CONTENTS
1 DESCRIPTION OF THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 73
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 76
3 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 84
4 USE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 87
INSTALLER INSTRUCTIONS
IMPORTANT
When carrying out commissioning of the boiler, you are highly recommended to perform the following checks:
– Make sure that there are no liquids or inflammable materials in the immediate vicinity of the boiler.
– Make sure that the electrical connections have been made correctly and that the ear th wire is connected to a
good earthing system.
– Open the gas tap and check the soundness of the connections, including that of the burner.
– Make sure that the boiler is set for operation for the type of gas supplied.
– Check that the flue pipe for the outlet of the products of the combustion is unobstructed and has been pro-
perly installed.
– Make sure that any shutoff valves are open.
– Make sure that the system is charged with water and is thoroughly vented.
–
Check that the circulating pump is not locked (CAUTION: Remember to release the pump coupled with the control
panel, if necessary, to protect the electronic control card).
– Purge the system, bleeding off the air present in the gas pipe by operating the pressure relief valve on the gas
valve inlet.
FORMAT 25-30/60
ENGLISH
FONDERIE SIME S.p.A. of Via Garbo 27 - Legnago (VR) - Italy declares that its hot water boilers, which bear the CE mark under
Gas Directive 90/396/CEE and are fitted with a safety thermostat calibrated to a maximum of 110°C, are not subject to application of PED Directive 97/23/CEE as they meet the requirements of article 1 paragraph 3.6 of the Directive.
1.1 INTRODUCTION
The “FORMAT” wall hung boilers with
D.H.W. storage tank allow for a multiple
number of requests to be met thanks to the
abundance of available water which the
capacious tank unit makes possible.
They comply with the European directives
90/396/EEC, 89/336/EEC, 73/23/EEC,
92/42/EEC and the European norms EN
483 - EN 625.
They may be fuelled by natural gas (methane) and butane gas (G30) or propane (G31).
In this manual you will find the instructions
relative to the following boiler models:
– “FORMAT 25/60 OF”
with electronic ignition and modulation,
open chamber, natural draught.
– “FORMAT 25/60 BF - 30/60 BF”
with electronic ignition and modulation,
room sealed, forced draught.
Follow the instructions given in this manual
for the correct installation and perfect functioning of the appliance.
73
1 DESCRIPTION OF THE BOILER
1.2 DIMENSIONS
1.2.1 “25/60 OF” model
600
13 5
D
865
225
110
495
782
460
=
=
25
12 5
80 70 70 70 107
EUCMRG
63
Fig. 1
600
10 5
865
235
110
495
782
460
=
=
25
12 5 80 7 0 70 7 0 10 7
E
U
CMRG
ø100/60
910
63
Fig. 1/a
1.2.2 “25/60 BF - 30/60 BF” models
CONNECTIONS
R C.H. return 3/4”
M C.H. flow 3/4”
G Gas connection 3/4”
E D.H.W. inlet 1/2”
U D.H.W. outlet 1/2”
C Re-circulation 1/2”
CONNECTIONS
R C.H. return 3/4”
M C.H. flow 3/4”
G Gas connection 3/4”
E D.H.W. inlet 1/2”
U D.H.W. outlet 1/2”
C Re-circulation 1/2”
25/60 OF
D ø mm 130
74
1.3 TECHNICAL FEATURES
(1) Flow calculated with a fixed temperature on the D.H.W. potentiometer of 60 °C for a maximum period of 10 minutes
(2) The gas consumptions refers to the calorific value at standard conditions at 15°C - 1013 mbar
(3) Dif ferential measure between the pressure upstream of the gas valve and the depr ession in the sealed room
25/60 OF 25/60 BF 30/60 BF
Heat output
Nominal kW 8,4 ÷ 23,2 9,3 ÷ 25,0 11,6 ÷ 29,5
kcal/h 7.200 ÷ 20.000 8.000 ÷ 21.500 10.000 ÷ 25.400
Minimum kW 8,4 9,3 11,6
kcal/h 7.200 8.000 10.000
D.H.W. heat output
Nominal kW 23,2 25,0 29,5
Heat input
Nominal kW 10,8 ÷ 25,8 10,8 ÷ 26,7 13,5 ÷ 31,6
Minimum kW 10,8 10,8 13,5
Water content l 445
Adsorbed power consumption W 105 165 180
Electrical protection grade
IP X4D IP X4D IP X4D
Maximum water head bar 3 3 3
Maximum temperature °C 85 85 85
Expansion vessel
Water content/Preloading pressure l/bar 8/1 8/1 8/1
C.H. setting range °C 40÷80 40÷80 40÷80
D.H.W. setting range ° C 10 ÷6 0 10 ÷6 0 10 ÷6 0
D.H.W. production
Tank capacity l 60 60 60
Continuous D.H.W. flow rate at ∆t 30°C l/h 684 684 774
Specific D.H.W. flow rate EN 625
(1)
l/min 14,5 14,5 16,1
D.H.W. maximum water head bar 7 7 7
Recovery time from 25°C to 55°C min 4’ 30” 4’ 30” 4’
D.H.W. expansion vessel l 2,5 2,5 2,5
Smoke temperature °C 110 123 123
Smoke flow gr/s 21,0 17,0 20,0
Category II2H3+ II2H3+ II2H3+
Type B11BS
C12 - C32 - C42 - C52 C12 - C32 - C42 - C52
Weight kg 74 82 82
Main gas nozzles
Quantity n° 13 13 15
Methane ø mm 1,30 1,30 1,30
G30 - G31 ø mm 0,75 0,76 0,76
Gas flow
(2)
Methane m3st/h 2,73 2,83 3,34
Butane (G30) kg/h 1,99 2,06 2,44
Propane (G31) kg/h 1,96 2,03 2,40
Gas burner pressure
Methane mbar 1,8÷9,7 1,9÷10,8
(3)
1,7÷11,3
(3)
Butane (G30) mbar 4,7÷27,4 4,7÷28,4
(3)
4,7÷28,1
(3)
Propane (G31) mbar 6,3÷35,3 4,7÷35,3
(3)
4,7÷35,9
(3)
Gas supply pressure
Methane mbar 20 20 20
Butane (G30) mbar 30 30 30
Propane (G31) mbar 37 37 37
75
7
1
6
24
2
3
4
18
15
8
28
9
19
20
16
13
14
27
12
22
26
21
17
23
5
25
11
8
28
10
14
G
R
M
C
U
E
1.4 FUNCTIONAL DIAGRAM
KEY
1 Fan (“25/60 BF - 30/60 BF” versions)
2 Water-gas exchanger
3 Combustion chamber
4 Gas valve
5 D.H.W. tank
6 Heating sensor
7 Safety stat 100°C
8 Air vent valve
9 C.H. pump
10 D.H.W. pump
11 Expansion vessel
12 D.H.W. safety valve
13 Safety valve
14 Boiler drain
15 Water pressure switch
16 Automatic by-pass
17 D.H.W. expansion vessel
18 Gas cock (optional)
19 C.H. return cock (optional)
20 C.H. flow cock (optional)
21 D.H.W. cock (optional)
22 D.H.W. drain cock
23 D.H.W. sensor (SB)
24 Limit st at 80°C
25 Magnesium anode
26 Fixing jig (optional)
27 Filling cock
28 Non return valve
1.5 MAIN COMPONENTS
17
16
15
14
13
12
11
1
2
3
4
5
6
7
8
9
10
Fig. 3
KEY
1 Control panel
2 Gas valve
3 C.H. pump
4 Non return valve
5 Burner
6 Water pressure switch
7 Water-gas exchanger
8 Limit stat 80°C
9 Fan (“BF” version)
Smoke stat (“OF” version)
10 Smoke pressure switch (“BF” version)
Smoke chamber (“OF” version)
11 Expansion vessel
12 D.H.W. storage tank
13 Safety stat 100 °C
14 Heating sensor (SM)
15 Air vent valve
16 D.H.W. pump
17
16
15
14
12
13
11
1
2
3
4
5
6
7
8
9
10
FORMAT 25/60 OFFORMAT 25/60 BF - 30/60 BF
Fig. 2
The boiler must be installed in a fixed location and only by specialized and qualified
firms in compliance with all instructions
contained in this manual.
Furthermore, the installation must be in
accordance with current standards and
regulations.
2.1 VENTILATION OF
BOILER ROOM
The “25/60 OF”
version boilers must be
installed in adequately ventilated domestic
rooms. It is essential that in rooms where
the boiler are installed at least as much air
can arrive as required by normal combustion of the gas consumed by the various
appliances. Consequently, it is necessary to
make openings in the walls for the air inlet
into the rooms. These openings must meet
the following requirements:
– have a total free section of at least 6
cm2for every kW of heat input, with a
minimum of 100 cm2;
– They must be located as close as possi-
ble to floor level, not prone to obstruction and protected by a grid which does
not reduce the effective section required
for the passage of air.
The “25/60 BF - 30/60 BF” version boilers may instead be installed, without any
constraints regarding location or supply of
air for combustion, in any domestic rooms.
2.2 BOILER SUPPORT BRACKET
For the mounting of the suppor t bracket of
the boiler, which is supplied, observe the following instructions (fig. 4):
– Fix the bracket to the wall with appro-
priate dowels.
– Check with a spirit level that it is perfec-
tly in horizontal plane.
2.2.1 Fixing jig (optional)
The fixing jig code 8081209 is supplied with
an instruction sheet for the fixing.
2.2.2 Fitting the pipe elbows (optional)
To fit the connecting elbows supplied in kit
code 8075419, follow the instructions
reported in fig. 5.
2.2.3 Fitting isolating valves (optional)
To fit the isolating valves, supplied in kit code
8091807, follow the instructions mentioned
in fig. 6.
2.2.4 Replacement wall kit
for other makes (optional)
The kit code 8093900 is supplied complete with mounting instructions.
2.3 CONNECTING UP SYSTEM
Before proceeding to connect up the boiler,
you are recommended to make the air circulating in the piping in order to eliminate
any foreign bodies that might be detrimental to the operating ef ficiency of the appliance. When making the hydraulic connections,
make sure that the dimensions indicated in
fig. 1 are respected.
The discharge pipe of the safety valve
must be connected to a collector funnel
for channelling away any discharge if the
safety valve goes into action.
The gas connection must be made using
seamless steel pipe (Mannesmann type),
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 sufficient 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);
– 2.0 mbar for family III gases (butane or
propane).
An adhesive data plate is sticked inside the
front panel; it contains all the technical data
identifying the boiler and the type of gas for
which the boiler is arranged.
76
2 INSTALLATION
Fig. 4
KEY
1 Fixing jig
2 Copper pipe 3/4”x18
3 Gasket ø 24/17
4 Gas cock 3/4”MF
5 Elbow 3/4”x 18
6 Gasket ø 18,5/11,5
7 Elbow 1/2”x14
9 Elbow 1/2”x14
Fig. 5
KEY
1 Fixing jig
2 Straight coupling 1/2”x14
3 Gasket ø 18,5/11,5
4 Elbow 1/2”x14
5 D.H.W. cock stub pipe
6 D.H.W. cock 1/2”MF
7 C.H.-D.H.W cock
3/4”MF
8 Gasket ø 24/17
9 Gas cock 3/4”MF
10 Straight coupling 3/4”x18
11 Copper pipe 3/4”x18
12 Straight coupling
3/4”x18 with olive
13 Flow cock:
yellow (“25/60” vers.)
and brown (“30/60” ver s.)
Fig. 6
2.3.1 Filter on the gas pipe
The gas valve is supplied ex factory with an
inlet filter, which, however, is not adequate to
entrap all the impurities in the gas or in gas
main pipes. To prevent malfunctioning of the
valve, or in cer tain cases even to cut out the
safety device with which the valve is equipped, install an adequate filter on the gas pipe.
2.4 CHARACTERISTICS
OF FEEDWATER
To prevent lime scale and damage to the
tap water exchanger, the water supplied
should have a hardness of no more than
20°F. In all cases the water used should be
tested and adequate treatment devices
should be installed. To prevent lime scale or
deposits on the primar y exchanger, the
water used to supply the heating circuit
should must be treated in accordance with
UNI-CTI 8065 standards. It is absolutely
essential that the water is to be treated in
the following cases:
– very extensive system (with high con-
tents of feedwater);
– frequent addition of makeup water into
the system;
– should it be necessary to empty the
system either par tially or totally.
2.5 SYSTEM FILLING
The filling of the boiler and of the system is
carried out by pressing the filling cock located on the bottom of the boiler (fig. 7).
The filling pressure of the system cold must
be 1 bar. Once the filling has been comple-
ted, close the filling cock.
2.6 FLOW REGULATOR (fig. 7/a)
At the inlet of the hot water a flow regulator
can be installed, from 10 l/min (yellow) for
the “25/60” version and from 12 l/ min
(brown) for the “30/60” version; the regulator is supplied in the kit of the connecting
taps code 8091805.
2.7 FLUE
The flue for the atmospherical expulsion of
the combustion products from natural
draught appliances must meet the following
requirements:
–
Be gas-tight to the combustion products,
waterproof and thermally insulated.
–
Be built of materials suitable for keep
resisting to normal mechanical stresses,
heat, and the action of combustion products and their possible condensates.
– Follow a ver tical path and not present
any throttling throughout its entire
length.
– Be adequately insulated to prevent phe-
nomena of condensation or smokes cooling, in particular if located outside the
building or in unheated ambiences.
– Be set at an adequate distance from
combustible or easily inflammable material by means of an air gap or suitable
insulating material.
– Have beneath the mouth of the first
smoke duct a chamber for collecting
solid material and any condensate; the
height of the chamber must be at least
500 mm.
Access to the chamber must be guaranteed by means of an opening provided
with an air-tight metal door.
– Have a circular, square, or rectangular
internal cross section; in the case of
square or rectangular sections, the corners must be rounded off with a radius
of not less than 20 mm. However,
hydraulically equivalent cross sections
are allowed.
– Be equipped with a chimney-pot at the
top, which must be outside the so-called
back-flow zone, so as to prevent the formation of back-flow, which prevents free
discharge of the products of combustion
into the atmosphere.
– Be devoid of mechanical means of suc-
tion located at the top of the pipe.
– No overpressure should be present in a
chimney that passes within or close up
to inhabited rooms.
2.7.1 Connecting up flue
Fig. 8 refers to the connection of the boiler
“25/60 OF” to the flue or chimney through smoke ducts. When making the connection, in addition to respecting the
dimensions given, you are recommended
to use gas-tight materials capable of resisting over time mechanical stresses and
the smokes heat.
At any point along the smoke duct, the temperature of the combustion products must
be higher than the dew point. More than a
total of three changes of direction must not
be made, including the inlet connection to
the chimney/flue. For any changes of direction use only curved pipe lengths.
Fig. 8/a shows some applications of draught terminals that ensure proper expulsion
of the combustion products, in case of
discharge through the wall.
77
Fig. 8
Fig. 7
Fig. 7/a
CLOSE
Fig. 8/a
2.8 COAXIAL DUCT
“25/60 BF -30/60 BF”
The coaxial inlet and outlet duct ø 60/100
is supplied in a kit code 8084805 complete
with mounting instructions.
2.8.1 Diaphragm installation
The diaphragm is supplied together with the
“30/60 BF” boiler version.
See figure 9 for the positioning.
ATTENTION:
Install the diaphragm only when the
length of the ø 60/100 coaxial duct is
less than 1 m.
2.8.2 Coaxial duct
accessories
The accessories necessary for the realisation of this type of discharge and some of
the connecting systems that can be used
are shown in fig. 10.
With the elbow supplied in the kit the
maximum length of the duct should not be
greater than 3 metres.
2.8.3 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 1 gives the minimum distances
to be observed, with reference to the type
of building shown in fig. 11.
2.8.4 Roof outlet
coaxial duct
The roof outlet terminal L.1284 cannot be
shortened and the positioning of the tile
distances must be no less than 600 mm
from the discharge terminal outlet (fig. 12).
The fittings required for this type of discharge and some of the connecting systems
that can be used are shown in fig. 13.
Up to a maximum of three extensions can
be added to reach a rectilinear length of
3.7 m. If it proves necessary to provide for
78
KEY
1a-b Coaxial duct kit code 8084802
2 Extension L.815 code 8084800
3 Vertical extension L.584 code 8086900
4 Supplementary 90° elbow code 8085600
TABLE1
Siting of terminal Appliances from 7 t o 35 kW
(distances in mm)
A - below openable window 600
B - below ventilation opening 600
C - below eaves 300
D - below balcony (1) 300
E - from adjacent window 400
F - from adjacent ventilation opening 600
G - from horizontal or ver tical soil or drain pipes (2) 300
H - from corner of building 300
I - from recess in building 300
L - from ground level or other treadable surface 2500
M - between two terminals set vertically 1500
N - between two t erminals set horizontally 1000
O - from a surface facing without openings or terminals 2000
P - as above but with openings and terminals 3000
Fig. 11
Fig. 10
1
) Terminals below a practicable balcony must be located in such a way that the total
path of the smoke from its outlet point from the terminal to its outlet point from the
external perimeter of the balcony, including the height of possible railings, is not less
than 2000 mm.
2) When siting terminals, where materials that may be subject to the action of the combustion products are present in the vicinity, e.g., eaves, gutters and downspouts painted or
made of plastic material, projecting timberwork, etc., dist ances of not less than 1500 mm
must be adopted, unless adequate shielding is provided to guard these materials.
Fig. 9
IMPORTANT:
Each additional 90° curve installed reduces the
available length by 0.90 metres.
Each additional 45° curve installed reduces the
available length by 0.45 metres.
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