Format HE
Installation and
servicing instructions
UK
Please read the Important Notice within
this guide regarding your boiler warranty
199838
ENSURE THAT THESE INSTRUCTIONS ARE LEFT
FOR THE USER AFTER COMPLETION OF THE
BENCHMARK SECTION
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.
IMPORTANT NOTICE
For the first year all of our appliances are protected by our manufacturer’s guarantee which covers both parts and
labour.
As you would expect from Sime Ltd, it is our aim to provide our valued customers with the best in after sales and
service.
To take advantage of any extended warranty offered, all you have to do is to adhere to these 3 simple conditions:
• The installation must be carried out to Manufacturers/Benchmark Standards by a Gas Safe Registered
Engineer, and recorded in the installation manual.
• The appliance must be registered with both Sime Ltd and Gas Safe within 30 days of installation.
• The appliance must be serviced annually, by either Sime Ltd or a Gas Safe registered engineer- ensuring that the
Benchmark service record in the installation manual is completed.
Failure to comply with the above will result in only the 12 month warranty being offered.
In the absence of any proof of purchase, the 12 month warranty period will commence from the date of manufacture
of the boiler as shown on the appliance data plate.
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
Format 25 HE:
Gas Council number 47-19-27
Format 30 HE:
Gas Council number 47-719-22
These appliances comply with the S.E.D.B.U.K. scheme, band “A”
CONTENTS
1 DESCRIPTION OF THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 6
2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 9
3 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 15
4 USE AND MAINTENANCE
(including BENCHMARK/Mains Pressure Hot Water Storage Checklist & Service Record) . . . . . . . . . . . . . . . pag. 18
5 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 25
6 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 28
7 EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag. 30
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?
– Has the Aquaguard Filter been cleaned (see 4.9)?
IPX4D
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
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
“FORMAT HE” boilers are high efficiency
premix condensating thermal appliances
which use microprocessor technology for
function control and management.
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
perfect operation of the appliance.
1 DESCRIPTION OF THE BOILER
15 7
Ø 60/100
90
700
400
Z
S3
30
12 5
60
335
335
=
=
15
760
10 0
19 5
70 70 70 70
=
=
R
M
G
E
U
S3
G
Fig. 1
1.2 DIMENSIONS
TABLE 2 - Minimum clearances
For ventilation For servicing
ABOVE THE APPLIANCE CASING 200 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 350 mm 500 mm
TABLE 1 - Connections
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
25 HE 30 HE
Z mm 197 133
1.3 TECHNICAL FEATURES
FORMAT 25 HE FORMAT 30 HE
Heat output nominal (80-60°C) kW (kcal/h) 22.7 (19,500) 27.3 (23,480)
Heat output nominal (50-30°C) kW (kcal/h) 24.5 (21.160) 29.8 (25,630)
Heat output minimum (80-60°C) kW (kcal/h) 8.4 (7,220) 10.2 (8,770)
Heat output minimum(50-30°C) kW (kcal/h) 9.3 (8,000) 11.3 (9,720)
Heat input nominal kW (kcal/h) 23.3 (20,040) 27.9 (24,000)
Heat input minimum kW (kcal/h) 8.7 (7,480) 10.5 (9,030)
Nominal D.H.W. heat input kW (kcal/h) 25.0 (21,500) 30.0 (25,800)
Minimum D.H.W. heat input kW (kcal/h) 8.7 (7,480) 10.5 (9,030)
Efficiency nom./min. output (80-60°C) % 97.5/97.0 97.9/97.0
Efficiency nom./min. output (50-30°C) % 105.8/107.3 106.9/107.4
Seasonal efficiency rating (SEDBUK) 90.0% (A) 90.2% (A)
Termal efficiency (CEE 92/42 directive) ★★★★ ★★★★
Class NOx 5 5
Smokes temperature maximum (80-60°C) °C 70 63
Smokes temperature minimum(80-60°C) °C 63 56
Smokes temperature maximum (50-30°C) °C 54 42
Smokes temperature minimum (50-30°C) °C 50 41
Smokes flow kg/h 39 47
CO2 maximum/minimum G20 % 9.0/9.0 9.0/9.0
CO2 maximum/minimum G31 % 10.0/9.9 10.0/9.9
Adsorbed power consumption W 145 145
Electrical protection grade
IP X4D X4D
CE certification n° 1312BP4098 1312BP4098
Category II2H3P II2H3P
Type B23-53 / C13-33-43-53-83 B23-53 / C13-33-43-53-83
CENTRAL HEATING
Maximum water head bar 3 3
Maximum temperature °C 80 80
Water content boiler l 4.9 5.3
C.H. setting range °C 20/75 20/75
Expansion vessel capacity l 8 8
Expansion vessel pressure bar 1 1
DOMESTIC HOT WATER
Minimum/maximum pressure bar 0.5/7.0 0.5/7.0
D.H.W. flow rate (EN 625) l/min 11.2 13.4
Continuous D.H.W. flow rate ∆t 30°C l/min 11.5 14.3
Continuous D.H.W. flow rate ∆t 35°C l/min 10.2 12.3
Minimum D.H.W. flow rate l/min 2 2
D.H.W. setting range °C 30/60 30/60
GAS PRESSURE AND NOZZLES
Gas supply pressure G20 mbar 20 20
Gas supply pressure G31 mbar 37 37
Nozzles quantity n° 1 1
Nozzles diameter G20 ø 6.0 7.0
Nozzles diameter G31 ø 4.4 5.0
C.H gas consumption nom./min. G20 m3/h 2.46/0.92 2.95/1.11
C.H. gas consumption nom./min. G31 kg/h 1.81/0.68 2.17/0.82
D.H.W. gas consumption nom./min. G20 m3/h 2.64/0.92 3.17/1.11
D.H.W. gas consumption nom./min. G31 kg/h 1.94/0.68 2.33/0.82
WEIGHT kg 40 43
7
8
22
21
1
2
3
4
5
6
12
11
10
9
8
7
15
14
13
18
28
17
27
26
23
24
25
19
20
16
U
E
G
M
R
S3
29
1.4 FUNCTIONAL DIAGRAM
KEY
1 Fan
2 Air-gas mixer
3 Main exchanger
4 Gas flow rate adjuster (shutter)
5 Gas valve
6 D.H.W. exchanger
7 Divertor valve
8 Water flow switch
9 Thermometer sensor
10 SM sensor (thermister)
11 Aqua Guard Filter System
12 Safety st at 100°
13 Auto air vent
14 Circulating pump
15 Automatic by-pass
16 Temperature/pressure gauge
17 Boiler drain
18 Safety valve
19 Expansion vessel
20 Condensation water trap
21 Upper automatic air vent
22 Limit stat 90°
23 D.H.W. filter
25 D.H.W. inlet cock
26 Gas cock
27 C.H. flow cock
28 C.H. return cock
29 Smoke stat 95°
Fig. 2
1.5 MAIN COMPONENTS
Fig. 3
KEY
1 Control panel
2 Wate flow switch
3 SM sensor (thermister)
4 Gas valve
5 Gas flow rate adjuster (shutter)
6 Gas test point
7 Air test point
8Fan
9 Main exchanger
10 Smoke stat 95°
11 Upper automatic air vent
12 Limit stat 90°
13 Ignition/ionization electrode
14 Ignition transformer
15 Safety stat 100°
16 Aqua Guard Filter System
17 Automatic air vent
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.
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
provided 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.
The gas connection must be made using
seamless steel or copper 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 m
3
/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).
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
The drip board and its water trap must be
connected to a civil drain through a pipe
with a slope of at least 5 mm per metre to
ensure drainage of condensation water.
The plastic pipes normally used for civil
drains are the only type of pipe which is
appropriate for conveying condensation
to the building’s sewer pipes.
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/a.
The system design should incorporate
the connections appropriate to one of
these methods.
2 INSTALLATION
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
ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM
Fig. 4/a
9
10
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 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 exceed 4.6 meter. Where the
supplementary bend code 8095850 is
used, the total length of the piping can
reach a maximum of 2.9 meter. When the
vertical extension code 8086950 is used,
the terminal part of the pipe must always
come out horizontally.
2.5.2 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
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 90° additional bend code 8095850
Fig. 6
max 4.6 m
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 ext ernal corners 300 mm 12 in
G Above adjacent ground, roof or balcony level 300 mm 12 in
H From a surface facing the terminal 600 mm 24 in
I From a terminal facing the terminal 1,200 mm 48 in
J From an opening in the carpor t
(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 fr om 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
TABLE 3
NOTE: Place the duct horizontally.
– 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 fitt ed 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 paint ed 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 surf ace.
– 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 wher e this would cause a nuisance
should be avoided.
NOTE: Before installing accessories, lubricate
the internal part of gaskets with silicon-based
products. Avoid using oils and greases.
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