic board. The temperature value detected by the SMC probe is read cyclically and used by the algorithm to manage the cascade in heating mode.
boiler is the only boiler to which the TAs and the room
-
-
er no. 1
boiler no. 1 acts as the main slave boiler in the cascade.
8.3 Approximate clearance measurements
m
≥ 1,2 m
≥ 1,2 m
≥ 1,2 m
CAUTION
Observe the required clearances.
≥ 1,5 m
≥ 0,1 m
Fig. 45
er no.s ... (from no. 2 to no. 7)
e boil
Slav
All slave boilers contribute to producing the heat needed to serve
the connected systems, and each slave boiler receives an on/off
command from the master boiler only.
The function (user) buttons on all of the slave boilers are disa
bled, with the exception of the RESET button which is used ONLY
ases where the boiler locks out.. The installer buttons remain
in c
enabled to ensure that the appliance is configured correctly.
Producing domestic hot water
Domestic hot water is produced when a storage tank is installed
in the system which can be managed as a “direct system” or as
signed to any boiler in the cascade, whether master or slave.
The neces
probe, tank pump, anti-legionella and any priority or simultane
ous operation (PAR 2).
m
sary parameters must clearly be set for managing the
WARNINGS
When boilers are connected in a cascade, they communicate ONLY with the master boiler, treating the cascade as a single heat generator where:
ade output = Boil
Casc
er output x no. of boilers installed
-
-
-
54
8.4 Main primary circuit
Italy only
Sime ALU HE
ditional components as they are equipped with the specific cascade board as standard. The cascade can be made up of between
o and eight boil
tw
boilers can be connected in a cascade without ad-
ers of the same model (e.g. three
ALU HE 80
).
GS
SE
Vsic
TA
ALU HE
MASTER
KEY:
TA Room thermostat for boiler activation
M Boiler delivery
R Boiler return
GS INAIL safety unit (Italy only)
Vsic Relief valve
M
ALU HE
SLAVE
n°1
R
Pcp Pcp Pcp
Vsic
Vsic
M
R
ALU HE
SLAVE
n°2...n°7
SP Hydraulic separator
MCP Primary circuit pump
NC Condensate neutraliser
SE External sensor (Obligatory)
SMC Cascade delivery probe
Vsic
M
R
Vsic
SMC
SP
NC
Fig. 46
m
CAUTION
The system designer is responsible for choosing and sizing up the system components and MUST follow the best practice
technical guidelines, as well as complying with the local and national legislation in force in the destination country.
55
8.5 Technical features
DESCRIPTION
80 116 160 200 240 280
ALU HE
CERTIFICATIONS
Country of intended installation
AT - BE - CH - CY - CZ - DK - EE - ES - FI - FR - GB - GR - HU
IE - IT - LT - LV - NL - NO - PT - SE - SI - SK
Fuel G20 / G31 G20
PIN number 1312CS6214
Category II2H3P I2H
Appliance classification B23P - C43 - C53 - C63 - C83
Class NO
x
(*) 6 (< 56 mg/kWh)
HEATING PERFORMANCE
HEAT INPUT (**)
Nominal flow (Q
Minimum flow (Q
n
max) (***) kW 80 115,5 160 200 240 280
nw
min) G20 / G31 kW 20 / 20 21 / 28,8 32 / 32 40 / 50 48 62
HEAT OUTPUT
Nominal (80-60°C) (P
Nominal (50-30°C) (P
Minimum G20 (80-60°C) (P
Minimum G20 (50-30°C) (P
Minimum G31 (80-60°C) (P
Minimum G31 (50-30°C) (P
n
max) (***) kW 77,8 112,3 156,1 195,7 234,4 275,4
n
max) (***) kW 83,8 122 168,2 208,6 251,8 295,3
n
min) kW 19,2 20,1 30,6 37,8 46,5 60,4
n
min) kW 21,6 22,8 34,3 42,5 52 66,0
n
min) kW 19,2 27,5 30,5 47,2 - -
n
min) kW 21,6 31,2 34,2 53,1 - -
EFFICIENCY
Max useful efficiency (80-60°C) % 97,3 97,2 97,5 97,8 97,7 98,3
Min useful efficiency (80-60°C) % 95,9 95,6 95,6 94,4 96,8 97,4
Max useful efficiency (50-30°C) % 104,7 105,6 105,1 104,3 104,9 105,4
Min useful efficiency (50-30°C) % 108,2 108,5 107,1 106,2 108,4 106,4
Useful efficiency at 30% of load (40-30°C) % 108,2 108,1 108,1 108,0 108,1 108,3
Losses after shutdown at 50°C W 251 276 301 327 352 377
ELECTRICAL SPECIFICATIONS
Power supply voltage V 230
Frequency Hz 50
Absorbed electrical power (Q
Absorbed electrical power at (Q
n
max) (***) W 211 263 230 360 408 438
n
min)30% (***) W 41 25 24 50 52 165
Absorbed electrical power in stand-by (***) W 6 6 6 6 6 6
Electrical protection degree IP XOD
COMBUSTION DATA
Smoke temperature at Max/Min flow (80-60°C) °C 66 / 57 65,1 / 56 61,9 / 58,1 69,6 / 58,1 70,7 / 58,3 69,2 / 61,5
Smoke temperature at Max/Min flow (50-30°C) °C 51 / 32 46,4 / 30,4 52,3 / 34,5 50,6 / 31,0 50,2 / 30,3 49,6 / 35,9
Smoke flow Max/Min (***) g/s 37,6 / 9,6 54,3 / 10,1 75,2 / 15,3 94,0 / 19,2 112,8 / 23 129,2 / 30
CO
2
at Max/Min flow rate (G20) % 9,3 / 9,1 9,3 / 9,1 9,3 / 9,1 9,3 / 9,1 9,3 / 9,1 9,5 / 9,0
CO
2
at Max/Min flow rate (G31) % 10,6 / 10,3 10,6 / 10,3 10,5 / 10,3 10,0 / 9,7 - -
NOx measured mg/kWh 56 52 54 44 37 41
NOZZLES GAS
Gas consumption at Max/Min flow rate (G20) (only at
max. Q
n
)
Gas consumption at Max/Min flow rate (G31) (only at
n
)
max. Q
Gas supply pressure (G20/G31)
3
/h 8,28 / 2,08
(***) m
(***) kg/h 6.25 / 1,55 8,98 / 2,19
mbar 20 / 37 20 / 37 20 / 37 20 / 37 20 20
kPa 2 / 3,7 2 / 3,7 2 / 3,7 2 / 3,7 2 2
12,08 /
2,21
17,01 /
3,38
12,41 /
3,14
21,16 /
4,23
25,39 /
5,08
29,6 / 6,55
15,55 / 3,8 - -
TEMPERATURE PRESSURE
Max operating temperature (T max) °C 85
Heating adjustment range °C 20÷80
Min/Max operating pressure
bar 0,8 / 6
kPa 80 / 600
Water content in boiler (***) l 12,5 15,3 18,0 22,9 25,6 28,4
Loss of load water side T nom (20°C) mbar 65 80 80 90 90 100
Max. T at min./max. power °C 35 / 25 35 / 25 35 / 25 35 / 25 35 / 25 35 / 25
Water flow rate T 20°C (only at max. Q
Water flow rate T 10°C (only at max. Q
n
) m3/h 3,34 4,83 6,67 8,41 10,08 11,84
n
) m3/h 6,69 9,66 13,34 16,82 20,16 23,7
Total residual head (outlet + inlet) Pa 250 250 200 200 200 100
(*) NOx class according to UNI EN 15502-1:2015
(**) Heat input calculated using the lower heat output (Hi)
(***) Multiply the value by the number of boilers that make up the cascade installation
G20 Hi.
9.45 kW/m3 (15°C, 1013 mbar) -
56
G31 Hi.
12.87 kW/kg (15°C, 1013 mbar)
8.6 Smoke outlet and combustion air inlet
SCR
SCR
SCR
The smoke outlet MUST be sized by an expert and installed by an
installer who MUST use approved materials, suited to the type of
appliances, and follow the best practice technical guidelines and
comply with the national and local legislation in force
m
CAUTION
– Smoke outlets that are inadequate or the wrong size
can have a negative impact on the combustion parameters and amplify the combustion noise.
The smoke outlet on each boiler in the cascade
–
should be connected to an exhaust flue. When nec
essary, use motorised valves (SCR), (see "Optional
essories").
acc
-
Load loss - Equivalent lengths
Leq (linear metres)
ALU HE
80
116
160
ALU HE
200
240
280
45° Ø 80
mm curve
45° Ø 100
mm curve
Inlet Outlet
90° Ø 80
mm curve
0,5 1 0,5 1
0,75 1,5 0,75 1,5
1 2 1 2
Leq (linear metres)
Inlet Outlet
90° Ø 100
mm curve
0,5 1 0,5 1
0,75 1,5 0,75 1,5
1 2 1 2
45° Ø 160
mm curve
45° Ø 200
mm curve
90° Ø 160
mm curve
90° Ø 200
mm curve
M
Øi Øi
M
M
Øi
Fig. 47
Smoke outlet connections
DESCRIPTION
Øi (internal
diameter)
80 116 160 200 240 280
mm 160 160 160 200 200 200
ALU HE
Combustion air inlet
For “type C” configurations, the combustion air inlet ducts MUST
be fed outside of the installation room and must power each sin
gle appliance in the cascade singularly.
d
DO NOT
create a manifold with the combustion air inlet ducts.
The table shows the maximum permitted lengths for the combustion air inlet ducts, expressed in metres.
ALU HE
80
116
160
200
240
280
Maximum permitted length (m)
Inlet
Øi 80 mm
10 -
9 8 -
- 10
- 9
- 8
Inlet
Øi 100 mm
8.7 Gas line
The gas supply line manifold (CG) must be sized by an expert, and
implemented during installation according to the line pressure
and the heat input of the appliances that make up the cascade.
G G G
-
8.8 Evacuating condensate
To evacuate the condensate, create a manifold with all of the
ducts, appliances and smoke outlet and put a neutralising device
in place, such as one of the models that can be supplied sepa
rately on request.
CG
Fig. 48
-
57
8.9 Electrical connections for the cascade
(Italy only)
External
supervision
(in MODBUS)
The electrical connections between the
which make up the cascade are shown in the following diagram,
and the wiring diagrams for the individual appliances are shown
on the next few pages.
m
WARNINGS
Sime
declines all responsible for any injury or damage
to persons, animals,or property as a result of failure to
provide adequate earthing of the appliance.
BLACK
GREEN
6
GND
BLUE
RED
–
+
Sime ALU HE
1
3 4 5
2
BOARD RS-485
–
+
GND
boilers
m
WARNINGS
–
The external temperature sensor “SE” is OBLIGATORY
and MUST be connected to the master boiler
– The cascade delivery probe “SMC” MUST be con-
nected to slave boiler no. 1.
BOILER BOARD (SLAVE ...)
.
- 2 wires with cross-section of
at least AWG24
- Shielded and twisted
- Characteristic impedance of
at least 100
- Shielding connected to the earth on
CABLE CHARACTERISTICS:
one side of the line only
BLACK
GREEN
BLACK
GREEN
6
GND
6
GND
BLUE
BLUE
RED
1
3 4 5
2
BOARD RS-485
–
–
+
+
GND
BOILER BOARD (SLAVE 1)
CASCADE DELIVERY PROBE (SMC)
RED
1
3 4 5
2
BOARD RS-485
–
–
+
+
GND
MODBUS
INTERFACE KIT
Code 8092278
3
2
2
OT
1
1
BOILER BOARD (MASTER)
Pmax
TS
Pmin
ISPESL SAFETY KIT
Fig. 49
58
8.10 Master boiler wiring diagram
GREEN
SR
CR
BLUE
5
BLACK
4
L 2
V
N
BLUE
BROWN
1
GREEN
RED
CD. 63228900
BROWN
BLUE
BROWN
68
A21242631 C
CN18CN10CN11
QU4 KAEV
BROWN
KAPI
KAVD2
SF
BLUE
KAEV
BLUE
KAPI
SF1
PC
PC1
OP
6
1
45
23
RS485
QU1
KAPI
MC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
L
N
PE
QU2KAVD1
N
PE
Pcp
ACS
N2
QU3
RISc
N3
L N
230 V - 50 Hz Pcp
Connections to be made by the installer
L
Live
N
Neutral
MCP
Primary circuit pump
PB
Storage tank pump
PM
Primary circuit modulat-
PB
ing pump(*)
PM VD
VD
Diverter valve
PWM-GND
F1-F2
TRA
V
Fan
Modulating pump signal (if
present)
Fuses (4 AT)
Ignition transformer
TPA
5V
GND
OUT
RED
GREEN
ORANGE
CN1 CN2 CN3
35
32 36 49 50 58
6972
CN12
N
F1
F2
BLACK
ER
GND
64
20
CN9
BLACK
BROWN
PWM
CN13
18
BLUE
KAVD2
VG1
PM
KAVD1
EA
L
69
CN14
72
CN7
L
N
N
VZ
VZ
AUXLAUX
TA1 230V
TRA
ER
Flame detection electrode
EA
Electrode on
Pm
Min. gas pressure switch
EV
Gas solenoid valve
TPA
Pressure transducer
SM
Delivery sensor (SM)
SR
Return Sensor (SR)
SF2
Exhaust sensor (SF)
SB/SA
JP1
Dial jumper or 0...10V DC or TA2 (**)
OP
Mechanical timer
SPS
Siphon pressure switch
SE
External sensor (Obligatory)
CR
Remote control or, alternatively, a MOD-
TS
Safety thermostat
TZ1÷TZ2
TA1 (230V)
VZ
Zone valve
AR
Remote alarm
AUX
Auxiliary connection
QU1..QU4
KAPI
Pump relay
KAEV
Fan relay
KAVD1
KAVD2
APS
Air pressure switch
RS485
GREEN
BLACK
BLACK
BLUE
BLUE
RED
RED
1 1
CN4
4
5
CN5
6
7
CN6
10
1117
11121314151617
AR
AR
BLUE
BROWN
GREEN
BLUE
JP1
10
2
3
4
5
6
7
8
9
BROWN
TS
BLUE
SF2
SM
C
SB/SA
0...10VDC
P
NA
BLUE
NC
BROWN
P
NA
SE
TZ1
TZ2
APS
NC
C
Pm
C
SPS
P
NC
NA
EV
Storage tank sensor or auxiliary sensor
(e.g. system delivery sensor, SMi)
BUS interface kit
Room thermostat for the zone
Room Thermostat
Thermal fuses (4 A)
Domestic hot water relay
Heating relay
Cascade board
(*) The
PM
pump (modulating) can be installed instead of the
Pcp
pump
(**) JP1 engaged = TZ2 usable; 0 ... 10V DC not usable; JP1 disengaged = TZ2 not usable; 0 ... 10V DC usable
Fig. 50
59
8.11 Wiring diagram for slave 1 boiler
GREEN
SR
L 2
V
N
BLUE
BROWN
KAEV
QU4
OP
5
4
1
BLUE
BLACK
GREEN
RED
6
RS485
CD. 63228900
1
45
23
CN18CN10CN11
A21242631 C
BROWN
KAPI
BLUE
KAEV
BLUE
TPA
5V
GND
OUT
RED
GREEN
ORANGE
CN1 CN2 CN3
35
32 36 49 50 58
BROWN
BLUE
BROWN
68
BLACK
ER
20
BLACK
6972
CN12
64
CN9
BROWN
CN13
18
BLUE
KAVD2
F1
F2
KAVD1
EA
N
69
CN14
72
CN7
N
AUXLAUX
TRA
L
L
VZ
RED
RED
10
1117
11121314151617
N
AR
VZ
TA1 230V
BLUE
BROWN
GREEN
BLACK
BLACK
BLUE
BLUE
GREEN
BLUE
1 1
CN4
4
5
CN5
6
7
CN6
JP1
AR
10
2
3
4
5
6
7
8
9
BROWN
TS
BLUE
SF2
SM
C
NA
BLUE
BROWN
P
NA
SB/SA
P
NC
APS
NC
C
SMC
Pm
C
P
EV
SPS
NC
NA
QU1
QU2KAVD1
QU3
KAPI
KAPI
KAVD2
MC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
L
N
PE
N
PE
Pcp
N2
ACS
RISc
N3
SF
SF1
PC
PC1
L N
230 V - 50 Hz Pcp
Connections to be made by the installer
L
Live
N
Neutral
MCP
Primary circuit pump
PB
Storage tank pump
PB
PM VD
PM
Primary circuit modulating
pump(*)
VD
Diverter valve
PWM-GND
Modulating pump signal (if
present)
GND
PWM
F1-F2
Fuses (4 AT)
TRA
Ignition transformer
V
Fan
SMC
Cascade delivery probe
ER
Flame detection electrode
EA
Electrode on
Pm
Min. gas pressure switch
EV
Gas solenoid valve
TPA
Pressure transducer
SM
Delivery sensor (SM)
SR
Return sensor (SR)
SF2
Exhaust sensor (SF)
SB/SA
PM
VG1
Storage tank sensor or auxiliary sensor
(e.g. system delivery sensor, SMi)
JP1
Dial jumper
OP
Mechanical timer
SPS
Siphon pressure switch
TS
Safety thermostat
VZ
Zone valve
AR
Remote alarm
AUX
Auxiliary connection
QU1..QU4
KAPI
KAEV
KAVD1
KAVD2
APS
RS485
Thermal fuses (4 A)
Pump relay
Fan relay
Domestic hot water relay
Heating relay
Air pressure switch
Cascade board
(*) The
60
PM
pump (modulating) can be installed instead of the
Pcp
pump
Fig. 51
8.12 Wiring diagram for slave 2-7 boilers
GREEN
SR
L 2
V
N
BLUE
BROWN
KAEV
QU4
OP
5
4
1
BLUE
BLACK
GREEN
RED
6
RS485
CD. 63228900
1
45
23
CN18CN10CN11
A21242631 C
BROWN
KAPI
BLUE
KAEV
BLUE
TPA
5V
GND
OUT
RED
GREEN
ORANGE
CN1 CN2 CN3
35
32 36 49 50 58
BROWN
BLUE
BROWN
68
BLACK
ER
20
BLACK
6972
CN12
64
CN9
BROWN
CN13
18
BLUE
KAVD2
F1
F2
KAVD1
EA
N
69
CN14
72
CN7
N
AUXLAUX
TRA
L
L
VZ
RED
RED
10
1117
11121314151617
N
AR
VZ
TA1 230V
BLUE
BROWN
GREEN
BLACK
BLACK
BLUE
BLUE
GREEN
BLUE
1 1
CN4
4
5
CN5
6
7
CN6
JP1
AR
10
2
3
4
5
6
7
8
9
BROWN
TS
BLUE
SF2
SM
C
NA
BLUE
BROWN
P
NA
SB/SA
P
NC
APS
NC
C
Pm
C
P
EV
SPS
NC
NA
QU1
QU2KAVD1
QU3
KAPI
KAPI
KAVD2
MC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
L
N
PE
N
PE
Pcp
N2
ACS
RISc
N3
SF
SF1
PC
PC1
L N
230 V - 50 Hz Pcp
Connections to be made by the installer
L
Live
N
Neutral
MCP
Primary circuit pump
PB
Storage tank pump
PB
PM VD
PM
Primary circuit modulating
pump(*)
VD
Diverter valve
PWM-GND
Modulating pump signal (if
present)
GND
PWM
F1-F2
Fuses (4 AT)
TRA
Ignition transformer
V
Fan
ER
Flame detection electrode
EA
Electrode on
Pm
Min. gas pressure switch
EV
Gas solenoid valve
TPA
Pressure transducer
SM
Delivery sensor (SM)
SR
Return sensor (SR)
SF2
Exhaust sensor (SF)
SB/SA
Storage tank sensor or auxiliary sensor
PM
VG1
JP1
Dial jumper
OP
Mechanical timer
SPS
Siphon pressure switch
TS
Safety thermostat
VZ
Zone valve
AR
Remote alarm
AUX
Auxiliary connection
QU1..QU4
KAPI
KAEV
KAVD1
KAVD2
APS
Air pressure switch
RS485
(e.g. system delivery sensor, SMi)
Thermal fuses (4 A)
Pump relay
Fan relay
Domestic hot water relay
Heating relay
Cascade board
(*) The PM pump (modulating) can be installed instead of the
Pcp
pump
Fig. 52
61
8.13 Displaying and setting cascade parameters
The parameters for
played and set in the same way as with single boilers (see “Pa-
rameter setting and display” and “Lis
m
WARNINGS
For the cascade to function correctly, the external sensor (SE) must be installed.
8.13.1 Routing the cascading boilers
m
CAUTION
Before changing “PAR 15” (routing the cascade), the
boilers in the cascade must be set to WINTER mode
n
On each boiler in the cascade, “PAR 15” must be set as follows:
–
"0"
to identify the master boiler
"1"
to identify slave boiler no. 1
–
"2"
to identify slave boiler no. 2
–
"3"
to identify slave boiler no. 3
–
"4"
to identify slave boiler no. 4
–
"5"
to identify slave boiler no. 5
–
"6"
to identify slave boiler no. 6
–
"7"
to identify slave boiler no. 7
–
NOTE:
Avoid labelling the slave boilers with the same number.
8.13.2 CASCADE parameters for the master boiler
After setting PAR 15 on the master boiler, and where there are
more than two boilers in the cascade, access the CASCADE parameters on the master boiler (identified by PAR A plus a number as shown in the table) and configure parameter PAR A1.
o access the CASCADE parameters:
T
– press buttons L and M (~ 2s) at the same time until the pa-
rameter menu shows
press buttons
–
“--”
appears on the display
– to access the CASCADE parameters, enter the following com-
binations of keys:
– to scroll through the parameters press buttons
– to change the parameter settings, press buttons Z and
– to exit the menu and go back to the first screen, press one
of the function buttons, excluding RESET, or wait approx. 60
seconds without pressing any buttons.
Sime ALU HE
boilers in a cascade can be dis-
t of par
ameters”).
.
and M (~ 2s) at the same time again until
L
N L M L.
Z
L
and
M
N
Type
No.
PAR A0
PAR A1
PAR A2
PAR A3
PAR A4
PAR A5
PAR A6
PAR A7
Description
Choosing
the cascade
strategy
Number
of boilers
installed
Reset operating hours
of boiler in
ascade
c
Next boiler
ignition
threshold
Last ignited
boiler
shutdown
threshold
Timeout for
reaching
the ignition
threshold
(time for
PAR A3
check)
Timeout for
reaching the
shutdown
threshold
(time for
PAR A4
check)
Offset for
setpoint re
quired from
s for
boiler
heating request (only
for PAR A0 =
0 – fixed set)
Range U/M Step
0 = fixed set
1 = dynamic
set
0……8 1 2
- - / 1 - - -
45-90 % 1 70
10-40 % 1 30
10-240 Sec 1 120
10-240 Sec 1 180
-
0……10 °C - 0
Default
- 0
8.14 Fault / malfunction codes
Every boiler in the cascade manages its own faults as described
in “Fault / malfunction codes”.
The faults that generate a lockout in a specific boiler are reset by
pressing the RESET button on the relevant boiler.
A lockout in the master boiler is reset either by pressing the RE
SET button or from a remote device.
or
the master and slave no. 1 boilers, specific faults can be
F
checked for as shown in the table:
Type No. Description
ALL 31 Cascade delivery probe (SMC) fault
ALL 35 Communication fault with RS485 boards
ALL 36 Number of boilers connected in cascade fault
ALL 70 Cascade stop general fault
ALL 71 General fault with a boiler in the cascade
-
62
Benchmark Commissioning &
Warranty Validation Service Record
It is a requirement that the boiler is installed and commissioned to the manufacturers’
To instigate the boiler warranty the boiler needs to be registered with the
manufacturer within one month of the installation. The warranty rests with the
end-user (consumer), and they should be made aware it is ultimately their
responsibility to register with the manufacturer, within the allotted time period.
It is essential that the boiler is serviced in line with the manufacturers’
recommendations, at least annually. This must be carried out by a competent Gas
Safe registered engineer. The service details should be recorded on the Benchmark
Service and Interim Boiler Work Record and left with the householder. Failure to
comply with the manufacturers’ servicing instructions and requirements will invalidate
the warranty.
www.hhic.co.uk
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
Failure to install and commission according to the manufacturers’ instructions and complete this Benchmark Commissioning Checklist will invalidate the
warranty. This does not affect the customer’s statutory rights.
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
63
GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD
www.centralheating.co.uk
Address:
Boiler make and model:
Boiler serial number:
Commissioned by (PRINT NAME): Gas Safe registration number:
Company name: Telephone number:
Company email: Company address:
Heating and hot water system complies with the appropriate Building Regulations? Yes
Time, temperature control and boiler interlock provided for central heating and hot water Yes
Boiler Plus requirements (tick the appropriate box(s))
Boiler Plus option chosen for combination boiler in ENGLAND
Weather compensation Smart thermostat with automisation and optimisation
Load compensation Flue Gas Heat Recovery
Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination boiler
Zone valves pre-existing Fitted Not required
Thermostatic radiator valves pre-existing Fitted Not required
Automatic bypass to system pre-existing Fitted Not required
pre-existing Fitted Not required
Water quality
What system cleaner was used? Brand: Product:
What inhibitor was used? Brand: Product:
pre-existing Fitted Not required
CENTRAL HEATING MODE measure and record (as appropriate)
Gas rate (for combination boilers complete DHW mode gas rate) m3/hr or ft3/hr
Central heating output left at factory settings? Yes No
If no, what is the maximum central heating output selected? kW
Dynamic gas inlet pressure mbar
Central heating return temperature °C
System correctly balanced/rebalanced? Yes
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)? Yes No
Water scale reducer/softener pre-existing Fitted Not required
Brand: Product:
Yes No
If yes- DHW expansion vessel pre-existing Fitted Not required
Pressure reducing valve pre-existing Fitted Not required
DOMESTIC HOT WATER MODE Measure and record
Gas rate m3/hr or ft3/hr
Dynamic gas inlet pressure at maximum rate mbar
Cold water inlet temperature °C
Hot water has been checked at all outlets Yes Temperature °C
CONDENSATE DISPOSAL
The condensate drain has been installed in accordance with the manufacturers’ instructions and/or BS5546/BS6798 Yes
Point of termination Internal External (only where internal termination impractical)
Method of disposal Gravity Pumped
ALL INSTALLATIONS
Record the following
At max rate: CO ppm CO
At min rate (where possible) CO ppm CO
2
2
instructions, and readings are correct? Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes
The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
Commissioning Engineer’s signature
Customer’s signature
Commissioning date:
instructions Yes
% CO/CO
% CO/CO
2
2
°C
Ratio
Ratio
© Heating and Hotwater Industry Council (HHIC)
64
www.centralheating.co.uk
SERVICE & INTERIM BOILER WORK RECORD
It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service /
interim work record is completed.
Service provider
When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
²
²
Date:
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
Date:
²
²
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
3
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
/h OR ft3/h
delete as appropriate Yes No
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
3
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
/h OR ft3/h
delete as appropriate Yes No
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
© Heating and Hotwater Industry Council (HHIC)
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
65
www.centralheating.co.uk
SERVICE & INTERIM BOILER WORK RECORD
It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service /
interim work record is completed.
Service provider
When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
²
²
Date:
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
Date:
²
²
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
3
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
/h OR ft3/h
delete as appropriate Yes No
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
3
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
/h OR ft3/h
delete as appropriate Yes No
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
© Heating and Hotwater Industry Council (HHIC)
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
SERVICE/INTERIM WORK ON BOILER delete as appropriate
Engineer name: Company name:
Telephone N
Max rate CO ppm CO
Min rate CO ppm CO
undertaken in accordance with manufacturers’
instructions, and readings are correct?”
Gas rate: m
System inhibitor concentration has been checked and
appropriate action taken, in accordance with BS 7593
and boiler manufacturers’ instructions. *
o
: Gas Safe registration No:
% CO/CO
²
% CO/CO
²
3
/h OR ft3/h
delete as appropriate Yes No
Date:
²
²
yes
yes n/a
Comments:
Signature:
instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers
attendance visit was in between annual services to attend a non-water facing component.
66
9 EXPLODED VIEWS
ALU HE 80 - 116 - 160
67
ALU HE 200 - 240 - 280
68
ALU HE 80 - 116 - 160
69
ALU HE 200 - 240 - 280
70
ALU HE 80 - 116
71
ALU HE 160
72
ALU HE 200 - 240 - 280
73
ALU HE 80 - 116 - 160 - 200 - 240 - 280
74
Pos. Code Description
80 116 160 200 240 280
ALU HE
1 6261520 Tray x x x
1 6261521 Tray x x x
2 6120401 Adjustable foot x x x x x x
3 6096910 Support x x x x x x
4 5204200 Complete boiler block x
4 5204210 Complete boiler block x
4 5204220 Complete boiler block x
4 5204230 Complete boiler block x
4 5204240 Complete boiler block x
4 5204250 Complete boiler block x
5 6248845 Lip seal ø150 x x x
5 6248846 Lip seal ø200 x x x
6 6278330 Burner x
6 6278331 Burner x
6 6278332 Burner x
6 6278333 Burner x
6 6278334 Burner x
6 6278335 Burner x
7 6192401 Flange 2" x x x x x x
8 6277215 Connector x x x x x x
9 6277213 Water trap x x x x x x
10 2100039 Blind plug x x x x x
10 6277216 Water trap siphon x
11 6277217
Condensate drainage
pipe
x x x x x x
12 6277132 Temper. probe NTC x x x x x x
13 6120572 Spigot reducer x x x x x x
14 6146733 H.L. stat 98°C x x x x x x
15 6120523
16 6273610
Spigot reducer 1/4" M
x 3/8" F
Water pressure transducer
x x x x x x
x x x x x x
17 6228000 Non return valve 1/4" x x x x x x
18 6146104 Hydrometer x x x x x x
19 6023103
Pressure test nipple
1/4"
x x x x x x
20 6256829 Bracket x x x x x x
21 6174831 Gasket x x x x x x
22 6278870 Air-gas full hose x x x x x x
23 6174834
Gasket for ignition
electrode
x x x x x x
24 6221680 Ignition electrode x x x x x x
25 6174835 Gasket for electrode x x x x x x
26 6221681 Ionisation probe x x x x x x
27 6174833 Sight frame insulation x x x x x x
28 6020104 Sight glass x x x x x x
29 6047402 Sight frame x x x x x x
30 6174832 Air-gas hose gasket x x x x x x
31 6105160 Flange x x
31 6105161 Flange x
32 6174816 Gasket for fan flange x x
32 6174837 Gasket for fan flange x
32 1010218 Pipe Ø 4x2 x x x
33 6261427 Fan x
33 6261428 Fan x
33 6261429 Fan x
33 6261430 Fan x x x
34 6226481 OR gasket 69.85X3.53 x x
34 6226488 ORing 4437 x x x x
35 6274395 Air/gas mixer x
35 6274393 Air/gas mixer x
35 6274396 Air/gas mixer x x
35 6274397 Air/gas mixer x x
36 6226482 ORing 32.99X2.62
x x
36 6226487 ORing 4212 x x x x
37 6089719 Gas val
ve x x
37 6089720 Gas valve x x
Pos. Code Description
80 116 160 200 240 280
ALU HE
37 6089721 Gas valve x
37 6089722 Gas valve x
38 6163101
38 6269376
Square flange with 1"
connectio
Square flange for gas
valve
x x
x x x x
39 2030223 Gasket NPR 24x35x4 x x
39 6221010 Nipple 1"1/2 X 1" x x x x
40 2030205 Gasket Ø 19.5x27x3 x x
40 2030254 Gasket Ø 33x44x3 x x x x
41 6251450 Gas inlet pipe x x
41 6251454 Gas inlet pipe x
41 6251455 Gas inlet pipe x x x
42 6043101 Gas pressure switch x x x x x x
43 2030225 Gasket Ø 5,5x11x2 x x x x x x
45 6225753 Air pressure switch x x x x x x
46 6225754 Air pressure switch x
46 6225750 Air pressure switch x x x x
46 6225751 Air pressure switch x
47 6229101
Smoke pressure switch bracket
x x x x x x
48 6043220 Connector 1/8" M x x x x x x
49 6023100
Pressure test nipple
Ø 1/8"
x x x x x x
50 1010217 Pipe Ø 6x4 x x x x x x
51 1010202 Silicon pipe Ø 8x1.5 x x x x x
51 1010218 Pipe Ø 4x2 x
52 1010204 Silicon pipe Ø 12x2 x x x x x x
53 6280500
54 6323446
3-ways junct. with
press. test
Casing left hand side
panel
x x x x x x
x x x x x x
55 6267142 Bracket x x x x x x
56 6323451
56 6323461
57 6323536
57 6323591
Casing left hand side
panel
Casing left hand side
panel
Casing right hand side
panel
Casing right hand side
panel
x x x
x x x
x x x
x x x
58 6256845 Bracket x x x x x x
59 6256737 Spacer x x x x x x
60 6256830 Bracket x x x x x x
62 6323716 Casing cover panel x x x
62 6323796 Casing cover panel x x x
63 6282110
Section casing top
cover L=599
x x x x x x
64 6087566 Insulation x x x
64 6087567 Insulation x x x
65 6275350 Rear upper panel x x x x x x
66 6275355 Rear lower panel x x x x x x
67 8089923
Reduction M/F 60/80
PP
x x
67 6083080 Duct flange d.80 x
67 6083081 Duct flange d.81 x x x
68 6246702 Junction collar x x
69 6028696 Diaphragm Ø40 x
70 6001175 Air intake pipe 80 x x
71 6235801
Pressure test nipple
M6
x x x
72 6083064 Flue inlet flange Ø 80 x x x
72 6083072
73 8089500
73 8089503
Suction collar
ø100/100
Air inlet terminal Ø
80 mm
Air inlet terminal Ø100
mm
x x x
x x x
x x x
74 1010150 Pipe Ø 80 flexible x x x
74 1010151 Pipe Ø 102 flexible x x x
75
Pos. Code Description
80 116 160 200 240 280
ALU HE
75 2051201 Hose clamp Ø 70-90 x x x
75 2051202 Hose clamp Ø 90-110 x x x
76 6323616
77 8102518
Casing front upper
door
Reducer diam. 150/160
kit
x x x x x x
x x x
78 6267042 Stud M4x20 x x x x x x
79 6150020 Nut M4 x x x
79 6248865 Gasket Ø 100 x x x
80 6248835 Lip seal for Øi 80 x x
81 6229360 Smoke damper d.150 x x
81 6229361 Smoke damper d.200 x x
82 6248847 Gasket Ø 160 x x x
90 6304700 Control panel x x x x x x
91 6305160 Guidelight with led x x x x x x
92 6305120 Kit Rubber button x x x x x x
93 6247327
Cap for time programmer
x x x x x x
94 6304890 Flap door assembly x x x x x x
95 6328900 Main P.C.B. x x x x x x
96 6305000 Cover x x x x x x
97 6305010 connection cover x x x x x x
98 6305020
99 6250021
Time programmer
cover
Rotation control panel
bracket
x x x x x x
x x x x x x
Pos. Code Description
80 116 160 200 240 280
ALU HE
100 6302000 Plastic pin x x x x x x
101 6267138
Rotation control panel
bracket
x x x x x x
102 6256836 Bracket x x x x x x
103 6098350 Ignition transformer x x x x x x
104 6190404 Relay x x x x x x
105 6190406 Relay support x x x x x x
106 6190405 Relay x x x x x x
107 6253410 Fuse holder 10x38 x x x x x x
108 6301467 Main P.C.B. converter x x x x x x
700 5200940
700 5200942
700 5200945
701 6221686
Complete control
panel
Complete control
panel
Complete control
panel
Ignition electrode
cable
x
x x
x x x
x x x x x x
702 8094101 External sensor x x x x x x
703 6316200 Connector 2 poli x x x x x x
704 6316202 Connector 4 poli x x x x x x
705 6316203 Connector 4 poli CN4 x x x x x x
706 6316204 Connector 8 poli CN7 x x x x x x
707 6233540 Fuse d.10x38 4A x x x x x x
76
10 APPENDIX 1 GUIDANCE HHIC
October 2018 Issue 1.0
Manufacturers Instructions
Manufacturer’s instructions must be followed for the correct connection of the
condensate discharge pipe from the boiler as this may vary due to the design
of the boiler. For example a visible air break and trap is not required if there is a
trap with a minimum condensate seal of 75 mm incorporated into the boiler.
Internal Pipe Run In Unheated Spaces
Condensate discharge pipes that are routed in an unheated space such as a loft
or garage should be insulated to prevent freezing.
Internal Condensate Pipe Discharge Termination
Internal condensate discharge pipework must be a minimum of 19mm ID
(typically 22mm OD) plastic pipe or as per manufacturer’s instructions and this
should “fall” a minimum of 45mm per metre away from the boiler, taking the
shortest practicable route to the termination point.
diagrams)
To minimise the risk of freezing during prolonged sub-zero conditions, an
internal “gravity discharge point” such as an internal soil stack (preferred
method), internal kitchen, utility room or bathroom waste pipe e.g. from a sink,
basin, bath or shower should be adopted, where possible.
Note - A suitable permanent connection to the foul waste pipe should be used.
Figures 1, 2(a), 2(b) show appropriate connection methods.
77
Figure 1 – Connection of condensate discharge pipe to internal soil and vent stack.
Note – Check manufacturer’s instructions to see if an air break is required.
1
8
2 5
7
3
4
6
Key
1 Boiler
2 Visible air break
3 75 mm trap
4 Visible air break and trap not required if there is a trap with a minimum condensate seal
of 75 mm incorporated into the boiler
5 Soil and vent stack
6 Invert
7 450 mm minimum up to three storeys
8 Minimum internal diameter 19 mm
78
Internal Condensate Pipe Discharge Termination
ath or
Figure 2(a) – Connection of a condensate discharge pipe downstream of a sink, basin, b
shower waste trap.
Note – Check manufacturer’s instructions to see if an air break is required.
1
8
2
7
11
12
5
4
3
10
9
6
Key
1 Boiler
2 Visible air break
3 75 mm trap
4 Visible air break and trap not required if there is a trap with a minimum condensate seal
of 75 mm incorporated into the boiler. In this case the 100 mm is measured to the trap
in the boiler.
5 Sink, basin, bath or shower
6 Open end of condensate discharge pipe direct into gully 25 mm min below grating but
above water level; end cut at 45 °
Note – the maximum external condensate discharge length is 3 metres
7 Sink lip
8 Minimum internal diameter 19 mm
9 Pipe size transition
10 Minimum internal diameter 30 mm
11 Water/weather proof insulation
12 Drain cover/leaf guard
79
Internal Condensate Pipe Discharge Termination
Figure 2(b) – Connection of a condensate discharge pipe upstream of a sink, basin, bath or
shower waste trap
1
2
6
8
94
10
3
7
5
Key
1 Boiler
2 Visible air break at plug hole – alternative connection can be below sink trap
3 75 mm sink, basin, bath or shower waste trap
4
5 Open end of condensate discharge pipe direct into gully 25 mm min below grating but
above water level; end cut at 45 °
Note – the maximum external condensate discharge length is 3 metres
6 Minimum internal diameter 19 mm
7 Pipe size transition
8 Minimum internal diameter 30 mm
9 Water/weather proof insulation
10 Fit drain cover/leaf guard
80
Internal Condensate Pipe Discharge Termination
The possibility of waste pipes freezing downstream of the connection point
should be considered when determining a suitable connection point - e.g. a
slightly longer pipe run to an internal soil stack may be preferable to a shorter
run connecting into a kitchen waste pipe discharging directly through the wall to
an external drain.
Note - Where “gravity discharge” to an internal termination is not physically
possible (e.g. the discharge point is above the appliance location, or access is
obstructed by a doorway), or where very long internal pipe runs would be
required to reach a suitable discharge point, then a condensate pump should be
used.
External waste pipes from kitchens, utility rooms or bathrooms such as sink,
basin, and bath or shower waste outlets should be insulated with waterproof UV
resistant, class 0 material, terminated below the grid but above the water line
it terminates into the grid. (See insulation section for guidance on suitable
materials).
Condensate Pumps
Use of a Condensate Pump to an Internal Termination
Condensate can be removed using a proprietary condensate pump, of a
minimise the risk of freezing during prolonged sub-zero spells, one of the
following methods internal to the property for terminating the boiler condensate
pump to a foul water discharge point should be adopted such as an internal soil
stack (preferred method), internal kitchen, utility room or bathroom waste pipe
such as sink, basin, and bath or shower waste. Figure 3 shows a typical
connection method.
81
Internal Condensate Pipe Discharge Termination
Figure 3 – Connection of a condensate pump - typical method (NB manufacturer’s detailed
instructions should be followed).
Note – Any external pipe work should be insulated, pipe cut at 45 degrees and a drain/ leaf
3
4
1
Key
1 Condensate discharge from boiler
2 Condensate pump
3 Visible air break at plug hole
4
5 75mm sink waste trap
5
2
Key
1 Boiler
6
2
4
8
7
3
9
2 Visible air break at plug hole
3 75 mm sink, basin, bath or shower
waste trap
4 Sink, basin, bath or shower with
10
5
1
5 Open end of condensate discharge
pipe direct into gully 25 mm min below
grating but above water level; end cut
at 45 °
condensate discharge length is 3 metres
6 Minimum internal diameter 19 mm
7 Pipe size transition
8 Minimum internal diameter 30 mm
9 Water/weather proof insulation
10 Fit drain cover/leaf guard
Note – the maximum external
82
External Connections
External Connections
pumped connection is impractical to install.
The pipe work from the boiler should be of a minimum 19mm ID or as per
manufacturer’s instructions and the condensate discharge pipe shall be run in a
standard drainpipe material, e.g. poly (vinyl chloride) (PVC), un-plasticized poly
(vinyl chloride) (PVC-U), acrylonitrile butadiene-styrene (ABS), polypropylene (PP)
or chlorinated poly (vinyl chloride) (PVC-C).
500mm for solid pipe and manufacturer’s recommendations should be followed.
The condensate pipe should be run internally as far as possible before going
externally and the pipe diameter should be increased to a minimum of 30mm
ID (typically 32mm OD) before it passes through the wall. The angle of the pipe
should slope downwards by at least 3 degrees as it passes through the wall to
assist in maintaining a good velocity as the condensate exits the building.
The external pipe run should be kept as short as possible to a maximum of 3
metres, taking the most direct and “most vertical” route to the discharge point,
with no horizontal sections in which condensate might collect.
83
External Connections
Figure 4 – Connection of condensate discharge pipe to external soil and vent stack
1
11
2
8
9
5
10
7
3
4
6
Key
1 Boiler
2 Visible air break
3 75 mm trap
4 Visible air break and trap not required if there is a trap with a minimum condensate seal
of 75mm incorporated into the boiler.
5 Soil and vent stack
6 Invert
7 450mm minimum upto three storeys
8 Minimum internal diameter 19 mm
9 Pipe size transition point
10 Minimum internal diameter 30mm
11 Water/weather proof insulation
84
External Connections
October 2018 Issue 1.0
Alternative Solutions
Cold weather protection methods approved or endorsed by boiler manufacturers
and/or service organisations may be adopted if these are considered suitable by
the parties involved. It is the responsibility of the manufacturer of these products
to ensure they have completed the necessary testing or calculations to ensure
the product offers suitable protection to prevent the condensate pipe from
freezing. The product manufacturer should provide information as to what level
of external temperature and for what time period the product can protect against
sub-zero temperatures, i.e. -15°C for 48 hours. BS6798 refers to devices that
gas. (BS6798 section 6.3.8 note 4). The boiler manufacturer’s instructions will
disposal of the condensate.
Additional Measures
measures detailed above for external condensate discharge pipes
• Insulate external pipe with a minimum thickness of insulation to be 19mm
“O” class PVC coated material.
• Fit trace heating – with insulation as recommended by manufacturer.
• Fit internal auxiliary(additional) high volume syphon unit
Auxiliary Syphon – Fitted Internally
where an external condensate pipe must
auxiliary siphon increases the volume of condensate discharge reducing the risk
of freezing. A further reduction in the potential for the pipe to freeze is achieved
when combined with the external insulation requirements.
85
External Connections
October 2018 Issue 1.0
Electric Trace Heating
condensate pipe to raise the temperature of the condensate pipe in freezing
conditions. Trace heating takes the form of an electrical heating element run in
physical contact along the length of the condensate pipe. The pipe is usually
covered with thermal insulation to retain heat losses from the pipe. Heat
generated by the element then maintains the temperature of the pipe. If such a
system is used then the installation instructions of the trace heating
insulation, etc. should be followed. All other relevant guidance on condensate
discharge pipe installation should also be followed.
Insulation Materials
Insulation used for external condensate pipes, sink or washing machine waste
pipes should be of class ‘O’ grade with an outer coating that is weather proof,
is recommended for 32mm external pipes.
Use of Air Breaks In Condensate Discharge Pipes
Heating engineers should follow manufacturer’s instructions on the use of air
breaks in condensate discharge pipes. A visible air break is not required if the
boiler condensate trap has a minimum condensate seal of 75mm incorporated
into the boiler.
Connecting to a rain water downpipe/External Soil Stack
When an external soil stack or rain water downpipe is used as the termination
(NB only permissible if this downpipe passes to a combined foul and rainwater
drainage system) an external air break must be installed between the condensate
86
External Connections
October 2018 Issue 1.0
Figure 5 – External termination to rainwater downpipe (NB only combined foul/rainwater
drain)
5
1
3
9
2
6
10
Key
1 Condensate discharge pipe from boiler
2 Pipe size transition point
3 Water/weather proof insulation
4 43mm 90° male/female bend
5 External rain water pipe into foul water
6 External air break
7 Air gap
8
9 Minimum internal diameter 19mm
10 Minimum internal diameter 30mm
11 End cut at 45°
7
4
8
11
87
External Connections
October 2018 Issue 1.0
External Termination of the Condensate Pipe
Where the condensate discharge pipe is terminated over an open foul drain or
gully, the pipe should terminate below the grating level, but above water level,
in order to minimise “wind chill” at the open end. Pipe drainage and resistance
to freezing will be improved if the termination end of the condensate pipe is cut
at 45 degrees as opposed to a straight cut.
The use of a drain cover (such as those used to prevent blockage by leaves)
must
page)shows a suitable connection method. Where the condensate drain pipe
terminates in a purpose-designed soakaway (see BS 6798:2014 or boiler
installation manual for soakaway design requirements) any above-ground
section of condensate discharge pipe should be run and insulated as described
above. Figure 7 (following page) shows a suitable connection method.
Unheated Areas in Buildings
Internal condensate drainage pipes run in unheated areas such as lofts,
basements and garages should be treated as external connections and insulated
accordingly. Weather proof materials may not be necessary and should be
assessed by the heating engineer.
Use of Air Breaks In Condensate Discharge Pipes
Installers should follow the manufacturer’s instructions on the use of air breaks
in condensate discharge pipes. A visible air break and trap is not required if the
boiler condensate trap has a minimum condensate seal of 75 mm incorporated
into the boiler.
88
External Connections
October 2018 Issue 1.0
Figure 6 – External drain, gully or rainwater hopper
1
2
9
7
10
5
11
3
4
8
6
Key
1 Boiler
2 Visible air break
3 38mm minimum trap
4 Visible air break and trap not required if there is a trap with a minimum condensate seal
of 38 mm incorporated into the boiler – refer to manufacturers instructions
5 External length of pipe 3 m maximum
6 Open end of condensate discharge pipe direct into gully 25 mm min below grating but
above water level; end cut at 45 °
7 Minimum internal diameter 19 mm
8 Pipe size transition point
9 Minimum internal diameter 30 mm
10 Water/weather proof insulation
11 Fit drain cover/leaf guard
89
External Connections
o when
October 2018 Issue 1.0
Figure 7 – Example of a purpose made soakaway
8
1
9
3
4
11
210
5
6
Key
1 Condensate discharge pipe from boiler
2 Ground (this section of the condensate discharge pipe may be run either above or below
round level); End cut at 45°
3 Diameter 100 mm minimum plastic tube
4 Bottom of tube sealed
5 Limestone chippings
6 Two rows of three 12 mm holes at 25 mm centres, 50 mm from bottom of tube and facing
away from house
7 Hole depth 400 mm minimum by 300 mm diameter
8 Minimum internal diameter 19 mm
9 Pipe size transition point
10 Minimum internal diameter 30 mm
11 Water/weather proof insulation
Manufacturers Instructions must be referred t
installing boiler condensate discharge pipes
7
90
9 APPENDIX 2
11 APPENDIX 2
FLOWCHART FOR CO AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER
The installation instructions should have been followed, gas type verified and gas supply pressure/rate checked as required prior to commissioning.
As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER, visually check the integri-
ty of the whole flue system to confirm that all components are correctly asembled, fixed and supported. Check that manufacturer's maximum flue lengths have not
Prior to its use, the flue gas analyser should have been maintained and calibrated as specified by the manufacturer. The installer must have the relevant competence
PRIOR TO CO AND COMBUSTION RATIO CHECK
been exceeded and all guidance has been followed (e.g. Gas Safe Technical Bulletin TB008).
The flue gas analyser should be of the correct type, as specified by BS 7967
for use of the analyser.
Check and zero the analyser IN FRESH AIR as per analyser manufacturer's instructions.
the air gas ratio valve is factory-set and must not be adjusted DURING
COMMISSIONING unless this action is recommended after discussions
If any such adjustment is recommended and further checking of the boiler
is required the installer/service engineer must be competent to carry out
this work and to use the flue gas analyser accordingly.
If the boiler requires conversion to operate with a different gas family
(e.g. conversion from natural gas to LPG) separate guidance will be provi-
ded by the boiler manufacturer and must be followed.
Analyser readings indicate that combustion products and inlet air must be
mixing. Further investigation of the flue is therefore required.
Check that flue components are assembled, fixed and supported as per boi-
ler/flue manufacturer's instructions.
Check that flue and flue terminal are not obstructed.
Is O2 less than
or equal to 20.6%
NOTE
with SIME LTD.
VERIFY FLUE INTEGRITY
YES
and
CO
2 less than 0.2%
NO
Turn off appliance and call SIME
LTD Technical HelplIne for advice.
the appliance must not be com-
missioned or used, until problems
are identified and resolved.
Check all seals around the appliance
burner, internal flue seals, door and
case seals. Rectify where necessary.
Is CO less than
350ppm
AND
CO/CO
2 ratio
less than 0.004
NO
YES
Set the boiler to operate at maximum rate (full load condi-
NOTE - Do not insert analyser probe during this period
CARRY OUT FLUE INTEGRITY CHECK USING ANALYSER
Insert analyser probe int o the air inlet test point and allow readings
NOTE - The flue must always be installed with flue test point.
This will be located within the first piece connected to the boiler.
NO
SET BOILER TO MAXIMUM RATE
tion). Allow sufficient time for combustion to stablilise.
to avoid possible "flooding" of sensor.
to stabilise.
Is O2 less than
or equal to 20.6%
and
2 less than 0.2%
CO
YES
CHECK CO AND COMBUSTION RATIO AT MAXIMUM RATE
With boiler still set at maximum rate, inser t analyser probe into
flue gas samplng point. Allow readings to stablise before recording.
NO
Is CO less than 350ppm
AND
CO/CO
2 ratio less than 0.004
YES
In accordance with boiler instructions, set boiler to operate at
minimum rate (to minimum load condition). Allow sufficient time for
NOTE: If manufacturer's instructions do not specify how to set
boiler to minimum rate contact Technical Helpline for advice.
SET BOILER TO MINIMUM RATE
combustion to stablilise.
Turn off appliance and call SIME LTD
Technical HelplIne for advice.
the appliance must not be commissio-
ned or used until problems are identi-
fied and resolved.
NOTE
Check and record CO and combustion
ratio at both maximum AND minimum
rate before contacting SIME LTD.
Ensure test points are capped, boiler case is correctly repleced and all other commissioning pro-
Complete Benchmark Checklist, recording CO and combustion ratio readings as required.
CHECK CO AND COMBUSTION RATIO AT MINIMUM RATE
With boiler set at minimum rate, insert analyser probe into flue gas
samplng point. Allow readings to stablise before recording.
NOTE - if no flue gas sampling point is present and the correct pro-
cedure is not specified in the manual, contact SIME LTD Technical
NO
Helpline for advice.
Is CO less than 350ppm
AND
2 ratio
CO/CO
less than 0.004
YES
BOILER IS OPERATING SATISFACTORILY
no further actions required
cedures are completed.
91
Sime Ltd
1a Blue Ridge Park
Thunderhead Ridge
Glasshoughton, Castleford, WF10 4UA
Phone: 0345 901 1114
Fax: 0345 901 1115
www.sime.co.uk
Email: enquiries@sime.co.uk
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