Friendly
Format
Installation and
servicing instructions
GB
Friendly Format 80:
Gas Council number 4771907
Friendly Format 80 E:
Gas Council number 4771908
Friendly Format 100 E:
Gas Council number 4771909
SIME COMBINATION BOILERS
Installer checklist
Please remember to carry out the following checks after installation. This will achieve complete customer satis-
faction, 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 log book provided been completed?
Please refer to commissioning instructions for filling in the log book
Note: All CORGI registered installers carry a CORGI ID Card.
You can check your installer is CORGI Registered by calling 01256 372300
1 TECHNICAL FEATURES AND DIMENSIONS
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 DIMENSIONAL DETAILS
1.3 GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 GENERAL REQUIREMENTS FOR INSTALLATION
2.1 STATUTORY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 BOILER POSITION
2.3 FLUE TERMINAL POSITION
2.4 VENTILATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.5 GAS SUPPLY
2.6 ELECTRICITY SUPPLY
2.7 EXTERNAL CONTROLS
2.8 WATER SYSTEMS - GENERAL
2.9 REQUIREMENTS FOR SEALED WATER SYSTEMS
2.10 D.H.W. SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 INSTALLING THE BOILER
3.1 UNPACKING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 FIXING THE WALL MOUNTING BRACKET
3.3 HANGING THE BOILER
3.4 FLUE AND TERMINAL PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 FLUE AND TERMINAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.6 SEPARATE DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 WATER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.8 GAS CONNECTIONS
3.9 SAFETY VALVE CONNECTION
3.10 WIRING INSTRUCTIONS
3.11 TIME-CLOCK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4 COMMISSIONING AND TESTING
4.1 FILLING THE WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 COMMISSIONING THE BOILER
4.3 SETTING THE C.H. INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 SETTING THE D.H.W. FLOWRATE
4.5 FINAL CHECKS
4.6 USER’S INSTRUCTIONS
5 ROUTINE SERVICING INSTRUCTIONS
5.1 MAIN BURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2 FAN ASSEMBLY
CONTENTS
5.3 HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.4 RE-ASSEMBLY
5.5 RE-COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 FAULT FINDING
6.1 EARTH CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 SHORT CIRCUIT CHECK
6.3 POLARITY CHECK
6.4 RESISTANCE TO EARTH CHECK
6.5 C.H. MODE - FAULT FINDING (“FRIENDLY FORMAT 80” model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.6 C.H. MODE - FAULT FINDING (“FRIENDLY FORMAT 80 E - 100 E” models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.7 D.H.W. MODE - FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7 INTERNAL WIRING DIAGRAMS AND VIEWS
7.1 FUNCTIONAL FLOW WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7.2 INTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
8 REPLACEMENT OF PARTS
8.1 HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
8.2 COMBUSTION CHAMBER INSULATION
8.3 FAN ASSEMBLY
8.4 MAIN BURNER
8.5 IGNITION/DETECTION ELECTRODES
8.6 GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8.7 AIR PRESSURE SWITCH
8.8 LIMIT THERMOSTAT
8.9 OVERHEAT THERMOSTAT
8.10 THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
8.11 IGNITION CONTROL BOX
8.12 DRIVER PCB
8.13 PUMP
8.14 D.H.W. HEAT EXCHANGER
8.15 DIVERTOR VALVE - COMPLETE
8.16 DIVERTOR VALVE - MICROSWITCH ASSEMBLY
8.17 C.H. EXPANSION VESSEL
8.18 PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
8.19 SAFETY VALVE
8.20 AUTOMATIC AIR VENT
8.21 TIME CLOCK
9 SHORT LIST OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.1 INTRODUCTION
The Sime “FRIENDLY FORMAT” are wall mounted, fan assist-
ed balanced flue combination boilers.
The appliance is supplied suitable for use with natural gas, (a
conversion kit is available for LPG) and provide central heating
and instantaneous production of D.H.W. Heat output is varied
according to demand by the modulating gas control on both
D.H.W. and C.H.
The appliance is supplied with a concentric air and flue duct
suitable for wall thicknesses up to 740 mm (29 in) although
extension duct kits are available and may be used up to a total
flue lenght of 3.0 m (118 in).
The combined flue and air duct can exit the boiler from either
side or from the rear of the appliance.
A vertical extension and additional flue elbow may be fitted. If
required, the boilers can also be fitted with a separate flues
kit (see section 3 for details).
The boiler is designed for use with sealed primary water systems and is supplied fully assembled and equipped with complete valve packs.
If the wall thickness is less than 0.5 m (19 in) the appliance
can be installed from inside the room without access to the
external wall although a wall liner is required.
This is available as an optional extra, and full details are given
in section 3.
The boiler can be used with a 240V room thermostat (class
II according to EN 60730.1).This booklet provides instructions
for the following boiler models:
– “FRIENDLY FORMAT 80” with electronic ignition and mod-
ulation;
– “FRIENDLY FORMAT 80 E” with electronic ignition and
modulation, mechanical time clock built-in ex factory.
– “FRIENDLY FORMAT 100 E” with electronic ignition and
modulation, mechanical time clock built-in ex factory.
1
1 TECHNICAL FEATURES AND DIMENSIONS
TABLE 2 - Minimum clearances
ABOVE THE APPLIANCE CASING 200 mm 8 in
AT THE R.H.S. 90 mm 3
1
/2in
AT THE L.H.S. 5 mm 1/4 in
BELOW THE APPLIANCE CASING 200 mm 8 in
IN FRONT OF THE APPLIANCE 450 mm 18 in
TABLE 1 - Connections
R C.H. return 22 mm Compression
M C.H. flow 22 mm Compression
G Gas connection 1/2 in Bsp
E Cold water 15 mm Compression
U Hot water 15 mm Compression
1.2 DIMENSIONAL DETAILS
80 - 80 E 100 E
L mm 450 500
Fig. 1
2
1.3 GENERAL DATA
TABLE 3a - Nominal boiler ratings (5 minutes after lighting) for “FRIENDLY FORMAT 80 - 80 E”
MODE OUTPUT INPUT (G.C.V.) BURNER PRESSURE
kW Btu/h kW Btu/h mbar inwg
CENTRAL HEATING RANGE 9.4 32,000 12.0 40,900 1.5 0.6
11.7 40,000 15.2 51,800 2.5 1.0
13.8 47,000 17.7 60,400 3.4 1.4
16.1 55,000 20.2 68,800 4.4 1.8
17.6 60,000 22.1 75,600 5.4 2.2
X* 19.0 65,000 23.7 80,900 6.0 2.4
20.8 71,000 25.7 87,800 7.4 3.0
22.3 76,000 27.3 93,200 8.3 3.3
23.4 80,000 28.6 97,700 9.3 3.7
DOMESTIC HOT WATER Max. 23.4 80,000 28.6 97,700 9.3 3.7
Min. 9.4 32,000 12.0 40,900 1.5 0.6
* Factory setting
80 - 80 E 100 E
Main burner injectors No of f 13 15
Dia mm 1.3 1.3
Water capacity l (gal) 3.4 (0.85) 3.4 (0.85)
Minimum water flow D.H.W. l/min (gal/min) 2 (0.5) 2 (0.5)
D.H.W. flow rate
at a temperature rise of 30°C l/min (gal/min) 11.2 (2.5) 13.8 (3.0)
35°C l/min (gal/min) 9.6 (2.1) 11.9 (2.6)
Static head Minimum bar (psi) 0.5 (7.3) 0.5 (7.3)
Maximum bar (psi) 3.0 (43.5) 3.0 (43.5)
D.H.W. pressure Minimum bar (psi) 0.5 (7.3) 0.5 (7.3)
Maximum bar (psi) 7.0 (102) 7.0 (102)
Weight Empty kg (lb) 43 (95) 49 (108)
Total (full) kg (lb) 46,5 (102) 52,5 (116)
Electrical supply 230 V - 50 Hz, Fused at 3 A
Internal fuse Line: F 1.6 A
Maximum power consumption Watt 150 160
Maximum gas consumpt. (G20) m
3
/h (ft3/h) 2.72 (96) 3.34 (118)
Max. working temperature °C (F) 95 (203) 95 (203)
Integral exp. vessel capacity l (gal) 7 (1.5) 10 (2.2)
TABLE 4 - General specifications
TABLE 3b - Nominal boiler ratings (5 minutes after lighting) for “FRIENDLY FORMAT 100 E”
MODE OUTPUT INPUT (G.C.V.) BURNER PRESSURE
kW Btu/h kW Btu/h mbar inwg
CENTRAL HEATING RANGE 11.4 39,000 14.9 51,000 1.5 0.6
13.5 46,000 17.4 59,500 2.3 0.9
15.8 54,000 20.2 69,100 3.2 1.3
17.8 61,000 22.6 77,500 4.1 1.6
19.0 65,000 23.8 81,250 4.5 1.8
X* 22.2 76,000 27.6 94,550 6.7 2.7
24.6 84,000 30.3 103,650 7.7 3.1
26.6 91,000 32.5 111,250 9.2 3.7
29.3 100,000 35.1 120,000 10.4 4.2
DOMESTIC HOT WATER Max. 29.3 100,000 35.1 120,000 10.4 4.2
Min. 11.4 39,000 14.9 51,000 1.5 0.6
* Factory setting
3
1.4 HYDRAULIC CIRCUIT
KEY
1Fan
2 Water-gas exchanger
3 Combustion chamber
4 Gas valve
5 D.H.W. exchanger
6 Diver tor valve with charging
7 NTC sensor
8 100°C safety thermostat
9 Air relief valve
10 Circulation pump
11 Expansion vessel
12 Safety valve
13 Drain plug
14 Manometer
15 Automatic by-pass
16 D.H.W. filter
17 C.H. return cock
18 C.H. flow cock
19 D.H.W. cock
20 Gas cock
21 Limit thermostat
Fig. 2
2.1 STATUTORY REQUIREMENTS
GAS SAFETY (INSTALLATION AND USE) REGULATIONS (as
amended). It is the law that all gas appliances are installed by
a registered person, in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure
that the law is complied with.
In addition to the above regulations, this appliance must be
installed in accordance with the current IEE Wiring
Regulations (BS 7671), Local Building Regulations, the
Building Standards (Scotland) (Consolidation) Regulations,
Byelaws of the local water undertaking, and Health and Safety
Document No 635 “The Electricity at Work Regulations
1989”. It should also be in accordance with the relevant recommendations in the current editions of the following British
Standards and Codes of Practice: BS5449, BS5546,
BS5440:1, BS5440:2, BS6798, BS6891, and BG.DM2,
BS7074, and BS5482 for propane installations.
Manufacturer’s instructions must NOT be taken in any way
as over-riding statutory obligations.
2.2 BOILER POSITION
In siting the combination boiler, the following limitations MUST
be observed:
– The boiler is not suitable for external installation. The posi-
tion selected for installation should be within the building,
unless otherwise protected by a suitable enclosure, and
MUST allow adequate space for installation, servicing, and
operation of the appliance, and for air circulation around it
(section 2.4).
– This position MUST allow for a suitable flue termination to
be made. The combination boiler must be installed on a
flat vertical wall which is capable of supporting the weight
of the appliance, and any ancillary equipment.
– If the combination boiler is to be fitted in a timber framed
building it should be fitted in accordance with the Institute
of Gas Engineers document for Gas Installations In Timber
Frame Housing, Reference 16E/UP/7: 1998. If in doubt,
advice must be sought from the gas supplier.
– If the appliance is installed in a room containing a bath or
shower, any electrical switch or control utilising mains
electricity must be so situated that it cannot be touched
by a person using the bath or shower. Attention is drawn
to the requirements of the current I.E.E. Wiring Regulations (BS 7671), and in Scotland the electrical provisions
of the Building Regulations applicable in Scotland.
– A compartment used to enclose the appliance MUST be
designed and constructed specifically for this purpose. An
existing cupboard, or compartment, may be used provided it is modified accordingly.
– Where installation will be in an unusual location, special
procedures may be necessary. BS6798 gives detailed
guidance on this aspect.
2.3 FLUE TERMINAL POSITION
Detailed recommendations for flue installation are given in
BS5440:1. The following notes are for general guidance:
– The boiler MUST be installed so that the terminal is
exposed to the external air.
– It is important that the position of the terminal allows free
passage of air across it at all times.
– It is ESSENTIAL TO ENSURE, in practice that products of
combustion discharging from the terminal cannot reenter the building, or any other adjacent building, through
ventilators, windows, doors, other sources of natural air
infiltration, or forced ventilation/air conditioning. If this
does occur, the appliance MUST be turned OFF IMMEDIATELY and the gas supplier consulted.
–
The minimum acceptable dimensions from the terminal to
obstructions and ventilation openings are specified in fig. 3.
– If the terminal discharges into a pathway or passageway
check that combustion products will not cause nuisance
and that the terminal will not obstruct the passageway.
– Where the lowest part of the terminal is fitted less than 2
m (78 in) above ground, above a balcony or above a flat
roof to which people have access, the terminal MUST be
4
Terminal position
Directly below an openable window, air
vent or any other ventilation opening
Below guttering, drain pipes or soil pipes
Below eaves, balconies or carport roof
From vertical drain pipes or soil pipes
From internal or external corners
Above adjacent ground, roof or bal-
cony level
From a surface facing the terminal
From a terminal facing the terminal
From an opening in the carport (eg
door, window into dwelling)
Vertically from a terminal on the
same wall
Horizontally from a terminal on the
same wall
Adjacent to opening
A
B
C/D
E
F
G
H
I
J
K
L
M
Minimum spacing
300 mm 12 in
75 mm 3 in
200 mm 8 in
75 mm 3 in
300 mm 12 in
300 mm 12 in
600 mm 24 in
1,200 mm 48 in
1,200 mm 48 in
1,500 mm 60 in
300 mm 12 in
300 mm 12 in
TABLE 5
2 GENERAL REQUIREMENTS FOR INSTALLATION
Fig. 3
protected by a purpose designed guard. Terminal guards
are available from Quinnell, Barrett, and Quinnell, Old Kent
Road, London. State model C2, (G.C. Part No 382946).
– Where the terminal is fitted within 850 mm (34 in) of a
plastic or painted gutter, or 450 mm (18 in) of painted
eaves, an aluminium shield at least 1,500 mm (59 in) long
must be fitted to the underside of the painted surface.
– The air inlet/outlet flue duct MUST NOT be closer than
25 mm (1 in) to combustible material.
– In certain weather conditions the terminal may emit a
plume of steam. This is normal but positions where this
would cause a nuisance should be avoided.
2.4 VENTILATION REQUIREMENTS
Detailled recommendations for air supply are given in
BS5440:2. The following notes are for general guidance:
–
It is not necessary to have a purpose provided air vent in the
room or internal space in which the appliance is installed.
2.5 GAS SUPPLY
– The gas supplier should be consulted at the installation
planning stage in order to establish the availability of an
adequate supply of gas.
– An existing service pipe MUST NOT be used without prior
consultation with the gas supplier.
– A gas meter can only be connected by the gas supplier or
their contractor.
– An existing meter should be of sufficient size to carry the
maximum boiler input plus the demand of any other
installed appliance. (BS6891: 1988).The gas required for
the boiler is specified in
Table 4
.
– The governor at the meter must give a constant outlet
pressure of 20 mbar (8 inwg) for natural gas when the
appliance is running.
– The gas supply line should be purged.
NOTE: Before purging open all doors and windows, also
extinguish any cigarettes, pipes, and any other naked
lights.
–
The complete installation must be tested for gas soundness.
– It is important to assure an adequate gas supply to the
appliance. No more than 3 m of 15 mm pipe should be
used. Where the supply exceeds 3 m the pipe should be
suitbly sized only reducing to 15 mm for the last 3 m prior
to the appliance.
2.6 ELECTRICITY SUPPLY
The appliance MUST be earthed. A mains supply of 230 V 50 Hz single phase is required. All external controls and
wiring MUST be suitable for mains voltage.
Wiring should be in 3 core PVC insulated cable NOT LESS
than 0.75 mm
2
(24 x 0.2 mm) to BS6500, Table 16. Wiring
external to the boiler MUST be in accordance with current
l.E.E. Wiring Regulations (BS 7671) and local regulations. The
supply connection to the flying lead provided MUST be made
to a fused double pole switch, having a 3 mm (1/8 in) contact
separation in both poles, serving only the boiler and system
controls. The fuse rating should be as per the original instructions. This connection should be readily accessible and be
made adjacent to the boiler (except in the case of bathroom
installations for domestic boilers where the point of connection to the mains MUST be outside of the bathroom).
2.7 EXTERNAL CONTROLS (Refer to section 3.10)
The boiler is intended for use with a 240 V room thermostat.
The connection is made inside the control box as described in
section 3.10.
2.8 WATER SYSTEMS - GENERAL
– This appliance is designed for connection to sealed cen-
tral heating water systems.
– Check that the mains water pressure is suf ficient to pro-
duce the required D.H.W. flow rate, but does not exceed
the maximum D.H.W. pressure (
Table 4
). If necessary, a
pressure reducing valve must be fitted to the mains supply before the D.H.W. inlet connection.
2.9 REQUIREMENTS FOR SEALED WATER SYSTEMS
The heating system design should be based on the following
information:
a) The available pump head is given in fig. 4.
b) A minimum flow rate corresponding to a heating differen-
tial of 11°C must be obtained at all times.
c) A heating by-pass is usually only required when micro-
bore piping is used on the system. If however condition
(b) can not be satisfied a heating by-pass should be fitted.
If thermostatic radiator valves are to be installed, at least
one radiator should be without a thermostatic valve (usually the bathroom radiator).
d) A sealed system must only be filled by a competent per-
son using one of the approved methods shown in fig. 6.
The system design should incorporate the connections
appropriate to one of these methods.
e) The following paragraphs outline the specifications of the
items fitted to the boiler.
5
0
600
200
1600
140012001000800600400
PORTATA (l/h)
PREVALENZA RESIDUA (mbar)
500
400
100
200
300
con by-pass
senza by-pass
25
30
25
30
Format - Planet - Open
KEY
1 Available Head for “80 - 80 E” models
2 Available Head for “100 E” model
Flow rate (l/sec)
Available head (mbar)
Fig. 4
2
1
1
2
with boiler by-pass
without boiler by-pass
6
TYPICAL SYSTEM DESIGN
ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM
NOTE: A drain cock should be installed at the lowest point of the heating circuit and beneath the appliance.
NOTES:
– When it is not possible to avoid a situation where the initial system pressure and static head are equal a manually fit-
ted top up container should be fitted as shown above.
Take note of the requirements relative to container capacity: height above system, inclusion of a non-return valve,
stop cock and automatic air vent in the feed pipe, as shown in fig. 5.
Note also the feed pipe connection is made to the heating return as close to the appliance as possible.
– The Local Water Undertaking MUST approve ALL connections between the system and a water storage cistern or
water main supplying D.H.W.
METHOD 1 (complies with BS6798.1987)
METHOD 2 (complies with BS6798.1987)
Fig. 5
Fig. 6
2.9.1 Pump
The available head shown in fig. 4 is that in excess of the appliance hydraulic resistance, i.e. that available for the system at
any given heating load up to the maximum output in C.H.
mode. Never reduce the pump speed below maximum as this
will reduce D.H.W. output. The pump speed is indicated on the
side of the pump speed selector switch (if fitted).
2.9.2 System volume (total water content)
The following Table gives the maximum system volume that
the integral expansion vessel can sustain under different
charge pressure conditions.
If the system volume exceeds that shown, an additional expansion vessel must be fitted and connected to the heating system
primary return pipe as close as possible to the appliance.
If an extra vessel is required, ensure that the total capacity of
both vessels is adequate. Further details are available in the
current issues of BS5449 and BS6798.
NOTE: If the pressure gauge indicates 2.65 bar or greater
when the appliance is at maximum temperature with all
radiators in circulation an extra expansion vessel is
required.
2.9.3 Pressure gauge
A pressure gauge is mounted on the appliance facia panel.
2.9.4 Safety valve
A safety valve set at 3 bar (43.5 psi) is fitted to the appliance
and a discharge pipe is routed to outside of the appliance.
This discharge pipe should be extended to terminate safely
away from the appliance and where a discharge would not
cause damage to persons or property but would be detected.
The pipe should be able to withstand boiling water, be a minimum of 15 mm in diameter, and not include any horizontal
runs prone to freezing.
2.10 D.H.W. SYSTEMS
– The authority of the local Water Company should be
obtained before the appliance is connected to the cold
water mains supply. Check that the mains supply pressure is within the prescribed limits (
Table 4
).
If necessary, a pressure reducing valve should be fitted to
the mains supply before the D.H.W. inlet connection.
– The final 600 mm (24 in) of the mains supply pipe to the
boiler must be copper.
– A maximum D.H.W. flow rate of 10.3 l/m (2.3 gpm) (13
l/m (2.9 gpm) for “FRIENDLY FORMAT 100 E”) is recom-
mended. Higher flow rates will not damage the appliance
but may lower the water temperature below an acceptable level.
– If the appliance is installed in an area where the tempo-
rary hardness of the water supply is high, say over 150
ppm, the fitting of an in line scale inhibitor may be an
advantage. Consult the Local Water Undertaking if in
doubt.
– Devices capable of preventing the flow of expansion water:
e.g. non return valves and/or loose-jumpered stop cocks
should not be fitted unless separate arrangements are
made for expansion water.
– For specific information relating to fittings (eg. Showers,
washing machines etc.) suitable for connection in the
D.H.W. circuit, consult the Local Water Undertaking, however the following information is given for guidance.
2.10.1 Domestic hot/cold water supply
taps and mixing taps
All equipment designed for use at mains water pressure is
suitable.
2.10.2 Showers
Any mains pressure shower is suitable, but if the unit has a
loose head which may become immersed in bath water either
an anti-syphonage device must be fitted, or the length of the
flexible hose must be reduced so that it cannot fall closer than
13 mm (1/2 in) to the top of the bath.
2.10.3 Bidets
Providing that the appliance is of the over-rim flushing type, the
outlets are shrouded and it is impossible to attach a temporary
hand held spray, no anti syphonage device is necessary.
7
Vessel charge and initial system
pressure
Total water content of system
using 7 l (1.54 gal) capacity expan-
sion vessel supplied with appliance
(“FRIENDLY FORMAT 80 - 80 E”)
Total water content of system
using 10 l (2.2 gal) capacity expan-
sion vessel supplied with appliance
(“FRIENDLY FORMAT 100 E”)
For systems having a larger capaci-
ty multiply the total system capacity
in litres (gal) by the factor to obtain
the total minimum expansion vessel
capacity required litres (gal)
bar
psi
l
gal
l
gal
0.5
7. 3
87
19 .1
124
27.3
.0833
1. 5
21.8
44
9.7
63
13.9
.15 6
1. 0
14.5
64
14.0
91
20.0
.10 9
TABLE 6
3.1 UNPACKING THE BOILER
The standard appliance is supplied in two separate cardboard
cartons. In addition up to two extension duct kits may be used.
If the appliance is to be installed without access to the outside
wall, the wall liner will also be required. Unpack each carton
and check the contents against the following lists:
Appliance package:
– combination boiler (assembled);
– installation and servicing instructions;
– users instructions;
– wall mounting templates (paper);
– wall mounting bracket assembly ;
– fixing screws with wall plugs;
– plastic bags containing:
– gas service cock;
– C.H. F/R isolation valves;
– D.H.W. isolation valve;
– D.H.W. elbow connection;
– D.H.W. compression fitting;
– aluminium ring;
– associated fixing screws;
– associated gaskets;
– safety valve discharge pipe.
Flue Package:
– inner duct (flue) c/w flue terminal and centering springs;
– outer duct (air);
– junction collar with protective metal sleeve;
– flue elbow with gasket;
– rubber sealing ring.
3.2 FIXING THE WALL MOUNTING BRACKET
Before installing the appliance ensure that the chosen location is suitable (section 2.2) and that the requirements for
flue position, (section 2.3), and minimum clearances, (
Table 2
)
are satisfied. These minimum clearances are essential to provide access for servicing, and are included on the wall mounting templates.
– Open the paper wall mounting templates. If a rear flue is
to be used, discard the side templates and secure the
rear template in the desired position. For a side flue application, secure both the rear and appropriate side template in position.
– Mark the position of the two wall mounting bracket fixing
holes, the two lower frame fixing holes, and the flue/air
duct hole on the appropriate wall(s).
– Remove the template(s) and drill the top two fixing holes
using a 10 mm masonry drill and the bottom two fixing
holes using a 6 mm masonry drill. Fit the plastic plugs provided.
– Cut the hole in the wall for the flue/air duct. The diameter
should not be less than 100 mm (4 in) and must be horizontal. If the hole is not accessible from the outside of the
building, its minimum diameter should be sufficient to
allow the insertion of the wall liner (130 mm - 5
1
/4in
diameter) which will be sealed with mortar. Refer to fig.
13. (The wall liner is available as an optional extra).
– Accurately measure the wall thickness, and note this
dimension for later use.
– Secure the wall mounting bracket in position using the
screws provided. Ensure that it is the correct way up, as
indicated in fig. 7.
3.3 HANGING THE BOILER
– Remove the outer casing front panel fixing screw (6 fig. 8)
and remove the front panel (5 fig. 8) by pulling forwards,
starting at the top corners.
– Lift the appliance into position. The upper cross member
locates onto the wall mounting bracket. Slide the appliance sideways (if necessary) until the lower frame fixing
holes line up with the wall plugs.
– Screw in the wall mounting bracket adjusting screws until
the appliance is secure and vertical, then fit the two lower
fixing screws to prevent any further movement using a
long screwdriver.
8
KEY
1 Wall mounting bracket
2 Plastic wall plug (2 Off)
3 Woodscrew (2 Off)
4 Washer (2 Off)
5 Adjustment screw (2 Off)
3 INSTALLING THE BOILER
KEY
1 Self-tapping screw
2 Rear panel
3 L.H. side panel
4 R.H. side panel
5 Front panel
6 Fixing bracket
Fig. 7
Fig. 8
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