ECOMFORT
PLUS
Installation and
servicing instructions
GB
All descriptions and illustrations provided in this manual have been carefully prepared but we reserve the right to make changes
and improvements in our products that may affect the accuracy of the information contained in this manual.
The Benchmark Scheme
Sime Ltd is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and
commissioning 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
Ecomfort System Plus 25 HE: Ecomfort Plus 25 HE:
Gas Council number 41-283-10 Gas Council number 47-283-13
Ecomfort Plus 30 HE:
Gas Council number 47-283-14
These appliances comply with the S.E.D.B.U.K. scheme, band “A”
Please refer to commissioning instructions for filling in the checklist 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
CONTENTS
1 DESCRIPTION OF THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 6
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 10
3 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 18
4 USE AND MAINTENANCE (including BENCHMARK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 21
5 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 26
6 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 29
7 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 31
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 manufac-
turing 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?
– Has the Aquaguard Filter been cleaned (see 4.9)?
– Has the condensate trap been filled (see section 2)?
IPX4D
Important Information
IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, IN
ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). The manufacturer’s instructions must not be taken as overriding any statutory requirements, and failure to comply with these
regulations may lead to prosecution.
No modifications to the appliance should be made unless they are fully approved by the manufacturer.
GAS LEAKS: DO NOT OPERATE ANY ELECTRICAL SWITCH, OR USE A NAKED FLAME. TURN OFF THE GAS SUPPLY
AND VENTILATE THE AREA BY OPENING DOORS AND WINDOWS CONTACT THE GAS EMERGENCY SERVICE ON
0800111999.
6
1.1 INTRODUCTION
“ECOMFORT PLUS” is a boiler that has a
condensing heat exchanger downstream
from the fan to allow the heat contained in
exhaust fumes to be recovered.
The boiler is equipped as standard with
frost protection and circulating pump anti-
jamming system.
The instructions given in this manual are
provided to ensure proper installation and
correct operation of the appliance.
1 DESCRIPTION OF THE BOILER
70
70
70
70
50
30
55
55
22
718
25
12 5
60
335
450
245
16 5
ø 60/100
90
700
1.2 DIMENSIONS
TABLE 1/a - Connections “ECOMFORT PLUS 25 HE - 30 HE”
R C.H. return 22 mm Compression
M C.H. flow 22 mm Compression
G Gas connection 15 mm Compression
E D.H.W. inlet 15 mm Compression
U D.H.W. outlet 15 mm Compression
S3 Condensation outlet ø 20
TABLE 2 - Minimum clearances
For ventilation For servicing
ABOVE THE APPLIANCE CASING 400 mm 300 mm
AT THE R.H.S. 15 m m 15 m m
AT THE L.H.S. 15 m m 15 m m
BELOW THE APPLIANCE CASING 200 mm 200 mm
IN FRONT OF THE APPLIANCE 100 mm 500 mm
TABLE 1 - Connections “ECOMFORT SYSTEM PLUS 25 HE”
R C.H. return 22 mm Compression
M C.H. flow 22 mm Compression
G Gas connection 15 mm Compression
S3 Condensation outlet ø 20
Fig. 1
ECOMFORT PLUS SYSTEM 25 HE
ECOMFORT PLUS 25-30 HE
(coaxial duct ø 60/100)
ECOMFORT PLUS 30 HE
(coaxial duct ø 80/125)
245
16 5
19 0
700
450
ø 80/125
25
S3
12 5
55
22
718
G
M
G
60
335
R
=
70
70
70 70
EU
55
50
=
30
1.3 TECHNICAL FEATURES
ECOMFORT PLUS SYSTEM 25 HE 25 HE 30 HE
Heat output nominal (80-60°C) kW 25.0 25.0 29.0
Heat output nominal (50-30°C) kW 27.2 27.2 31.5
Heat output minimum (80-60°C) kW 9.6 9.6 11.3
Heat output minimum (50-30°C) kW 10.2 10.2 12.0
Heat input nominal kW 25.5 25.5 29.5
Heat input minimum kW 10.2 10.2 12.0
Efficiency min./nom. output (80-60°C) % 94.2/98.3 94.2/98.3 94.2/98.3
Efficiency min./nom. output (50-30°C) % 100.0/106.8 100.0/106.8 100.0/106.8
Seasonal efficiency rating (SEDBUK) (A) (A) (A)
Termal efficiency (CEE 92/42 directive) ★★★★ ★★★★ ★★★★
Class NOx 3 3 3
Smokes temperature maximum (80-60°C) °C 60 60 60
Smokes temperature minimum (80-60°C) °C 60 60 60
Smokes temperature maximum (50-30°C) °C 40 40 40
Smokes temperature minimum (50-30°C) °C 40 40 40
Smokes flow kg/h 58.0 58.0 61.0
CO2 maximum/minimum G20 % 7.0/2.5 7.0/2.5 7.5/2.8
CO2 maximum/minimum G30/G31 % 8.0/2.8 8.0/2.8 8.8/3.3
Adsorbed power consumption W 150 150 160
Electrical protection grade IP X4D X4D X4D
CE certification n° 1312BT5040 1312BT5040 1312BT5040
Category II2H3+ II2H3+ II2H3+
Type
B22P-52P/C12-32-42-52-82 B22P-52P/C12-32-42-52-82 B22P-52P/C12-32-42-52-82
WEIGHT kg 41 43 43
CENTRAL HEATING
Maximum water head bar 3 3 3
Maximum temperature °C 85 85 85
Water content boiler l 5.0 5.0 5.0
C.H. setting range °C 30/80 30/80 30/80
Expansion vessel capacity l 8 8 8
Expansion vessel pressure bar 1 1 1
DOMESTIC HOT WATER
Minimum/Maximum pressure bar - 0.2/7.0 0.2/7.0
D.H.W. flow rate (EN 625) l/min - 11.7 13.6
Continuous D.H.W. flow rate ∆t 30°C l/min - 11.9 13.8
Continuous D.H.W. flow rate ∆t 35°C l/min - 10.1 11.8
D.H.W. setting range °C - 30/60 30/60
GAS PRESSURE AND NOZZLES
Gas supply pressure G20 mbar 20 20 20
Gas supply pressure G30 mbar 28-30 28-30 28-30
Gas supply pressure G31 mbar 37 37 37
Nozzles quantity n° 12 12 14
Nozzles diameter G20 ø 1.30 1.30 1.30
Nozzles diameter G30/G31 ø 0.77 0.77 0.77
Burner gas pressure min./max. G20 mbar 2.0/11.5 2.0/11.5 2.1/11.7
Burner gas pressure min./max. G30 mbar 4.8/28.5 4.8/28.5 5.0/28.5
Burner gas pressure min./max. G31 mbar 4.8/36.5 4.8/36.5 5.0/36.5
C.H gas consumption G20 m3/h 2.70 2.70 3.12
C.H. gas consumption G30/G31 kg/h 2.01 2.01 2.33
7
8
1
23
4
5
7
8
9
11
14
15
13
18
19
20
25
2624
17
16
S3
RMG
20
19
21
22
23
24
25
26
RMGEU
18
14
15
13
11
12
9
10
7
8
6
5
4
1
2
3
17
S3
16
KEY
1 Post-condenser
2 Smoke stat 95°
3 Fan
4 Main exchanger
5 SM sensor (thermister)
6 Aqua Guard Filter System
7 Safety stat 100°
8 Thermometer sensor
9 Gas valve
10 D.H.W. exchanger
11 Water flow switch
12 Divertor valve
13 Automatic by-pass
14 Circulating pump
15 Auto air vent
16 Expansion vessel
17 Condensation water trap
18 Safety valve
19 Temperature/pressure gauge
20 Boiler drain
21 D.H.W. filter
23 D.H.W. inlet cock
24 Gas cock
25 C.H. flow cock
26 C.H. return cock
R C.H. return
M C.H. flow
G Gas connection
E D.H.W. inlet
U D.H.W. outlet
S3 Condensation outlet ø 20
1.4 FUNCTIONAL DIAGRAM
Fig. 2
ECOMFORT SYSTEM PLUS 25 HE
ECOMFORT PLUS 25 - 30 HE
1.5 MAIN COMPONENTS
Fig. 3
KEY
1 Water flow switch
2 Water trap
3 Safety stat 100°
4 Aqua Guard Filter System
5 Main exchanger
6 SM sensor (thermister)
7Fan
8 Smoke stat 95°
9 Smoke pressure switch
10 Positive test point
11 Post-condenser
12 Combustion chamber
13 Ignition/ionization electrode
14 Burner
15 Gas valve
16 Automatic air vent
17 Control panel
18 Negative test point
ECOMFORT SYSTEM PLUS 25 HE
ECOMFORT PLUS 25 - 30 HE
9
10
The boiler must be installed in a fixed location and only by specialized and qualified person in compliance with all instructions contained in this manual. The boiler should be
installed in accordance with the Gas Safety
Regulations.
It is important that the condensate trap
be filled prior to operating the boiler. The
trap can be filled by pouring water carefully into the inner flue connection prior to
installation of the flue. Care should be
taken not to allow any water to enter the
outer flue.
2.1 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 pro-
vided air vent in the room or compartment in which the appliance is installed.
2.2 FIXING THE WALL
MOUNTING BRACKET
– Mark the position of the two wall mount-
ing bracket fixing holes and the flue/air
duct hole on the appropriate wall(s).
– Drill the top two fixing holes using a 10
mm masonry drill and 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.
– 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. 4.
2.3 CONNECTING UP SYSTEM
Before proceeding to connect up the boiler,
you are recommended to flush out the system
in order to eliminate any foreign bodies that
might be detrimental to the operating efficiency of the appliance. When making the
hydraulic connections, make sure that the
clearances indicated in fig. 1 are respected.
To facilitate the hydraulic connections the boiler is equipped with a valve pack code
5184817 complete with instructions sheet.
A safety valve set at 3 bar is fitted to the
appliance, the discharge pipe provided
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 a minimum of 15 mm Ø
and should be able to withstand boiling
water, any should avoid sharp corners or
upward pipe runs where water may be
retained.
Gas Connection
: The gas connection must
be made using seamless steel or copper
pipe, galvanized and with threaded joints
provided with gaskets, excluding three-piece
connections, except for initial and end connections. Where the piping has to pass
through walls, a suitable insulating 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 suf ficient to
cover the maximum demand, 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.
2.3.1 Connection of condensation
water trap (fig. 4/a)
To ensure safe disposal of the condensate
produced by the flue gases, reference should
be made to BS6798:2000. The boiler incorporates a condensate trap which has a seal of
75mm, therefore no additional trap is
required. The condensate should ideally be discharged internally into an internal waste
pipe(washing machine/sink waste) or a soil
pipe to avoid the risk of freezing. External pipe
runs should be avoided, but if it is necessary,
the pipework should be at least 32mm and
protected from the risc of freezing with a
waterproof insulation and the length kept to a
minimum and not exceeding 3 m. termination
should be into an external gully or purpose
made soakaway.
NOTE: All pipework must have a continuous
fall from the boiler and must be resistant to
corrosion by condensate, copper or steel is
NOT suitable. It should be noted that the
connection of a condensate pipe to a drain
may be subject to local building control
requirements.
2 INSTALLATION
Fig. 4/a
1
2
3
4
KEY
1 Wall mounting bracket
2 Plastic wall plug (2 Off)
3 Woodscrew (2 Off)
4 Washer (2 Off)
Fig. 4
11
2.3.2 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. 16.
b) The burner star ts when the C.H. flow
reaches 400÷450 l/h. This safety condition is ensured by the flow switch.
c) The appliance is equipped with an inter-
nal by-pass that operates with system
heads (H) greater than 3 m. The maximum flow through the by-pass is about
300 l/h. 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 person using one of the
approved methods shown in fig. 4/b.
The system design should incorporate
the connections appropriate to one of
these methods.
2.4 CHARACTERISTICS
OF FEEDWATER
– 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.
–
For optimum performance af ter installation this boiler and its 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”.
– This must involve the use of a propri-
etary cleanser, such as Sentinel X300
or X400, or Fernox Superfloc. Full
instructions are supplied with the products, but for immediate information
please contact GE Betz (0151 420
9563) or Fernox (01799 550 811)
directly.
– For long term protection against corro-
sion and scale, after flushing it is recommended that an inhibitor such as
Sentinel X100, or Fernox MB-1 or Copal
is dosed in accordance with the guidelines given in BS 7593.
Failure to flush and add inhibitor to
the system may invalidate the appliance warranty.
– It is important to check the inhibitor
concentration after installation, system
modification and at every service in
accordance with the manufacturer’s
instructions. (Test kits are available
from inhibitor stockists).
– At every service the Aquaguard Filter
(4.9) should be checked and cleaned.
2.5 COAXIAL DUCT ø 60/100
The air inlet-smoke outlet assembly, code
8096250, is included in the standard supply of the appliance complete with mounting
instructions.
NOTE: to use only special accessories for
condensing boilers.
2.5.1 Coaxial flue diaphragm
The boiler "25 HE" is supplied of series
with diaphragm ø 87.5 to mount like indicated in figure (fig. 4/c).
ATTENTION: the diaphragm should be
used only when the length of the coaxial
duct is below 1,5 m (only for “25 HE”
model).
2.5.2 Coaxial duct accessories
The accessories to be used for this type of installation and some of the connecting systems that
may be adopted are illustrated in
fig. 5.
With the pipe bend included in the kit, the
maximum length of the piping should not
Fig. 5
KEY
1a-b Coaxial duct kit code 8096250
2 Extension L. 1000 code 8096150
3 Vertical extension L. 140 with take-off point code 8086950
4 a 90° additional bend code 8095850
4 b 45° additional bend code 8095950
max. 5.0 m (“25 HE” model)
max. 2.5 m (“30 HE” model)
NOTE: Place the duct horizontally.
NOTE: Before installing accessories, lubricate the internal part
of gaskets with silicon-based
products. Avoid using oils and
greases.
IMPORTANT:
– Each additional 90° curve installed reduces
the available length by 1.0 metres.
– Each additional 45° curve installed reduces
the available length by 0.50 metres.
ONLY FOR “25 HE” MODEL
Fig. 4/c
ALTERNATIVE METHODS OF
FILLING A SEALED SYSTEM
Fig. 4/b
12
exceed 5.0 meter (25 HE) - 3.0 meter (30
HE). When the vertical extension code
8086950 is used, the terminal part of the
pipe must always come out horizontally.
2.6 COAXIAL DUCT ø 80/125
(only for “30 HE” model)
The air inlet-smoke outlet assembly ø
80/125 is supplied in a kit code 8096253
complete with mounting instructions.
With the pipe bend included in the kit, the
maximum length of the piping should not
exceed 5.0 meter.
The diagrams in fig. 5/a illustrate a number of examples of different coaxial outlets
ø 80/125.
2.7 POSITIONING THE OUTLET
TERMINALS
The outlet terminals for forced-draught
appliances may be located in the external
perimeter walls of the building.
To provide some indications of possible solutions, Table 3 gives the minimum distances
to be observed, with reference to the type
of building shown in fig. 6.
Fig. 5/a
KEY
1 Coaxial duct kit code 8096253
2 a Extension L. 1000 code 8096171
2 b Extension L. 500 code 8096170
3 Adapter ø 80/125 code 8093150
4 a 90° additional bend code 8095870
4 b 45° additional bend code 8095970
6
Hinged tile code 8091300
7 Coaxial roof exit terminal L. 1285 code 8091205
IMPORTANT:
– Each additional 90° curve installed reduces the available length by 1.0 metres.
– Each additional 45° curve installed reduces the available length by 0.50 metres.
min. 2,5 m - max. 5 m
min. 4 m - max. 7 m
Only for “30 HE” model
4
y
C42
x + y = max 3 m
2
2
3
x
6
7
max 4 m
2
3
C32
1
2
max 3 m
1
C12
13
Fig. 6
– 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 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 gut-
ter, or 450 mm (18 in) of painted eaves, an aluminium shield at least 1,500 mm
(59 in) long must be fitted to the under side of the painted surface.
– The air inlet/outlet flue duct MUST NOT be closer than 25 mm (1 in) to com-
bustible 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.
Terminal position Minimum spacing
A Directly below an openable window, air vent
or any other ventilation opening 300 mm 12 in
B Below guttering, drain pipes or soil pipes 75 mm 3 in
C/D Below eaves, balconies or carpor t roof 200 mm 8 in
E From vertical drain pipes or soil pipes 75 mm 3 in
F From internal or external corners 300 mm 12 in
G Above adjacent ground, roof or balcony level 300 mm 12 in
H From a boundary or surface facing the boiler 600 mm 24 in
I From a terminal facing the terminal 1,200 mm 48 in
J From an opening in the carport
(eg door, window into dwelling) 1,200 mm 48 in
K Vertically from a terminal on the same wall 1,500 mm 60 in
L Horizontally from a terminal on the same wall 300 mm 12 in
M Horizontally from a vertical terminal to a wall 300 mm 12 in
N Horizontally from an openable window or other opening 300 mm 12 in
P Above an openable window or other opening 300 mm 12 in
Q From an adjacent vertical terminal 600 mm 24 in
TABLE 3
14
2.8 SEPARATE PIPES ø 80
(Optional alternative
twin pipe system)
A special kit may be used to separate the
flue gas outlet from the fresh air intake (fig.
7).
The maximum overall length of the intake
and exhaust ducts depends on the head
losses of the single fittings installed
(excluding the doublers) and must not be
greater than 11.5 mm H2O (“25 HE”
model) and 8.0 mm H2O (“30 HE” model).
For head losses in the fittings, refer to Table
4.
NOTE: To use only special accessories for
condensing boilers.
2.8.1 Separate pipe accessories
Kit code 8089912 is supplied for this purpose (fig. 8).
2.9 ELECTRICAL CONNECTION
The boiler is supplied with an electric cable.
Should this require replacement, it must be
purchased exclusively from SIME.
The electric power supply to the boiler must
be 230V - 50Hz single-phase through a
fused main switch fitted with a 3amp fuse,
with at least 3 mm spacing between contacts. Respect the L and N polarities and
the earth connection.
NOTE: SIME declines all responsibility for
injury or damage to persons, animals or
property, resulting from the failure to provide for proper earthing of the appliance.
2.9.1 Electrical board (fig. 12)
Before performing any kind of operation,
disconnect the unit from the power supply
using the bipolar switch of the plant.
Placing the boiler selector in position “OFF”
does not disconnect the electric board
from the power supply.
Remove the three screws (9) fixing the con-
trol board, and pull forward the panel until it
tilts downwards. In order to gain access to
the electrical board components, unscrew
the four screws fixing the control panel
cover.
2.9.2 Room thermostat (fig. 12)
After having removed the jumper, connect
electrically the room thermostat to terminals 1-2 of the junction box (8).
In order to have better room comfort and
temperature control, we suggest you to
use a room thermostat belonging to
Class II, as specified by standard
EN60730.1 (clean contact).
KEY
1 Gasket ø 125/95
2 Fixing screw
3 Flue outlet flange
4 Inlet air diaphragm
115
ø 80
ø 80
110
16 5
255
10 0
245
TABLE 4
Accessories ø 80 Head loss (mm H2O) “25 HE” model Head loss (mm H2O) “30 HE” model
Inlet Outlet Inlet Outlet
90° elbow MF 0.25 0.35 0.30 0.40
45° elbow MF 0.15 0.25 0.20 0.30
Extension L. 1000 (horizontal) 0.20 0.25 0.20 0.30
Extension L. 1000 (vertical) 0.20 0.15 0.20 0.20
Terminal 0.10 0.35 0.10 0.40
Roof outlet terminal * 1.30 0.15 1.50 0.20
* The loss of the roof exit terminal in aspiration concludes the collector code 8091400
N° segments Total load loss mm H2O
to remove “25 HE” model
- 0 ÷ 2,0
n° 1 2,0 ÷ 4,0
n° 1 e 2 4,0 ÷ 6,0
da n° 1 a 3 6,0 ÷ 7,0
da n° 1 a 4 7,0 ÷ 8,0
da n° 1 a 6 8,0 ÷ 9,0
da n° 1 a 8 9,0 ÷ 10,0
without diaphragm 10,0 ÷ 11,5
Fig. 8
N° segments Total load loss mm H2O
to remove “30 HE” model
- 0 ÷ 1,0
n° 1 e 2 1,0 ÷ 2,0
da n° 1 a 3 2,0 ÷ 3,0
da n° 1 a 4 3,0 ÷ 4,0
da n° 1 a 6 4,0 ÷ 5,0
da n° 1 a 7 5,0 ÷ 6,0
da n° 1 a 8 6,0 ÷ 7,0
without diaphragm 7,0 ÷ 8,0
Fig. 7
2
3
1
4
15
Fig. 12
ATTENTION: After having removed the three screws (9) tilt
the panel downwards to gain access.
KEY
1 Thermohydrometer
2 Time programmer (optional)
4 Main PCB
5 Ear th faston
6 Control panel protection
7 Cover (TA)
8 Connector (TA)
9 Fixing screw
IMPORTANT
Before performing any kind of operation, disconnect the unit
from the power supply using the bipolar switch of the plant.
Placing the boiler selector in position “OFF” does not disconnect
the electric board from the power supply.
9
125
67
4
8
16
JUMPERS
JP4
CN1
CN6
CN7
CN2
WHITE
GREY
95 °C SMOKE STAT
TERMINAL
BOARD
100 °C SAFETY STAT
RELAY
Fig. 13
2.9.3 ECOMFORT SYSTEM PLUS 25 HE wiring diagram
NOTE:
– The room thermostat (TA) may be connected to the terminals 1.
– To remote control the boiler connect an external clock to the terminals 1-2 (24 V) of the “TA” connector and set the
built-in clock to “constant” mode (see user instructions for details).
JUMPERS POSITION AND FEATURES
JUMPER POSITION AND FEATURE SUPPLY POSITION
CLOSED OPEN
JP4 - METANO/GPL Ready to function with LPG Ready to function with natural gas Open
WATER SENSOR
17
JUMPERS
JP4
CN1
CN6
CN7
CN2
95 °C SMOKE STAT
TERMINAL
BOARD
100 °C SAFETY STAT
Fig. 13/a
2.9.4 ECOMFORT PLUS 25 - 30 HE wiring diagram
NOTE:
– The room thermostat may be connected to the terminals 15-16 (CN1) of the “TA” connector after having removed the
link.
– To remote control the boiler connect an external clock to the terminals 1-2 (24 V) of the “TA” connector and set the
built-in clock to “constant” mode (see user instructions for details).
JUMPERS POSITION AND FEATURES
JUMPER POSITION AND FEATURE SUPPLY POSITION
CLOSED OPEN
JP4 - METANO/GPL Ready to function with LPG Ready to function with natural gas Open
WATER SENSOR
18
3.1 ELECTRONIC BOARD
The electronic board is manufactured in
compliance with the 2006/95/CEE lowvoltage directives. It is supplied with 230V.
The electronic components are guaranteed
against a temperature range of 0 up to
+60°C. An automatic and continuous
modulation system enables the boiler to
adjust power to the various system requirements or the user’s needs.
3.1.1 Fault and malfunction signaling
The indicator LEDS signaling irregular
and/or incorrect operation of the equipment are indicated in fig. 14.
3.1.2 Devices
The electronic board is equipped with the
following devices (fig. 15):
– Connector “JP4” (4)
With the connector disconnected, the
boiler is ready to function with METHANE;
with the connector connected with GPL.
ATTENTION: It is essential that the operations described above be carried out by
authorized technical staff.
3.2 TEMPERATURE SENSOR
Antifreeze system managed by active heating NTC sensor when water temperature
is 6°C. The heating sensor works also as a
limit thermostat which switches of f the burner when temperature is over 90°C.
When sensor (SM) is interrupted, neither
of the boiler's heating services will function.
Table 5 shows the resistance values (Ω)
obtained on the heating sensor as the temperature varies.
3 CHARACTERISTICS
Fig. 14
121045
3
7
8
9
Fig. 15
TABLE 5
Temperature (°C) Resistance (Ω)
20 12.090
30 8.313
40 5.828
50 4.161
60 3.021
70 2.229
80 1.669
KEY
1 Jumper JP2
2 Fuse (1,6 AT)
3 D.H.W. potentiometer
4 Connector “JP4”
5 Rotay switch
7 Block red led
8 C.H. potentiometer
9 Bi-colour led gree/orange
10 Connector “TA”
Bi-colour green led off if power is cut-off.
Bi-colour orange led: C.H. sensor (SM) fault.
Green led flashing: fan/smoke pressure switch.
F
lashing orange led no water circulation.
Flashing red led indicates a problem in the line post-condenser.
Red led on, ignition blocked/safety stat /smoke stat tripped:
turn the rotary switch in the position ( )
to restore functioning
19
3.3 ELECTRONIC IGNITION
Ignition and flame detection is controlled by
a sole electrode located on the burner. It
guarantees maximum safety with intervention times, for accidental switching off or
gas failure, within one second.
3.3.1 Operating cycle
Rotate the selector knob to summer or winter, and verify that green LED ( ) lights up
to confirm the presence of voltage.
The burner must be ignited within 10
seconds max.
However, it is possible for ignition failures to
occur, with consequent activation of “locked
out” signal:
– Gas failure
The electrode continues spark discharge
for a maximum of 10 sec. If the burner
does not light, the board - after a 5
second ventilation stop - reactivates
discharge for further 10 seconds. This
cycle will be repeated 5 times, after that,
the lock-out red LED will light up.
This may occur upon first ignition or after
long periods of boiler lay-off when there is
air in the pipes.
It may be caused by the gas cock being
closed or by one of the valve coils having
a break in the winding, so that the valve
cannot open.
– Ignition electrode fails to spark
The electrode continues spark discharge
for a maximum of 10 sec. If the burner
does not light, the board - after a 5
second ventilation stop - reactivates
discharge for further 10 seconds. This
cycle will be repeated 5 times, after that,
the lock-out red LED will light up.
This may be due to a break in the wire of
the electrode or to the wire not properly
fastened to the ignition transformer terminal.
The electrode itself may touch earth or
may be heavily worn out and needs replacing. The electronic board is defective.
When there is a sudden voltage failure, the
burner shuts down immediately; when the
power supply returns, the boiler will start
up again automatically.
3.4 FLOW SWITCH
SAFETY VALVE
A flow switch safety valve (8 fig. 2) interve-
nes, blocking the operation of the burner if
the boiler is without water due to the formation of air bubbles in the heat exchanger
or if the circulator is not working correctly
or because the “Aqua Guard” heating circuit filter is clogged.
3.5 SYSTEM
AVAILABLE
HEAD
The head available for the heating plant is
shown as a function of the flow in graph in
fig. 16.
To obtain the maximum head available to
the system, turn off the by-pass by turning
the union to the vertical position (fig. 16/a).
Fig. 16
Fig. 16/a
BY-PASS ON
BY-PASS OFF
D.H.W. FLOW RATE ADJUSTER
(it does not include SYSTEM 25 HE)
600
500
400
300
Available head (mbar)
200
10 0
0
25 HE
By-pass on
By-pass off
10 0
30 HE
25 HE
700600500400300200
800
30 HE
900
Flow rate (l/h)
1000
Ecomfort Plus
110 0
By-pass inserito
By-pass escluso
20
3.6 SMOKE PRESSURE
SWITCH
The air pressure switch is factory set to
the values 42-52 Pa (“25 HE” model) and
52-62 Pa (“30 HE” model) to guarantee
boiler functioning even with intake and
flue pipes at the maximum permitted
length.
The value of the signal to the pressure
switch is measured using a special instrument connected to the pressure intake
(10-18 fig. 3).
3.7 ELECTRICITY
CONNECTION
FOR ZONE SYSTEMS
When installing a system of this type, use a
separate electrical line to which room thermostats with their local valves will be connected.
Connect micro switches or relay contacts
on terminals 15-16 of the “TA” connector
of the electronic card after removing the
existing jumper (fig. 17).
CR1
CR
Connettore "TA"
Fig. 17
KEY
TA-TA1 Zone room stat
VZ-VZ1 Zone valve
R-R1 Zone relay
CR-CR1 Relay contact or micro zone valve
NOTE: Relays are used only if the area
valves have no microswitches.
“TA” connector
L
VZ
TA
R
VZ1
TA 1
R1
N
21
SIME SUPPORT
THE BENCHMARK INITIATIVE
All relevant sections of the Benchmark
Checklist must be filled in at the time of
installation. Commissioning of the boiler is
not complete until this is done. The boiler
service record must be completed at each
service.
4.1 FILLING THE WATER SYSTEM
– Open the flow and return valves.
– Loosen the automatic air vent cap.
– Open all radiator valves and system air
vents. Fill the system with water using
one of the approved methods described
in section 2.3.2 to about 0.5 bar
greater than the system design pressure. Close all air vents. Do not close
the A.A.V.
– Check the system for water soundness.
–
Completely drain the appliance and heat-
ing system, thoroughly flush the system,
and refill the system design pressure.
–
Before refillimg check and clean the Aqua-
guard filter (4.9).
4.1.1 Flow Rate Adjustment
The DHW flow rate should be set using the
flow rate adjuster (see fig. 16/a) to the
value shown in section 1.3.
4.2 GAS VALVE
The boilers are equipped standard with the
SIT 845 SIMGA/HONEYWELL VK 4105M
/SIEMENS VGU 50 gas valve (fig. 21).
The gas valve is set at two pressure values:
maximum and minimum. According to the
type of gas burnt, these correspond to the
values given in Table 6. The gas pressures
at the maximum and minimum values, are
factory set. Consequently they must not be
altered. Only when you switch the appliance
from one type of gas supply (methane) to
another (butane or propane), it is permitted to alter the operating pressure.
4.3 GAS CONVERSION
This operation must be performed by
authorised personnel using original Sime
components.
To convert from natural gas to LPG or vice
versa, perform the following operations (fig.
22):
– Close the gas cock.
– Disassemble the burner manifold (3).
– Replace the main nozzles (6) supplied in
a kit, inserting the copper washer (4).
Use a ø 7 spanner to perform this operation.
–
Remove the “METANO/GPL” connector
link on the card and set it in the posi-
tion corresponding to the gas to be
used (4 fig. 15).
– To set the values of maximum and mini-
mum gas pressure, follow the instructions given in section 4.5.1.
– After have ultimated the conversion of
the boiler, please stick onto the casing
panel the plate showing the relevant feeding gas which is included into the kit.
NOTE: When reassembling components
which you have removed, replace gas
seals; test all gas connections after
assembly using leak detector fluid. In no
circumstances should a naked flame be
used.
4.5.1
Adjusting valve pressure
Set maximum and minimum pressure on
gas valves as follows (fig. 22/a):
– Connect the column or a manometer to
the intake downstream of the gas valve.
Disconnect the valve VENT pressure test
point tube (5 fig. 21).
– Remove the cap (1) from the modulator.
– Place the hot tap water potentiometer
knob at the maximum position.
– Turn on the boiler using the four-way
switch and turn on a hot water tap all
the way.
– Remember that rotating clockwise will
increase pressure while rotating anti-
4 USE AND MAINTENANCE
SIT 845 SIGMA HONEYWELL VK 4105M
KEY
1 Modulator
2 EV1-EV2 coils
3 Pressure inlet upstream
4 Pressure inlet downstream
5 VENT pressure test point
TABLE 6
Burner Modulator Burner Modulator
Type of gas max. pressure mbar current min. pressure mbar current
25 HE 30 HE mA 25 HE 30 HE mA
G20 * 11.5 11.7 130 2.0 2.1 0
G30 28.5 28.5 165 4.8 5.0 0
G31 36.5 36.5 165 4.8 5.0 0
(*) Max. burner pressure is guaranteed only when the supply pressure exceeds the max. burner pressure by at
least 3 mbar.
Fig. 21
Fig. 22
KEY
1 Swivel connection 1/2”
2 Locknut 1/2”
3 Burner manifold
4 Washer ø 6.1
5 Burners
6 Nozzle M6
7 Screw
WARNING: To ensure a perfect seal,
always use the washer (4) supplied
in the kit when replacing nozzles,
even in burner units for which it is
not specified.
SIEMENS VGU 50
4
5
3
5
4
1
2
3
6
2
2
1
1
3 4 5
22
clockwise will diminish it.
– Adjust maximum pressure using the nut
(3) with a wrench to the maximum pressure value indicated in Table 6.
– Do not adjust minimum pressure until
you have adjusted maximum pressure.
– Turn off the supply power to the modula-
tor, and keep the hot water tap turned on.
– Lock the nut (3) in place, turn the screw
/nut (2) to the minimum pressure indicated in Table 6.
– Turn off the boiler and turn it back on
again several times, keeping the hot water
tap turned on at all times and checking
that the maximum and minimum pressure values correspond to the established
values; correct the settings if necessary.
– Adjust, checking that you have restored
the power to the modulator.
– Put the pipe back on the valve VENT
pressure test point.
– Remove the manometer, remembering
to tighten the screw for closing the pressure test point.
– Put the plastic cap (1) back on the modu-
lator and seal with a drop of coloured
sealant if necessary.
4.8 REMOVAL OF OUTER CASING
It is possible to completely disassemble the
shell for an easy maintenance of the boiler
as showed in fig. 21.
4.9 CLEANING AND MAINTENANCE
Preventive maintenance and checking of
efficient operation of equipment and safety
devices must be carried out exclusively by
authorized technical personnel.
4.10 CLEANING THE C.H. WATER FILTER
“AQUA GUARD” (fig. 22)
To clean the filter, close the flow/return valves, turn off the power to the control panel,
remove the casing and empty the boiler
using the drain provided until the hydrometer shows “zero”. Place a container for collection underneath the filter, unscrew the
cap and proceed to clean the filter, removing impurities and limestone deposits.
Check the seal o-ring before reassembling
the cap with the filter.
Fig. 21
Fig. 22
Fig. 22/a
KEY
1 Plastic tap
2 Minimum pressure adjusting nut
3 Maximum pressure adjusting nut
SIT 845 SIGMA HONEYWELL VK 4105M
SIEMENS VGU 50
1
3
2
1
2
23
4.11 CHIMNEY SWEEP FUNCTION
(fig. 23)
To carry out the verification of combustion
in the boiler turn the selector and stop on
the position ( ) until the green/orange led
starts to flash intermittently.
From that moment the boiler will star t functioning in heating mode at the maximum
power, with switching off at 80°C and
restarting at 70°C.
Before activating the chimney sweep function make sure that the radiator valves or
eventual zone valves are open.
The test may be carried out also during hotwater service functioning.
To do so it is enough, after having activated
the chimney sweep function, to take some
hot water from one or more cocks.
Even in this condition the boiler functions at
the maximum temperature always with the
primary controlled between 80°C and 70°C.
During the entire duration of the testing the
hot water taps must remain open.
After verifying the combustion the boiler
should be switched off by placing the selector on the OFF position; then return the
selector to the desired function.
ATTENTION: After about 15 minutes, or
once the hot water request has been fulfilled, the chimney sweep function automatically deactivates.
4.12 BOILER SERVICING
4.12.1 Routine Servicing
To ensure continued efficient operation of
the appliance, it is recommended that it is
checked and serviced at regular intervals.
The frequency of service will depend on the
particular installation and conditions of
usage, but in general once a year should be
adequate.
It is the law that a competent person such
as a Gas Safe Register registered engineer,
must carry out any service work.
4.12.2 Combustion Check
Incorporated into the flue elbow or vertical
adaptor is a sampling point.
The grey plastic cap should be unscrewed
and the flue gas sampled using a flue gas
analyser.
During the test the boiler can be operated
in “chimney sweep mode” see 4.11.
The correct CO2 reading can be found in
section 1.3.
4.12.3 Burner inspection
Remove the burner as described in section
6.3.
Inspect the burner and if necessary clean
using a soft brush.
Check the Ignition/ionisation electrode,
check the gap (4mm+/- 0.5mm)
4.12.4 Combustion Chamber
Remove any loose debris from the combustion chamber using a soft brush and a
vacuum cleaner.
Take care not to damage the rear insulation
panel.
4.12.5 Condensate Trap
The condensate trap would not normally
require removal during service, but it can be
checked.
Water should be poured into the inner flue.
Great care must be taken to ensure no
water enters the outer flue.
Check that the water flows freely to the
drain.
Should it require removal, firstly remove
wire clip securing the condensate drain rubber pipe to the condensate trap.
Remove the pipe.
Remove the two screws securing the condensate trap bracket.
Clean the trap and refit in reverse order.
4.12.6 Flow Switch
The operation of the flow switch should be
checked at each service.
Remove small cover retaining screw and
remove the cover.
When the pump is running and water is
flowing around the boiler, the actuator lifts
off the microswitch.
Check the operation of the actuator. Ensure
that it is free and that it lifts and returns.
If necessary lubricate the pivot point of the
actuator.
Isolate the boiler.
Drain it using the drain provided.
Remove the microswitch by carefully pulling
it forward off its mounting pins.
Remove the screw securing the mounting
plate, then pull off the plate.
Pull out the actuator pin.
Lubricate the centre “O” ring.
Refit the actuator ensuring that the flat side
of the round section is to the bottom.
Re-assemble remaining parts (see 4.12.7
before refilling the boiler).
4.12.7 Aquaguard Filter
It is recommended that the aquaguard filter
is checked at each service.
See section 4.10.
Fig. 23
Bi-colour green/orange
flashing led
Spia lampeggiante
verde/arancio
3
2
4
5
24
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
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 this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
Customer Name Telephone Number
Address
Boiler Make and Model
Boiler Serial Number
Commissioned by (print name) GAS SAFE REGISTER ID Number
Company Name Telephone Number
Company Address
Commissioning Date
To be completed by the customer on receipt of a Building Regulations Compliance Certificate
Building Regulations Notification Number (if applicable)
CONTROLS Tick the appropriate boxes
Time and Temperature Control to Heating Room Thermostat and Programmable
Programmer/Timer
Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer/Timer Combination Boiler
Heating Zone Valves Fitted Not Required
Hot Water Zone Valves Fitted Not Required
Thermostatic Radiator Valves Fitted Not Required
Automatic Bypass to System Fitted Not Required
Boiler Interlock Provided
Room Thermostat Compensation Control
ALL SYSTEMS
The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions Yes
What system cleaner was used?
What inhibitor was used? Quantity
:
*
Load/Weather Optimum Start
litres
CENTRAL HEATING MODE Measure and Record:
Gas Rate
Burner Operating Pressure (if applicable)
Central Heating Flow Temperature
Central Heating Return Temperature
m3/hr OR
mbar OR Gas Inlet Pressure mbar
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)? Yes
If yes, has a water scale reducer been fitted? Yes
What type of scale reducer has been fitted?
DOMESTIC HOT WATER MODE Measure and Record:
Gas Rate
Burner Operating Pressure (at maximum rate)
Cold Water Inlet Temperature
Hot water has been checked at all outlets Yes
Water Flow Rate
m3/hr OR
mbar OR Gas Inlet Pressure (at maximum rate) mbar
No
No
Temperature
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes
ALL INSTALLATIONS
If required by the manufacturer, record the following CO
The heating and hot water system complies with the appropriate Building Regulations Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes
% OR CO ppm OR CO/CO
2
Ratio
2
ft
°C
°C
ft
°C
°C
l/min
3
/hr
3
/hr
Commissioning Engineer’s Signature
Customer’s Signature
(To confirm satisfactory demonstration and receipt of manufacturer’s literature)
All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.
*
A Building Regulations Compliance Certificate will then be issued to the customer.
©Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk
25
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.
Service Provider
Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s
instructions.
Always use the manufacturer’s specified spare part when replacing controls.
SERVICE 1 Date
Energy Efficiency Checklist completed? Yes
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
SERVICE 3 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
Yes
SERVICE 5 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
Yes
No
No
No
SERVICE 2 Date
Energy Efficiency Checklist completed? Yes
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
SERVICE 4 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
Yes
SERVICE 6 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
Yes
No
No
No
SERVICE 7 Date
Energy Efficiency Checklist completed? Yes
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
SERVICE 9 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
Yes
No
No
SERVICE 8 Date
Energy Efficiency Checklist completed? Yes
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
SERVICE 10 Date
Energy Efficiency Checklist completed?
Engineer Name
Company Name
Telephone Number
GAS SAFE REGISTER ID Number
Comments
Signature
Yes
No
No
26
If an electrical fault occurs on the appliance
the preliminary electrical system checks
must be carried out first.
When any service or replacement of electrical components which has required the
breaking and re-making of electrical connections has taken place, the following tests
must be repeated:
– ear th continuity;
– shor t circuit;
– polarity;
– resistance to ear th.
5.1 EARTH CONTINUITY CHECK
Appliances must be electrically disconnect-
ed, meter set on Ω (ohm) x 1 scale and
adjust zero if necessary. Tests leads from
any appliance earth point (e.g. inside control
box) see wiring diagrams (section 7) to
earth pin on plug.
Resistance should be less than 1 Ω (ohm). If
the resistance is greater than 1 Ω (ohm)
check all earth wires for continuity and all
contacts are clean and tight. If the resis-
tance to earth is still greater than 1 Ω
(ohm) then this should be investigated
futher.
5.2 SHORT CIRCUIT
CHECK
Switches turned FULL ON - meter set on Ω
(ohms) x 1 scale. Test leads from L to N on
appliance terminal block, if meter reads 0
then there is a short circuit.
Meter set on Ω (ohm) x 100 scale. Repeat
it with leads from L to E. If meter reads less
than infinity (∞) there is a fault.
NOTE: Should it be found that the fuse has
failed but no fault is indicated, a detailed
continuity check (i.e. by disconnecting and
checking each component) is required to
trace the faulty component.
It is possible that a fault could occur as a
result of local burning/arcing but no fault
could be found under test. However, a
detailed visual inspection should reveal
evidence of burning around the fault.
5.3 POLARITY CHECK
Appliance reconnected to mains supply and
meter set on 300 V ac scale. Test at appliance terminal block.
– Test leads from L to N meter reads
approx.: 240 V ac.
– Test leads from L to E “ ” meter reads
approx. 240 V ac.
–
Test leads from N to E “ ” meter reads
from 0 to 15 V ac.
5.4 RESISTANCE TO
EARTH CHECK
Appliance must be disconnected from main
supply and meter on Ω (ohm) x 100 scale.
All switches including thermostat on test
leads from L to E - if meter reads other than
infinity (∞) there is a fault which should be
isolated.
A detailed continuity check is required to
trace the faulty component.
IMPORTANT:
These series of checks are the first electrical checks to be carried out during a
fault finding procedure. On completion
of the service/fault finding task which
has required the breaking and remaking
of electrical connections then the
checks 5.1 Earth continuity, 5.3 Polarity
and 5.4 Resistance to earth must be
repeated.
5 FAULT FINDING
27
5.5 C.H. MODE - FAULT FINDING
Start from cold Rotary switch set to WINTER position.
Room thermostat (if fitted) calling for heat and all D.H.W. taps off.
C.H. thermostat set to maximum position.
Clock in the on position (if fitted).
NOTE:
After completing fault finding reset the room thermostat (if fitted) to the required setting. If the appliance will not function check the wiring
to the clock and if necessary, replace the clock.
Is there power
at the external
socket?
Make
power
available
Does
the pump
start?
Does
the fan
start?
Turn the clock
in the right
position
Is fuse
at mains
plug OK?
Is the clock in
the correct
band time?
Is there voltage
available
to the fan?
Replace
the clock
Replace fuse in mains
plug
Check the
time clock does
his contacts
open and close when
the clock turns?
Replace
the fan
Make it free to rotate
Put a jumper
on the room
thermostat
connection
Check the
power supply
cable
Is pump shaft
free to rotate?
Is there voltage avail-
able
to the pump?
Replace
the pump
Check pump
connection
Does the boiler lock-out
without starting the
burner?
The boiler
lock-out
starting
the burner
Is there a spark
at the ignition
electrode?
Is the ionization probe
connected to the main
PCB and the ground?
Check the
gas supply
Check for continuity
between ignition elec-
trode and ignition
transformer
The gap between igni-
tion electrode and hood
is correct?
Fit correctly the ignition
electrode
Is the gas
available?
Check the
connection of
the gas valve on
the control board PCB
Is there voltage at the
gas valve?
Replace the
gas valve
Yes
No
Is there a jumper on
the room
thermostat
connection?
No
Yes
No
Yes
No
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
No
No
Yes
YesYes
No
No
Yes
No
No
No
No
Yes
No
Verify that the safety
and fume thermostats
are working correctly?
Replace the
thermostats
No
Is the
connection of the
fume and safety
thermostats cor-
rect?
Reset the
connection
No
Yes
Restor e the
connection
Verify that the safety
and fume thermostats
are working correctly?
No
Yes
Yes
Check the
connection of
the thermostats
Replace the
thermostats
No
Yes
28
5.6 D.H.W. MODE - FAULT FINDING
Start from cold - rotary switch set to SUMMER position, D.H.W. thermostat set to maximum, and all D.H.W. taps OFF.
Is there power
at the external
socket?
Make
power
available
Open any tap.
Is there an
adequate flow
rate of D.H.W. avail-
able?
Does the microswitch
of the divertor valve
operate correctly?
Does
the fan
start?
Is fuses
at mains
plug OK?
Clean or replace the
divertor valve
Is there voltage
available
to the fan?
Replace fuses in
mains plug
Does
the pump
start?
Replace
the fan
Make it free to rotate
Replace the microint-
erruptor
Check the
power supply
cable
Is pump shaft
free to rotate?
Check pump
connection
Replace
the pump
Does the boiler lockout without starting
the
burner?
The boiler
lock-out
starting
the burner
Is there a spark
at the ignition
electrode?
Is the ionization probe
connected to the main
PCB and the ground?
Check the
gas supply
Check for continuity
between ignition elec-
trode and ignition
transformer
The gap between igni-
tion electrode and
hood
is correct?
Fit correctly the igni-
tion electrode
Is the gas
available?
Restor e the
connection
Check the
connection of
gas valve on
the control board PCB
Is there voltage at the
gas valve?
Replace the
gas valve
Yes
No
No
Yes
No
No
Yes
No
Yes
Yes
Yes
Yes
Yes
No
Yes
No
No
Yes
Yes
No
Yes
No
No
No
Is there voltage avail-
able
to the pump?
No
Yes
Yes
No
Yes
Yes
Verify that the safety
and fume thermostats
are working correctly?
Replace the
thermostats
No
Is the
connection of the
fume and safety
thermostats cor-
rect?
Reset the
connection
No
Yes
Yes
No
Verify that the safety
and fume thermostats
are working correctly?
Yes
Check the
connection of
the thermostats
Replace the
thermostats
No
29
Note: Use silicone grease to ease the fitting of any push fit connections.
6.1 Expansion Vessel
– Isolate power supply
– Remove boiler cover
– Isolate flow and return valves
– Drain boiler using fitted drain vent
– Disconnect expansion pipe
– Remove expansion vessel securing nut
– Remove vessel
– Check new vessel for correct pressure
1- 1.25 bar
– Refit in reverse order.
6.2 Ignition/Ionisation electrode
– Isolate power supply
– Remove boiler cover
– Remove sealed chamber cover
– Remove PCB cover
– Disconnect ignition lead
– Carefully remove lead through PCB
cover and burner compartment
– Remove electrode fixing screw and
remove electrode from burner
– Replace in reverse order.
6.3 Main Burner
– Isolate power supply
– Isolate gas supply
– Remove boiler cover
– Remove sealed chamber cover
– Remove burner cover
– Disconnect gas connection to burner
– Remove locknut securing burner assem-
bly
– Remove ignition/ionisation electrode
– Carefully lift out burner assembly
– Refit in reverse order
– Test for gas tightness.
6.4 Fan assembly
– Isolate power supply
– Remove boiler cover
– Remove sealed chamber cover
– Disconnect wiring to fan
– Remove two fan fixing screws
– Carefully pull fan forward and to the
right to disconnect fan from post con-
denser
– Remove air pressure switch sensing
tube
– Apply light coating of silicone grease to
nozzle of new fan
– Refit in reverse order.
6.5 Main Heat Exchanger
– Isolate power supply
– Isolate gas supply
– Isolate flow and return valves
– Drain boiler using drain vent
– Remove fan assembly as described in
6.4
– Remove 4 screws and remove fan
mount ing plate
– Disconnect thermistor (SM sensor)
– Disconnect flow and return connections
– Lif t out heat exchanger
– Refit in reverse order.
6.6 95°C Limit stat
– Isolate power supply
– Remove boiler cover
– Remove sealed chamber cover
– Remove fan as described in 6.4
– Remove wires from 95°C stat
– Remove stat fixing screws
– Apply heat sink compound to new stat
– Refit in reverse order.
6.7 Air Pressure Switch
– Isolate power supply
– Remove boiler cover
– Remove sealed chamber cover
– Remove screws securing air pressure
switch
– Note position of wires before removal
– Note position of sensing tube before
removal
– Refit in reverse order.
6.8 100°C Safety Stat
– Isolate power supply
– Remove boiler cover
– Disconnect 100°C safety stat
– Remove fixing screws
– Refit in reverse order.
6.9 Thermistor (SM sensor)
– Isolate power supply
– Remove boiler cover
– Remove sealed chamber cover
– Isolate flow and return valves
– Drain boiler using drain vent
– Disconnect thermistor
– Unscrew thermistor (catch any water
lost)
– Refit in reverse.
6.10 Gas Valve
– Isolate power supply
– Isolate gas supply
– Remove boiler cover
– Disconnect wiring from gas valve
– Disconnect sensing tube
– Remove gas valve
– Refit in reverse order ensuring seals are
replaced as required
– Recommission boiler and adjust gas
pressures as described in section 4.5.1
– Check for gas tightness.
6.11 Circuit Board (PCB)
– Isolate power supply
– Remove screws securing control panel
– Lower panel to horizontal position
– Remove PCB cover
– Disconnect all wiring
– Remove control knobs
– Remove PCB fixing screws
– Transfer trimmer spindles to new board
– Ensure PCB links are matched to old
board
– Refit in reverse order
– Recommission boiler.
6.12 Pump Motor
– Isolate power supply
– Remove boiler cover
– Isolate flow and return valves
– Drain boiler using drain vent
– Remove plug connection
– Remove 4 x fixing screws, catch any lost
water
– Refit in reverse using new washers.
6.13 Diverter Valve Microswitch
– Isolate power supply
– Remove boiler cover
– Pull microswitch assembly forward off
the diverter valve head
– Refit in reverse order.
6.14 Domestic Hot Water
Heat exchanger
– Isolate power supply
– Isolate flow and return
– Turn on DHW tap
– Close cold water supply isolation valve
– Drain boiler using drain vent
– Remove diverter valve microswitch as
described in 6.13
– Remove microswitch actuator from top
of diverter valve
– Remove 3 x heat exchanger fixing
screws
– Remove plate heat exchanger, catch any
water lost
– Ensure that the four “O” rings are remo-
ved from the technil assembly
– Fit the new “O” ring supplied with the
new heat exchanger to the heat exchan-
ger
– Refit in reverse order.
6.15 Diverter Valve
– Remove Diverter valve microswitch as
described in 6.13
– Remove plate heat exchanger as descri-
bed in 6.14
6 REPLACEMENT OF PARTS
30
– Remove the securing clip at retaining
the plug at the LHS of diverter assembly
NOTE: a internal spring will push off the
plug. Retain
– Remove internal bush from spindle
– Remove diverter valve head securing
clip
– Pull diver ter valve head from assembly
– Remove spindle from assembly comple-
te with bush and spacer
– Replace in reverse order replacing “O”
rings as required.
6.16 Auto Air Vent (AAV)
– Isolate power supply
– Isolate flow and return valves
– Remove boiler cover
– Drain boiler using drain vent
– Remove AAV
– Replace in reverse order.
6.17 Safety Valve
– Isolate power supply
– Isolate flow and return valves
– Remove boiler cover
– Drain boiler using drain vent
– Disconnect pipe from safety valve
– Remove safety valve securing clip
– Remove safety valve, catch any water
lost
– Refit in reverse.
6.18 Pressure / Temperature Gauge
– Isolate power supply
– Isolate flow and return valves
– Remove boiler cover
– Drain boiler using drain vent
– Remove the clip securing the pressure
sensor
– Remove the clip securing thermometer
bulb
– Carefully remove the gauge
– Refit in reverse order.
31
7 EXPLODED VIEWS
7.1 ECOMFORT SYSTEM PLUS 25 HE
3830033/549 ECOMFORT PLUS 25 HE SYSTEM 11.05.2009 1/3
COD. TYPE D
AT E P A
GE
32
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
1 6138570 Side frame part
2 6138771 Frame assembly upper support
3 6255431 Expansion vessel lower support
4 • 5139130 Expansion vessel l.8 - 3/8” M
5 6146305 Brass Nut 3/8”
7 6034153 Condensate drainage pipe
8 6257521 Combustion chamber lower air deflector
9 6010827 Post-condenser fixing bracket
10 6300801 Post-condensator
11 6248855 P.C. inlet/oulet smokes gasket
12 6112320 P.C. smokes stat extension
13 6226443 O-Ring Ø 11,5 x 1,5
15 6257522 Air deflector
16 6288432 Combustion chamber rear panel
17 5190700 Main burner assembly
18 • 6235931 Ignition-ionisation electrode
19 6146301 Brass nut 1/2”
21 6288610 Combust. chamber lef t hand side panel
22 6139773 Combustion chamber rear insulation
23 6139792 Combustion chamber side insulation
24 6257530 Comb. chamber right/left air deflector
25 6028707 Air intake gasket
26 6288000 Air intake
27 6174257 Heat exchanger
28 • 6231351 Plunged sensor
29 • 6022010 Sensor gasket
30 6260616 Smoke chamber upper panel
31 6225630 Fan
32 6288720 Combustion chamber front panel
33 6139786 Combustion chamber front insulation
34 6264831 C.H. return pipe
36 6226616 Pipe fixing spring
37 6227211 Exchanger-post condensatoeintlet pipe
38 • 6226601 Spring for heat exchanger connection
39 2005201 Screw “HI-LO” TSP 3x12
40 6264731 C.H. flow pipe
41 6247360 Cap for time programmer
42 2030228 Gasket Ø 17x24x2
43 • 6146701 100°C safety stat
44 • 6277204 Water trap
45 6189574 Water trap fixing bracket
47 • 6017310 Flexible pipe
48 6226414 O-ring 117 Ø 13,1x2,62 EP851
49 2030226 Gasket Ø 10,2x14,8x2
50 6138880 Frame assembly lower side
51 6146302 Brass nut 3/4”
52 6226607 Pipe fixing spring
53 6028705 Gasket EP709 for Dab
54 2000201 Screw M5x40
55 • 6040201 Pressure relief valve
56 6100202 Ogive for pipe Ø 15
57 6168401 Locking nut for pipe Ø 15
59 6288200 Sealed chamber side panel
60 • 6225707 Air pressure switch
61 6280500 3-ways junct. with press. test nipple
62 6280550 Cap for 3-ways junction
63 6146303 Brass Nut 1/8”
64 6243820 SIT gas valve type 845 SIGMA
65 6226850 Gas inlet pipe
66 6226945 Pipe connecting gas valve-main burner
67 2030227 Gasket Ø 12x18x2
68 6289818 Control panel
69 6273210 Guidelight - 2 ways out
70 • 6217003 Temperature and pressure gauge
71 6301400 Main PCB
72 6201505 Trimmer spindle Ø 6
73 6201502 Trimmer spindle Ø 6
74 2211610 Earth faston
75 • 6269810 Ignition cable
76 6289900 Control panel protecting cover
77 6290300 Control panel cable cover
78 6290200 Room stat connection cover
79 6290100 White knob Ø 40
80 6009585 Control panel bracket
81 • 6131401 Microswitch for flowmeter
82 6009557 Relay fixing bracket
3830033/549 ECOMFORT PLUS 25 HE SYSTEM 11.05.2009 2/3
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
EPYT .DOC EGAPETAD
Fonderie Sime S.p.A. - Via Garbo, 27 - 37045 Legnago (Verona) - Tel. +39-0442-631111 - Fax +39-0442-631292 - www.sime.it
• Recommended stock par ts - Com ponenti da tenere a scorta
33
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
83 6247326 Cap for knob hole
84 6290014 Flap door
85 6226605 Fixing spring
86 2051100 Retaining spring
87 6288310 Sealed chamber front panel
88 6001210 Peephole
89 6287331 Casing
90 2013302 Fastener for self tapping screw
91 2004510 Screw 8Px7/8”
92 6112420 Control panel screw
93 • 6028624 Air diaphragm Ø 87.5
94 6154402 Main burner nozzle NP 130 natural gas
94 A 6154410 Main burner nozzle NP 77 GLP
95 6177505 Ball cock 3/4” x 22
96 6022004 Copper washer Ø 6
97 6177530 Gas cock 3/4” F x 15
98 6157602 Pressure relief valve drain pipe
99 • 5192600 Dab VA55 pump kit
100 6281509 Motor ring pump Dab VA55
101 5192200 Gasket for sealed chamber
102 6263912 Fan pressure test point
103 • 6149303 Flow water switch
104 6227520 Pipe connecting water flow switch
105 • 6190403 Relay Omron G2R-1-T
106 2211004 Terminal strip
107 6290350 Terminal strip protection cover
108 • 6017210 Manual air vent 1/4”
109 • 6013101 Automatic air vent
110 6296916 By-pass
111 6281500 Straight fitting 3/4”
112 6058811 Smoke deflector
5184818 Fitting cocks kit
5187370 Technyl hydraulic group
5191189 Complete control panel
6031206 Main cable L=2000
6299924 6 pole Stocko connector CN7
6299988 4 pole Lumberg cable connector CN2
5144719 Conversion kit to LPG
• 6281506 O-ring kit for hydraulic group
6281507 Split pin kit for hydraulic group
6281534 Gaskets kit
6299987 14 pole Lumberg cable connector CN6 up to s.n. 3829300566
6319102 14 pole Lumberg cable connector CN6 From s.n. 3829300567
Products reference:
8104013: Ecomfort Plus 25 HE System
Check the correspondence with the boiler data plate.
3830033/549 ECOMFORT PLUS 25 HE SYSTEM 11.05.2009 3/3
EPYT .DOC EGAPETAD
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
• Recommended stock par ts - Com ponenti da tenere a scorta
Fonderie Sime S.p.A. - Via Garbo, 27 - 37045 Legnago (Verona) - Tel. +39-0442-631111 - Fax +39-0442-631292 - www.sime.it
34
7.2 ECOMFORT PLUS 25-30 HE
3830032/547 ECOMFORT PLUS HE 11.05.2009 1/3
COD. TYPE D
AT E P A
GE
35
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
1 6138570 Side frame part
2 6138771 Frame assembly upper support
3 6255431 Expansion vessel lower support
4 • 5139130 Expansion vessel l.8 - 3/8” M
5 6146305 Brass Nut 3/8”
6 6288120 Sealed chamber rear panel
7 6034153 Condensate drainage pipe
8 6257521 Combustion chamber lower air deflector
9 6010827 Post-condenser fixing bracket
10 6300801 Post-condenser
11 6248855 P.C. inlet/oulet smokes gasket
12 6112320 P.C. smokes stat extension
13 6226443 O-Ring Ø 11,5 x 1,5
15 6257522 Air deflector
16 6288432 Combustion chamber rear panel
17 5190700 Main burner assembly 25
17 A 5190752 Main burner assembly 30
18 • 6235931 Ignition-ionisation electrode
19 6146301 Brass nut 1/2”
20 6288510 Combust. chamber right hand side panel
21 6288610 Combust. chamber lef t hand side panel
22 6139773 Combustion chamber rear insulation
23 6139792 Combustion chamber side insulation
24 6257530 Air deflector
25 6028707 Air intake gasket
26 6288000 Air intake
27 6174257 Heat exchanger
28 • 6231351 Plunged sensor
29 • 6022010 Sensor gasket
30 6260616 Smoke chamber upper panel
31 6225630 Fan
32 6288720 Combustion chamber front panel
33 6139786 Combustion chamber front insulation
34 6264831 C.H. return pipe
36 6226616 Pipe fixing spring
37 6227211 Exchanger-post condenser inlet pipe
38 • 6226601 Spring for heat exchanger connection
39 6264772 Pipe conn. C.H. filter-C.H. exchanger
40 6264748 C.H. flow pipe
41 6295501 C.H. filter 3/4”M x 3/4”M
42 2030228 Gasket Ø 17x24x2
43 • 6146701 100°C safety stat
44 • 6277204 Water trap 25
45 6189574 Water trap fixing bracket
47 • 6017310 Flexible pipe
49 2030226 Gasket Ø 10,2x14,8x2
50 6138880 Frame assembly lower side
51 6146302 Brass nut 3/4”
52 6226607 Pipe fixing spring
53 6028705 Gasket EP709 for Dab
54 2000201 Screw M5x40
55 • 6040201 Pressure relief valve
56 6100202 Ogive for pipe Ø 15
57 6168401 Locking nut for pipe Ø 15
59 6288200 Sealed chamber side panel
60 • 6225707 Air pressure switch 25
60 A 6227515 Heat exchanger inlet pipe 30
61 6280500 3-ways junct. with press. test nipple
62 6280550 Cap for 3-ways junction
63 6146303 Brass Nut 1/8”
64 6243820 SIT gas valve type 845 SIGMA
65 6226850 Gas inlet pipe
66 6226945 Pipe connecting gas valve-main burner
67 2030227 Gasket Ø 12x18x2
68 6289817 Control panel
69 6273210 Guidelight - 2 ways out
70 • 6217005 Temperature and pressure gauge
71 6301400 Main PCB
72 6201505 Trimmer spindle Ø 6
73 6201502 Trimmer spindle Ø 6
74 2211610 Earth faston
75 • 6269810 Ignition cable
76 6289900 Control panel protecting cover
77 6290300 Control panel cable cover
78 6290200 Room stat connection cover
79 6290100 White knob Ø 40
3830032/547 ECOMFORT PLUS HE 11.05.2009 2/3
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
EPYT .DOC EGAPETAD
Fonderie Sime S.p.A. - Via Garbo, 27 - 37045 Legnago (Verona) - Tel. +39-0442-631111 - Fax +39-0442-631292 - www.sime.it
• Recommended stock par ts - Com ponenti da tenere a scorta
36
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
80 6009585 Control panel bracket
81 • 6131401 Microswitch for flowmeter
82 5191900 Diver tor valve microswitch + support
84 6290014 Flap door
86 2051100 Retaining spring
87 6288310 Sealed chamber front panel
88 6001210 Peephole
89 6287331 Casing
90 2013302 Fastener for self tapping screw
91 2004510 Screw 8Px7/8”
92 6112420 Control panel screw
93 • 6028624 Air diaphragm Ø 87.5
94 6142330 Quarter bend 1/2” x 15
95 6177505 Ball cock 3/4” x 22
96 6177506 Ball cock 1/2” x 15
97 6177530 Gas cock 3/4” F x 15
98 6157602 Pressure relief valve drain pipe
99 • 5192600 Dab VA55 pump kit 25
99 A • 5192601 Dab VA65 circulating pump kit 30
100 6281509 Motor ring pump Dab VA55
100 A 6281511 Motor ring pump WSC F60 30
101 5192200 Gasket for sealed chamber
102 6263912 Fan pressure test point
103 6226429 O-ring 121
104 • 6013101 Automatic air vent
105 6265601 Plate-type heat exchanger 25
105 A 6265603 Plate-type heat exchanger 30
107 6281500 Straight fitting 3/4”
108 6281501 Straight fitting 1/2”
109 • 6017210 Manual air vent 1/4”
110 • 6281502 Flow water switch spare parts
111 • 6281504 Divertor valve
112 6281512 Water rate adjuster
114 6154402 Main burner nozzle NP 130 natural gas
114 A 6154410 Main burner nozzle NP 77 GLP
115 6247360 Cap for time programmer
116 2005201 Screw “HI-LO” TSP 3x12
117 6058811 Smoke deflector
5187323 Technyl hydraulic group 30
5191187 Complete control panel
6127210 Main cable L=2000 25
6299924 6 pole Stocko connector CN7 25
• 6233506 Fuse T1,6A 250V
6281523 C.H. Technyl manifold
6281524 D.H.W. Technyl manifold
8085606 90° elbow with take-off points
8102110 Gasket and flange kit
6289580 Cable + electrode P.C. resistance
5184817 Fitting cocks kit 25
• 5144716 Conversion kit to LPG
5144719 Conversion kit to LPG
6299988 4 pole Lumberg cable connector CN2
• 6281506 O-ring kit for hydraulic group
6281507 Split pin kit for hydraulic group
6281534 Gaskets kit
6299923 14 pole Lumberg cable connector CN6 up to s.n. 3846300420
6319101 14 pole Lumberg cable connector CN6 From s.n. 3846300421
Products reference:
8104012 : Ecomfort Plus 25 HE
8104011 : Ecomfort Plus 30 HE
Check the correspondence with the boiler data plate.
3830032/547 ECOMFORT PLUS HE 11.05.2009 3/3
EPYT .DOC EGAPETAD
ETONLEDOMNOITPIRCSEDEDOCNOITISOP
• Recommended stock par ts - Com ponenti da tenere a scorta
Fonderie Sime S.p.A. - Via Garbo, 27 - 37045 Legnago (Verona) - Tel. +39-0442-631111 - Fax +39-0442-631292 - www.sime.it
37
38
Cod. 6272248A - 05/09 - Documentation Dpt.
Sime Ltd
1a Blue Ridge Park
Thunderhead Ridge
Glasshoughton, Castleford, WF10 4UA
Customer Service: 0870 9911114
Sales: 0870 9911116
Technical Support: 0870 9911117
Main Fax: 0870 9911115
www.sime.ltd.uk
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