Sime Format B Installation And Servicing Instructions

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Format B

Installation and

servicing instructions

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 80 B:

Gas Council number 47-283-07

Format 100 B:

Gas Council number 47-283-08

These appliances comply with the S.E.D.B.U.K. scheme, band “D”

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 been flushed in accordance with the guidelines given in BS7593 “Treatment of water in domes-

tic hot water central heating systems”?

– 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?

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.

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

1.1 INTRODUCTION

The Sime “FORMAT B” are wall mounted, fan assisted balanced flue combination boilers. The appliance is supplied suitable for use with natural gas, L.P.G. and provide central heating and instantaneous production of D.H.W. Heat output is varied according to demand by the modulating gas control on both D.H.W. and C.H. The appliance is supplied with a telescopic air/flue duct suitable for wall thicknesses up to 635 mm (25 in) although extension duct kits are available (see details in section 3.4). The combined flue and air duct can exit the boiler from either side or from the rear of the appliance. A vertical extension

and additional flue elbow may be fitted. If required, the boilers can also be fitted with a separate flues kit (see section 3 for details). The boiler is designed for use with sealed primary water systems and is supplied fully assembled and equipped with complete valve packs. The boiler can be used with a 24V room thermostat (class II according to EN 60730.1).

This booklet provides instructions for the boiler models: “FORMAT 80 B - FORMAT 100 B” with following features: – electronic ignition, – fully modulating.

1 TECHNICAL FEATURES AND 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 Cold water 15 mm Compression

U Hot water 15 mm Compression

1.2 DIMENSIONAL DETAILS

80 B 100 B

L mm 400 450 K mm 215 240

Fig. 1

1.3 GENERAL DATA

80 B 100 B

Heat output

Nominal kW 23.8 30.8

Minimum kW 8.9 11.8

Heat input

Nominal kW 25.5 33.0

Minimum kW 10.2 13.5

Termal efficiency (CEE 92/42 directive) ★★★ ★★★

Class NOx 33

Water content l 2.2 2.4

Adsorbed power consumption W120 165

Electrical protection grade

IPX4D IPX4D

Maximum water head bar 3 3

Maximum temperature °C 85 85

Expansion vessel

Water content/Preloading pressure l/bar 7/1 8/1

C.H. setting range °C 30÷80 30÷80

D.H.W. setting range °C 30÷60 30÷60

D.H.W. flow rate (EN 625) l/min 11.3 14.5

Continuous D.H.W. flow rate ∆t 30°C l/min 11.4 14.7

Minimum D.H.W. flow rate l/min 2.2 2.2

D.H.W pressure

Minimum/Maximum bar 0.1/7 0.2/7

Smokes temperature °C 90/102 105/129

Smokes flow gr/s 15.6/16.9 20.2/22.0

Losses after shutdown to 50°C W/h 78 79

Category II

2H3+ II2H3+

Typ e B22-52/C12-32-42-52-82 B22-52/C12-32-42-52-82

Electrical supply 230V - 50 hz, fused at 3 A 230V - 50 hz, fused at 3 A

Internal fuse Line: F1.6A Line: F1.6A

Weight kg 38 40

Main burner nozzle

Quantity n° 12 14

Natural gas (G20) ø mm 1.30 1.30

LPG (G30 - G31) ø mm 0.77 0.80

Gas consumption *

Natural gas (G20) m

/h 2.70 3.49

Butane (G30) kg/h 2.01 2.60

Propane (G31) kg/h 1.98 2.56

Burner gas pressure

Natural gas (G20) mbar 2.0÷11.8 2.5÷14.5

Butane (G30) mbar 4.8÷28.5 4.7÷28.2

Propane (G31) mbar 6.3÷36.5 6.0÷36.2

Gas supply pressure

Natural gas (G20) mbar 20 20

Butane (G30) mbar 28 - 30 28 - 30

Propane (G31) mbar 37 37

* Gas consumption f igures express the lowest calorif ic power of pure gas under standard conditions at 15°C – 1013 mbar; this figure may differ from the actual

figure, which is dependent on gas composition and environmental conditions.

EMR

1.4 HYDRAULIC CIRCUIT

Fig. 2

GAS D.H.W. M.C.W. FLOW RETURN

KEY

1Fan 2 Bithermal exchanger 3 D.H.W. probe (SS) 4 100°C safety stat 5 Combustion chamber 6 C.H. sensor (SM) 7 Gas valve 8 Water pressure switch 9 Temperature and pressure gauge

10 Circulation pump

11 Air relief valve 12 Expansion vessel 13 Automatic by-pass 15 Water flow switch 16 Drain plug 17 D.H.W. filter 18 Safety valve 19 C.H. return cock 20 C.H. flow cock 21 D.H.W. cock 22 Gas cock

1.6 BOILER OPERATION

The boiler operating mode is controlled by the selector switch on the control panel. When set to winter ( ) it will operate in the Domestic Hot Water and Central Heating modes. For Domestic Hot Water only the selector switch should be set to summer ( ). Domestic hot water supply always takes priority over central heating. If a demand for hot water is required during a central heating period, the boiler will automatically switch to hot water mode until the demand is satisfied.

1.6.1 Central Heating mode

If there is a call for central heating the pump will start to circulate the primary heating water and the fan will run at full speed; once the air pressure switch has been proved the burner will light. The burner output then automatically adjusts to suit the system demand; as the temperature of the heating

water in the boiler approaches that set by the adjustable central heating control knob the burner output is reduced. When this set temperature is reached, the burner extinguishes and the fan stops. The pump continues to run for 30 seconds to prevent residual heat build up in the boiler. The burner will not relight for 3 minutes unless there is a demand for domestic hot water during this period.

1.6.2 Domestic Hot Water mode

The pump does not operate on a DHW demand, the fan runs and once the air pressure switch has proved the boiler will light. The burner output then automatically adjusts to suit the demand required to raise the temperature set by the adjustable domestic hot water control knob. When the hot water demand has been satisfied, it passes to the operation in C.H., if the selector is set to winter ( ) and there is a C.H. demand, otherwise the burner will extinguish.

1.5 INTERNAL VIEW

Fig. 3

KEY

1 Control panel 2 Burner 3 100°C safety stat 4 C.H. sensor (SM) 5Fan 6 Air pressure switch 7 Bithermal exchanger 8 Combustion chamber

9 D.H.W. sensor (SS) 10 Gas valve 11

Manifold with intakes

2.1 STATUTORY REQUIREMENTS

GAS SAFETY (INSTALLATION AND USE) REGULATIONS (as amended). It is the law that all gas appliances are installed by a registered person, in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that the law is complied with. In addition to the above regulations, this appliance must be installed in accordance with the current IEE Wiring Regulations (BS 7671), Local Building Regulations, the Building Standards (Scotland) (Consolidation) Regulations, Byelaws of the local water undertaking, and Health and Safety Document No 635 “The Electricity at Work Regulations 1989”. It should also be in accordance with the relevant recommendations in the current editions of the following British Standards and Codes of Practice: BS5449, BS5546, BS5440:1, BS5440:2, BS6798, BS6891, and BG.DM2, BS7074, and BS5482 for propane installations.

Manufacturer’s instructions must NOT be taken in any way as over-riding statutory obligations.

2.2 BOILER POSITION

In siting the combination boiler, the following limitations MUST be observed: – The boiler is not suitable for external installation. The

position selected for installation should be within the building, unless otherwise protected by a suitable enclosure, and MUST allow adequate space for installation, servicing, and operation of the appliance, and for air circulation around it (section 2.4).

– This position MUST allow for a suitable flue termination to

be made. The combination boiler must be installed on a flat vertical wall which is capable of supporting the weight of the appliance, and any ancillary equipment.

– If the combination boiler is to be fitted in a timber framed

building it should be fitted in accordance with the Institute of Gas Engineers document for Gas Installations In Timber Frame Housing, Reference 16E/UP/7: 1998. If in doubt, advice must be sought from the gas supplier.

– If the appliance is installed in a room containing a bath or

shower, any electrical switch or control utilising mains electricity must be so situated that it cannot be touched by a person using the bath or shower. Attention is drawn to the requirements of the current I.E.E. Wiring Regulations (BS 7671), and in Scotland the electrical provisions of the Building Regulations applicable in Scotland.

– A compartment used to enclose the appliance MUST be

designed and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified accordingly.

– Where installation will be in an unusual location, special

procedures may be necessary. BS6798 gives detailed guidance on this aspect.

2.3 FLUE TERMINAL POSITION

Detailed recommendations for flue installation are given in BS5440:1. The following notes are for general guidance: – The boiler MUST be installed so that the terminal is

exposed to the external air.

– It is important that the position of the terminal allows free

passage of air across it at all times.

– It is ESSENTIAL TO ENSURE, in practice that products of

combustion discharging from the terminal cannot reenter the building, or any other adjacent building, through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation/air conditioning. If this does occur, the appliance MUST be turned OFF IMMEDIATELY and the gas supplier consulted.

– The minimum acceptable dimensions from the terminal

to obstructions and ventilation openings are specified in fig. 4.

– 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.

– Where the terminal is fitted within 850 mm (34 in) of a

plastic or painted gutter, or 450 mm (18 in) of painted eaves, an aluminium shield at least 1,500 mm (59 in) long must be fitted to the underside of the painted surface.

– The air inlet/outlet flue duct MUST NOT be closer than 25

mm (1 in) to combustible material.

– In certain weather conditions the terminal may emit a

plume of steam. This is normal but positions where this would cause a nuisance should be avoided.

2 GENERAL REQUIREMENTS FOR INSTALLATION

Fig. 4

TABLE 5

Terminal position Minimum spacing in mm A Directly below an openable window, 300

air vent or any other ventilation opening

B Below guttering, drain pipes or soil pipes 25* C/D Below eaves, balconies or carport roof 25* E From vertical drain pipes or soil pipes 75 F From internal or external corners 25 G Above adjacent ground, 300

roof or balcony level

H From a surface facing the terminal 600 I From a terminal facing the terminal 1,200 J From an opening in the carport 1,200

(e.g. door, window into dwelling)

Vertically from a terminal on the same wall

1,500

Horizontally from a terminal on the same wall

300

Horizontally from a ver tical terminal to a wall

300

N Horizontally from an openable 300

window or other opening

P Above an openable window or other opening 300

* With “heat shield” installed in accordance to BS 5440 Pt1.

2.4 VENTILATION REQUIREMENTS

Detailled recommendations for air supply are given in BS5440:2. The following notes are for general guidance: –

It is not necessary to have a purpose provided air vent in the room or compartment in which the appliance is installed.

2.5 GAS SUPPLY

– The gas installation should be in accordance with BS6891.

The gas required for the boiler is specified in section 1.3.

– Ensure that the pipework from the meter to the appliance

is of adequate size.

– The governor at the meter must give a constant outlet

pressure of 20 mbar (8 inwg) for natural gas and 30 - 37 mbar (12 - 15 inwg) for LPG, when the appliance is running.

– The gas supply line should be purged.

NOTE: Before purging open all doors and windows, also extinguish any cigarettes, pipes, and any other naked flames.

– The complete installation must be tested for gas

soundness.

2.6 ELECTRICITY SUPPLY

The appliance MUST be earthed. A mains supply of 230 V 50 Hz single phase is required. All external controls and wiring MUST be suitable for mains voltage.

Wiring should be in 3 core PVC insulated cable NOT LESS than 0.75 mm

(24 x 0.2 mm) to BS6500, Table 16. Wiring external to the boiler MUST be in accordance with current l.E.E. Wiring Regulations (BS 7671) and local regulations. The supply connection to the flying lead provided MUST be made to a fused double pole switch, having a 3 mm (1/8 in) contact separation in both poles, serving only the boiler and system controls; the fuse rating should be 3 amp. This connection should be readily accessible and be made adjacent to the boiler (except in the case of bathroom installations for domestic boilers where the point of connection to the mains MUST be outside of the bathroom).

2.7 EXTERNAL CONTROLS (Refer to section 3.9)

The boiler is intended for use with a 24 V room thermostat. The connection is made inside the control box as described in section 3.9.

2.8 WATER SYSTEMS - GENERAL

– This appliance is designed for connection to sealed central

heating water systems.

– Check that the mains water pressure is sufficient to

produce the required D.H.W. flow rate, but does not exceed the maximum D.H.W. pressure (1.3 point).

Where mains pressure exceed 6 bar a pressure reducing valve must be fitted in the D.H.W. inlet.

2.8.1 Treatment of water circulating systems

–

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 proprietary 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 corrosion 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).

2.9 REQUIREMENTS FOR SEALED WATER SYSTEMS

The heating system design should be based on the following information: a) The available pump head is given in fig. 5. b) The burner starts 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 internal 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. 7. The system design should incorporate the connections appropriate to one of these methods.

e) The following paragraphs outline the specifications of the

items fitted to the boiler.

200

1600

140012001000800600400

PO RTATA ( l/ h)

PREVALENZA RESIDUA (mbar)

500

400

100

200

300

30-28

25-23

Open BF TS2 - Metropolis - GG M

600

30-28

25-23

By-pass inserito By-pass escluso

KEY 1 Available Head for “80 B” models 2 Available Head for “100 B” model

Flow rate (l/sec)

Available head (mbar)

Fig. 5

By-pass ON By-pass OFF

TYPICAL SYSTEM DESIGN

NOTE: A drain cock should be installed at the lowest point of the heating circuit and beneath the appliance.

Fig. 6

Fig. 7

ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM

2.9.1 Pump

The available head shown in fig. 5 is that in excess of the appliance hydraulic resistance, i.e. that available for the system at any given heating load up to the maximum output in C.H. mode. Never reduce the pump speed below maximum as this will reduce D.H.W. output. The pump speed is indicated on the side of the pump speed selector switch (if fitted).

2.9.2 System volume (total water content)

The following Table gives the maximum system volume that the integral expansion vessel can sustain under different charge pressure conditions. If the system volume exceeds that shown, an additional expansion vessel must be fitted and connected to the heating system primary return pipe as close as possible to the appliance. If an extra vessel is required, ensure that the total capacity of both vessels is adequate. Further details are available in the current issues of BS5449 and BS6798.

NOTE: If the pressure gauge indicates 2.65 bar or greater when the appliance is at maximum temperature with all radiators in circulation an extra expansion vessel is required.

2.9.3 Pressure gauge

A pressure gauge is mounted on the appliance facia panel.

2.9.4 Safety valve

A safety valve set at 3 bar (43.5 psi) is fitted to the appliance and a discharge pipe is routed to outside of the appliance. This discharge pipe should be extended to terminate safely away from the appliance and where a discharge would not

cause damage to persons or property but would be detected. The pipe should be able to withstand boiling water, be a minimum of 15 mm in diameter, and installed with a continuous fall.

2.10 D.H.W. SYSTEMS

– Check that the mains supply pressure is within the

prescribed limits (1.3 point). If necessary, a pressure reducing valve should be fitted to the mains supply before the D.H.W. inlet connection.

– A maximum D.H.W. flow rate of:

11.4 l/m (3.0 gpm) for “FORMAT 80 B” and 14.7 l/m (3.9 gpm) for “FORMAT 100 B” is recommended. Higher flow rates will not damage the appliance but may lower the water temperature below an acceptable level.

– If the appliance is installed in an area where the temporary

hardness of the water supply is high, say over 150 ppm, the fitting of an in line scale inhibitor may be an advantage. Consult the Local Water Undertaking if in doubt.

– Devices capable of preventing the flow of expansion water:

e.g. non return valves and/or loose-jumpered stop cocks should not be fitted unless separate arrangements are made for expansion water.

– For specific information relating to fittings (eg. Showers,

washing machines etc.) suitable for connection in the D.H.W. circuit, consult the Local Water Undertaking, however the following information is given for guidance.

2.10.1 Domestic hot/cold water supply taps and mixing taps

All equipment designed for use at mains water pressure is suitable.

2.10.2 Showers

Any WRAS approved shower suitable for the mains water pressure available may be used. A loose or flexible shower head type may require the fitting of an anti-syphon device to comply wth water by-laws.

2.10.3 Bidets

Providing that the appliance is of the over-rim flushing type, the outlets are shrouded and it is impossible to attach a temporary hand held spray, no anti syphonage device is necessary.

Vessel charge and initial system

pressure

Total water content of system

using 8 l (1.76 gal) capacity expan-

sion vessel supplied with appliance

For systems having a larger capaci-

ty multiply the total system capacity

in litres (gal) by the factor to obtain

the total minimum expansion vessel

capacity required litres (gal)

bar

psi

gal

0.5

7. 3

21.1

.0833

1. 5

21.8

11. 2

.15 6

1. 0

14.5

16.2

.10 9

TABLE 6

Appliance package:

– combination boiler (assembled); – installation and servicing instructions; – users instructions; – wall mounting templates (paper); – wall mounting bracket; – fixing screws with wall plugs; – plastic bags containing:

– gas service cock; – C.H. F/R isolation valves; – D.H.W. isolation valve; – D.H.W. elbow connection; – associated fixing screws; – associated gaskets; – safety valve discharge pipe.

3.1 FIXING THE WALL MOUNTING BRACKET

Before installing the appliance ensure that the chosen location is suitable (section 2.2) and that the requirements for flue position, (section 2.3), and minimum clearances, (

Table 2

) are satisfied. These minimum clearances are essential to provide access for servicing, and are included on the wall mounting templates. – Open the paper wall mounting templates. If a rear flue is to

be used, discard the side templates and secure the rear template in the desired position. For a side flue application, secure both the rear and appropriate side template in position.

– Mark the position of the two wall mounting bracket fixing

holes and the flue/air duct hole on the appropriate wall(s).

– Remove the template(s) and drill the two fixing holes using

a 10 mm masonry drill. Fit the plastic plugs provided.

– Cut the hole in the wall for the flue/air duct. The diameter

should not be less than 100 mm (4 in) and must be horizontal. Refer to fig. 12-14.

– 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. 8.

3.2 HANGING THE BOILER

– Lift the appliance into position. The upper cross member

locates onto the wall mounting bracket.

– Screw in the wall mounting bracket adjusting screws until

the appliance is secure and vertical.

3.3 COAXIAL DUCT ø 60/100

The air inlet-smoke outlet assembly ø 60/100 is supplied in a kit code 8084811. For the assembly follow what is indicated in figure 9: – Make a hole in the wall sufficiently large to allow an inser-

tion of a PVC pipe 130 mm ø of the same length as the thickness of the wall it has to pass through. Then fix the PVC pipe in place using cement mortar.

– Before to inser t the duct in the wall hole fit in position the

3 INSTALLING THE BOILER

Fig. 8

KEY 1 Wall mounting bracket 2 Plastic wall plug (2 Off)

3 Woodscrew (2 Off) 4 Washer (2 Off) 5 Adjustment screw (2 Off)

KEY A Elbow 90° B Sponge-rubber

gasket ø 125/95 C White inner duct D Grey outer duct E Junction collar F Screw

NOTE: The kit can be extended to a maximum measure of 800 mm horizontal.

Fig. 9

outer wall seal (D).

– Push the tube outwards until the gasket comes out. Pull the

pipe inwards bringing the ring to rest on the wall. – Slide the inner ring (C). – Insert the inner/outer duct into the elbow (A) until the

ducts touch the inner part of the elbow where the diameter

becomes smaller. – Fit the sponge-rubber gasket (B) to the collar (E). – Secure the collar (E) to the sealed chamber using the four

screws provided. – Insert the elbow (A) into the collar (E) tightening the screw

(F).

With the curve supplied in the kit the maximum horizontal length of the flue must not exceed 3,6 metres.

The diagrams in fig. 10 illustrate a number of examples of different coaxial outlets.

NOTE: The air intake-flue outlet assembly must slope slightly downwards to prevent rain water getting into the boiler.

3.3.1 Coaxial flue diaphragm ø 60/100

The boiler is supplied as standard with a ø 86 diaphragm. With outlet type C12, install diaphragm ø 86 only if the coaxial flue is less than 1 metres long. For C32 discharge options, it is necessary to order the optional diaphragm separately ø 87,5 (cod. 6028624) and use it in accordance with the instructions provided in figure 11.

C12

C32

C42

min 1,3 m - max 5 m

x + y = max 3,5 m "25" x + y = max 3,0 m "30-35"

max 3,5 m "25" max 3,0 m "30-35"

KEY 1 Coaxial flue kit L. 810

code 8084811 2 a Extension L. 1000 code 8096103 2 b Extension L. 500 code 8096102 3 Vertical extension

L. 200 code 8086908 4 Additional 90° curve code 8095801 6 Ar ticulated tile code 8091300 7 Roof outlet terminal

L. 1284 code 8091200 8 Vertical condensation collector

L. 200 cód. 8092803

IMPORTANT: – Each additional 90° curve installed

reduces the available length by 1 metre.

– Each additional 45° curve installed

reduces the available length by 0.50 metres.

– It is advisable to assemble the conden-

sation collector (8) on vertical segments exceeding 2.5 metres in length and to limit maximum length to 4 metres.

Fig. 10

x + y = max 3,6 m

max 3,6 m

With outlet type C12, install diaphragm ø 86 only if the coaxial flue is less than 1 metres long.

With outlet type C32, use the following diaphragms, depending on flue length and without any additional curves:

Installations with vetrical Installations with vertical condensation

extension L. 200 code 8086908 collector code 8092803

Diaphragm Diaphragm Without Diaphragm None

ø 86

optional ø 87,5

diaphragm optional

ø 87,5

diaphragm

(cod. 6028623) (cod. 6028624) (cod. 6028624)

L min = 1,3 m L min = 2,5 m L min = 4 m L max = 2,5 m L min = 2,5 m

L max = 2,5 m L max = 4 m L max = 5 m L max = 4 m

Fig. 11

3.4 COAXIAL DUCT ø 80/125

The air inlet-smoke outlet assembly ø 80/125 is supplied in a kit code 8084830. For the assembly follow what is indicated in figure 12: –Make a hole in the wall sufficiently large to allow an insertion

of a pipe ø 125 mm.

–Before to insert the duct in the wall hole fit in position the

outer wall seal (D).

–Push the tube outwards until the gasket comes out. Pull the

pipe inwards bringing the ring to rest on the wall. –Slide the inner ring (C). –Insert the adapter (G) to the coaxial duct. –Insert the adapter to the elbow (A). –Fit the sponge-rubber gasket (B) to the collar (E).

–Secure the collar (E) to the sealed chamber using the four

screws provided.

–Insert the elbow (A) into the collar (E) tightening the screw

(F).

With the curve supplied in the kit the maximum horizontal length of the flue must not exceed 6 metres (vers. “Format 80 B”) - 7 metres (vers. “Format 100 B”).

The diagrams in fig. 13 illustrate a number of examples of different coaxial outlets.

NOTE: The air intake-flue outlet assembly must slope slightly downwards to prevent rain water getting into the boiler.

1055

295

115

ø 125

KEY A Elbow 90° B Sponge-rubber

gasket ø 125/95 C White inner duct D Grey outer duct E Junction collar F Screw G Adapter

Fig. 12

C12

C32

C42

min. 4 m - max 6 m "25"/7 m "30"

x + y = min. 3,6 m/max 6 m "25" x + y = min. 3,6 m/max 7 m "30"

min. 3,6 m - max 6 m "25"/7 m "30"

Fig. 17

IMPORTANT: – Each additional 90° curve installed reduces the available length by 1 metre. – Each additional 45° curve installed reduces the available length by 0.50 metres. – The insertion of the recovery condenses (8) is obligatory in the tipologia of C32 download. – The insertion of the recovery condenses (8) is obligatory in the tipologia of C42 download

when the section “y” is advanced to 2,5 metres.

KEY 1 Coaxial flue kit code 8084830 2 Extension L. 1000 code 8096130 3 Vertical extension L. 200 ø 60/100 code 8086908 4 a Additional 90° curve code 8095820 4 a Additional 45° curve code 8095920 5 Adapter from ø 80/125 code 8093120 6 Ar ticulated tile code 8091300 7 Roof outlet terminal L. 1284 code 8091200 8 Vertical condensation collector L. 200 ø 60/100 cód. 8092803

3.5 SEPARATE DUCTS (Optional alternative twin pipe system)

When installing the separate ducts, comply with the requirements of the current standards, as well as the following practical pointers: – With direct intake from outside, when the pipe is longer

than 1 m, you are recommended to insulate the piping so as to prevent the formation of condensation on the outside of the piping during particularly cold periods of the year.

– With the outlet pipe outside the building or in cold indoor

environments, insulation is necessary to prevent burner ignition failure. In such cases, provide for condensate

drainage.

– If a segment of the flue passes through a flammable wall,

this segment must be insulated with a glass wool pipe insulator 30 mm thick, with a density of 50 kg/m

The maximum overall length of the intake and exhaust ducts depends on the head losses of the single fittings installed and can reach approximately the following horizontal measures: – 15 m for “Format 80 B” model, – 21 m for “Format 100 B” model.

For head losses in the fittings, refer to

Table 7.

165

110

165

ø 80

100

Fig. 18

KEY 1 Sponge-rubber gasket

ø 125/95 2 Fixing screw 3 Smoke outlet flange 4 Air intake diaphragm 6 Manifold with intakes

80 B 100 B

Kmm 185 210

Fig. 18/a

N° segments Total load loss mm H2O

to remove 25 BF 30 BF

none 0 ÷ 3,0 0 ÷ 3,0

n° 1 3,0 ÷ 4,0 3,0 ÷ 4,0 n° 2 4,0 ÷ 5,0 4,0 ÷ 5,0 n° 3 5,0 ÷ 6,0 5,0 ÷ 6,0 n° 4 6,0 ÷ 7,0 6,0 ÷ 7,0 n° 5 6,0 ÷ 7,0 7,0 ÷ 8,0 n° 6 7,0 ÷ 8,0 8,0 ÷ 9,0 n° 7 7,0 ÷ 8,0 9,0 ÷ 10,0 n° 8 8,0 ÷ 9,0 10,0 ÷ 11,0 n° 9 8,0 ÷ 9,0 11,0 ÷ 12,0

n° 10 - 12,0 ÷ 13,0

without diaphragm 9,0 ÷ 10,5 13,0 ÷ 14,0

3.5.1 Separate flue accessories

Part No 8089904 is supplied for this purpose. The sectored diaphragm is to be used according to the maximum head loss allowed in both pipes, as given in fig. 18/a.

3.5.2 Use of air intake (fig. 19)

To use the air intake in this type of outlet you must perform the following operations: –

Remove the base of the air intake, using a tool to cut it off (a);

–Overturn the air intake (b) and replace the seal (5) with the

seal supplied in the kit code 8089904;

–Insert the intake diaphragm supplied in the kit code

8089904, pushing it in until it is in contact with the seat;

You can now insert the extension or curve in its housing to complete the intake (you need not use any seat or sealant).

3.6 WATER CONNECTIONS

3.6.1 Central heating connections

–

Fit the two C.H. isolation valves using the gaskets supplied to the flow and return connections as shown in fig. 2. The pipe connections are labelled on the lower part of the boiler.

– Connect the C.H. pipework as required.

3.6.2 D.H.W. connections

– Fit the D.H.W. isolation valve to the cold water inlet

connection as shown in fig. 2. – Fit the union connection to the D.H.W. outlet. – Connect the D.H.W. pipework as required.

3.7 GAS CONNECTIONS

– Screw the gas cock into the internal thread in the gas inlet

connection using a suitable jointing compound. – Connect the gas supply pipe.

3.8 SAFETY VALVE CONNECTION

– The appliance safety valve is located towards the R.H.S. of

the boiler and the discharge pipe is supplied loose. Remove

the two selftapping screws and lower the control box to

improve access. – Connect the discharge pipe to the valve outlet, and extend

the pipe to ensure that any discharge from the safety valve

is safely routed to a drain. The discharge pipe should be a

minimum of 15 mm copper, and must avoid sharp corners

or upward pipe runs where water may be retained.

3.9 WIRING INSTRUCTIONS

(Refer to sections 2.6 - 2.7 and fig. 20)

– Support the valve whilst tightening the nut and olive to

avoid damage to the technil assembly. – Disconnect the electric power supply before performing

any work. – Remove the three screws (9) locking the control panel in place

and pull the panel forward until it can be tilted downward. – To access the components of the electrical panel, unscrew

the four screws holding the protective guard in place (6).

Fig. 19

IMPORTANT: The three housings on the diaphragm permit assembly of the air intake in one position only (with numbers toward inside the boiler).

TABLE 7

Accessories ø 80 Load loss (mm H2O)

“80 B/100 B”

Intake Outlet Roof out. Intake

90° curve MF 0.30/0.30 0.40/0.50 –

45° curve MF 0.20/0.20 0.30/0.40 –

Extension L. 1000 (horizontal) 0.20/0.20 0.30/0.40 –

Extension L. 1000 (vertical) 0.30/0.30 0.20/0.30 –

Outlet terminal – 0.30/0.40 –

Intake terminal 0.10/0.10 – –

Manifold 0.20/0.30 – –

Roof outlet terminal L.1390 – – 0,50/0.60

Condensation collection T – 1.00/1.10 –

– To gain access to connector “TA”, remove the control

panel cover (7) and connect the room stat to the terminals 10-11 after having removed the jumper.

The thermostat or timer-thermostat, recommended for better room temperature control, must be class II as specified by standard EN 60730.1 (clean contact).

– Carry out electrical system checks through a suitable test

meter: earth continuity, polarity, resistance to earth and

short circuit. – Re-secure control box. – Ensure sufficient length of cable to allow access to control

panel.

Fig. 20

KEY 1 Temperature and pressure gauge 2 Easy-Stat Receiver housing (8092221) 4 Main PCB 5 Ear th faston 6 Control panel protection 7 Cover (TA) 8 Connector (TA)

ATTENTION: After having removed the three fixing screws, tilt the panel downward to gain access

SIME SUPPORT THE BENCHMARK INITIATIVE

All relevant sections of the logbook must be filled in at the time of installation and thereaf ter service information on the back page of the logbook. Commissioning of the boiler is not complete until the logbook is filled in. Before commissioning the appliance, the whole gas installation including the meter MUST be purged and tested for gas soundness in accordance with BS6891.

IMPORTANT: open all doors and windows, extinguish naked lights, and DO NOT SMOKE whilst purging the gas line. Before commencing the commissioning procedure, ensure that the gas service cock is turned on, the electricity supply is isolated, and that the D.H.W. and C.H. isolation valves are in the closed position.

4.1 FILLING THE WATER SYSTEM

– Open the C.H. flow and C.H. return valves (20 - 19 fig. 2). – Loosen the automatic air vent cap (11 fig. 2). – Open all radiator valves and system air vents. Fill the

system with water using one of the approved methods described in section 2.9 to about 0.5 bar greater than the system design pressure. Close all air vents. Do not close

the A.A.V. the one near the pump! – Check the system for water soundness. – Completely drain the appliance and heating system,

thoroughly flush the system, and refill the system design

pressure to BS 7593. – Open the D.H.W. inlet valve, open any hot tap, clear of air

bubbles. Close hot tap.

4.2 COMMISSIONING THE BOILER

– Loosen the screw and connect a pressure gauge to the

burner pressure test point on the gas valve (fig. 21).

– Ensure that the rotary switch on the facia panel is set to

the summer position “ ” (D.H.W. Only), turn the D.H.W. thermostat to maximum (fully clockwise), and turn on the electrical supply. Fully open any D.H.W. tap and the burner will light.

– Allow the boiler to run for at least 5 minutes and check

that the burner pressure is as stated in section 1.3. The D.H.W. burner pressure is factory set and should not require adjusting. If the burner pressure is low, check that the appliance has not begun to modulate (this will occur if the D.H.W. flow rate is low. If modulation is suspected, open all D.H.W. taps to maximise flow and recheck burner pressure). Check also the inlet pressure with the burner alight; this should be 20 mbar +/– 1.0 mbar standing pressure & the working inlet pressure limited to a loss no greater than 1.0 mbar for natural gas. If it is necessary to adjust the D.H.W. burner pressure the method is described in section 8.6.

– Reduce the D.H.W. draw off rate to the minimum

necessary to maintain the burner alight by carefully adjusting the D.H.W. inlet valve and check that the burner pressure decreases in response to D.H.W. temperature rise. Fully open the inlet valve.

– Close the D.H.W. tap and ensure that the burner is

extinguished and the pump stops.

4 COMMISSIONING AND TESTING

BURNER PRESSURE TEST POINT

Fig. 21

4.5 FINAL CHECKS

– Re-light and test for gas soundness. – Re-fit the casing front panel and securing brackets. – Set the C.H. and D.H.W. potentiometers to the required

settings.

– Ensure that the time clock is set at the desired time

periods. Set the room thermostat (if fitted) to the required setting.

4.6 USER’S INSTRUCTIONS

Upon completion of commissioning and testing the system, the installer should: – Give the “Users Instructions” to the householder and

emphasise their responsibilities under the “Gas Safety (Installation and Use) Regulations 1996 (as amended)”.

– Explain and demonstrate the lighting and shutdown

procedures.

– Advise the householder on the efficient use of the system,

including the use and adjustment of all system controls for both D.H.W. and C.H.

– Advise the user of the precautions necessary to prevent

damage to the system, and to the building, in the event of the system remaining inoperative during frost conditions.

– Explain the function of the boiler overheat thermostat, and

how to reset it. Emphasise that if cut-out persists, the boiler should be turned off and the installer or service engineer consulted.

– Stress the importance of an annual service by a

registered heating engineer.

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

If yes, and if required by the manufacturer, has a water scale reducer been ﬁtted?

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 Yes

If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation ﬁtted? Yes

Service Record

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. This is also a condition of any extended warranty offered.

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.

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Operative ID No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Date:

Engineer Name:

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Signature:

Service 1 Service 2

Service 3 Service 4

Service 5 Service 6

Service 7 Service 8

Service 9 Service 10

To ensure continued efficient operation of the appliance, it is recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once a year should be adequate. It is the law that any service work must be carried out by registered personnel (C.O.R.G.I.). Before commencing any service operation, ISOLATE the mains electrical supply, and TURN OFF the gas supply at the main service cock. Service the appliance by following the full procedure detailed below.

5.1 MAIN BURNER ASSEMBLY

– Remove the casing as showed in fig. 23. – Remove the 8 fixing screws securing the sealed chamber

front panel then remove the panel. – Unscrew the 7 screws securing the combustion chamber

front panel and remove the panel, taking care not to

damage the insulation. – Remove the electrode by unscrewing it from the burner

manifold. – Unscrew the burner manifold union and locking nut. Lift

the front of the burner to disengage manifold thread and

then lift the burner clear. – Remove the burner manifold by disconnecting the four

screws. – Inspect and if necessary, clean the injectors, electrodes,

and the main burner bars.

5.2 FAN ASSEMBLY

– Disconnect the electrical connections to the fan. Note the

position of the earth conductor. – Remove the three screws securing the fan.

– Tilt the fan forwards and remove in a downwards direction. – Inspect the fan assembly and clean if necessary.

5.3 BITHERMAL EXCHANGER

– Inspect the bithermal exchanger, and clean if necessary.

5.5 CHIMNEY SWEEP FUNCTION (combustion analysis)

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 start 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 D.H.W. mode. To do so it is enough, after having activated the chimney sweep function, to take some hot water from one or more outlets. 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.

5 ROUTINE SERVICING INSTRUCTIONS

8 SEALED CHAMBER SCREWS

3 FAN FIXING SCREWS

MAIN EXCHANGER

7 COMBUSTION CHAMBER FRONT PANEL SCREWS

BURNER MANIFOLD UNION

Fig. 24

Fig. 23

SCREWS

ATTENTION: After about 15 minutes, or once the hot water request has been fulfilled, the chimney sweep function automatically deactivates.

5.6 RE-ASSEMBLY

– Re-assemble all the components in reverse order and

replace all the gaskets fitted in the gas line. Ensure that all seals are correctly fitted and that the pressure sensing line is correctly fitted. Check that the fan earth connection is correctly re-fitted. Note that the fan polarity (Line and Neutral) is immaterial.

– Check for gas soundness before fitting the casing.

5.7 RE-COMMISSIONING

– Turn on the gas supply, and check for gas soundness whilst

the appliance is running.

– Check the operation of the appliance in both C.H. and

D.H.W. mode and ensure in both cases that the burner pressure after at least 5 minutes running is as stated on the data plate or in

Table 3

Adjust if necessary as described in section 8.

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: – earth continuity; – short circuit; – polarity; – resistance to earth.

6.1 EARTH CONTINUITY CHECK

Appliances must be electrically disconnected, 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 1Ω (ohm). If the resistance is greater than 1Ω

(ohm) check all earth wires for continuity and all contacts are clean and tight. If the resistance to earth is still greater than

1Ω (ohm) then this should be investigated futher.

6.2 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.

6.3 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.

6.4 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 6.1 Earth continuity, 6.3 Polarity and 6.4 Resistance to earth must be repeated.

6.5 FAULT FINDING LEDS

The indicator leds signalling irregular and/or incorrect operation of the equipment are indicated in fig. 26. Before commencing any service operation, ISOLATE the mains electrical supply, and TURN OFF the gas supply at the main service cock. It is the law that any service work must be carried out by registered personnel (Gas Safe Register).

6 FAULT FINDING

Fig. 26

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 failure.

Orange led flashes if water pressure is insuf ficient.

Flashing red led indicates a problem in the tap water probe (SS).

Red led on, ignition lock-out/safety and smokes stats

tripped: turn the selector switch briefly to the position

marked ( ) to restore functioning

6.6 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.

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

available

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 electrode and igni-

tion transformer

The gap between ignition 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

Is there a jumper

on the room

thermostat connection?

Yes

YesYes

Yes

Verify that the

safety

thermostat

is working correctly?

Replace the

thermostats

Is the

connection of

the safety

thermostats

correct?

Reset the

connection

Yes

Restore the

connection

Verify that the

safety

thermostat

is working correctly?

Yes

Check the

connection of

the thermostat

Replace the thermostat

Yes

6.7 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.

available?

Does

the fan

start?

Is fuses at mains plug OK?

Clean or replace

the water flow

switch

Is there voltage

available

to the fan?

Replace fuses in

mains plug

Replace the fan

Check the

power supply

cable

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 continu-

ity between ignition

electrode and igni-

tion transformer

The gap between ignition electrode

and hood

is correct?

Fit correctly the

ignition electrode

Is the gas available?

Restore 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

Verify that the

safety

thermostat

is working correctly?

Replace the

thermostats

Is the

connection of

the safety

thermostat

correct?

Reset the

connection

Yes

Verify that the

safety

thermostat

is working correctly?

Yes

Check the

connection of

the thermostat

Replace the

thermostat

7 WIRING & FUNCTIONAL DIAGRAMS

7.1 ILLUSTRATED FLOW WIRING DIAGRAM

CN2 (code 6299977)

CN6 (code 6299974)

CN7 (code 6299973)

CN1

JUMPERS

JP4

WHITE

100 °C SAFETY STAT

C.H. SENSOR (SM)

D.H.W. SENSOR (SS)

GAS VALVE

PRESSURE SWITCH

ROOM THERMOSTAT

PUMP

FAN

IGNITION/ IONISATION ELECTRODE

WATER FLOW SWITCH ASSEMBLY

TIME CLOCK

Fig. 27

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

8.1 BITHERMAL EXCHANGER

– Remove the fan as described in section 8.3. –

Disconnect the pressure sensing pipe from the flue box, lift the

collector hood assembly, tilt forwards, and remove the hood. – Isolate the C.H. flow and return valves. – Drain the bithermal exchanger using the drain cock (at the

bottom RHS of the appliance) – Unclip the bithermal exchanger securing clips and

unscrew completely the expansion vessel nut. – Disconnect the pipes from the exchanger and lift out the

heat exchanger. – Re-assemble in reverse order, ensuring that the bithermal

exchanger seals and clips are correctly located and that

the pressure sensing pipe is correctly re-fitted. The fan

polarity is not important except the earth conductor (G/Y

which is marked on the appliance). – Refill, and re-commission the system as described in

section 4.

8.2 COMBUSTION CHAMBER INSULATION

The design of this appliance is such that the rear and side insulation should not require replacement unless mechanically damaged.

IMPORTANT: When handling insulation panels, take care to avoid producing or inhaling dust particles. When removing old or damaged insulation panels, dampen with water to minimise dust.

To replace the insulation front panel, proceed as follows: – remove the combustion chamber front panel as described

in section 5.1; – replace the front insulation panel and glue it into position

on the front panel using the glue supplied. Re-assemble in

reverse order.

Should the rear or side panels become damaged, replace them as follows. – remove the heat exchanger as described in section 8.1; –

remove the side insulation panels followed by the rear panel; – re-assemble in reverse order, refill, and recommission the

system as described in section 4.

8.3 FAN ASSEMBLY

– Remove the casing front panel and sealed chamber front

panel as described in section 5.1. – Disconnect the electrical connections and the pressure

sensing pipes to the fan. Note the position of the earth

conductor. – Unscrew the three screws securing the fan. – Drop and tilt the fan forwards and remove in a downwards

direction. – Re-assemble in reverse order. Ensure that the earth

connection is correctly refitted. Note that the polarity (Line

and Neutral) is immaterial.

8.4 MAIN BURNER

– Remove the main burner by following section 5.1.

– Transfer the ignition electrode onto the new burner

assembly.

– Re-assemble in reverse order. Check the electrode gaps

(fig. 28) and test for gas soundness.

– Re-commission the appliance as described in section 4.

8.5 IGNITION/DETECTION ELECTRODE

– Remove the casing front panel and sealed chamber front

panel as described in section 5.1.

– Unscrew the single screw securing the electrode in

position, and release the electrode from the burner.

– Remove the electrode and disconnect its cable from the

ignition transformer.

– Replace the electrode and re-assemble in reverse order.

8.6 GAS VALVE

– Remove the casing front panel as described in section 5.1. – Disconnect the two leads from the modulating solenoid

and disconnect the valve connector (one screw). – Unscrew the nut between the inlet pipe and the valve. – Unscrew the burner manifold nut underneath the sealed

chamber, and withdraw the gas valve complete with outlet

pipe. – Transfer the outlet pipe onto the new gas valve, using a

new gasket (supplied with the valve). – Fit the new gas valve assembly into the appliance using the

other new gasket supplied on the valve inlet, and re-

assemble in reverse order. – Re-light the appliance, check for gas soundness, and re-

commission in accordance with section 4.

In addition it will be necessary to set the D.H.W. and C.H. heat inputs, with reference to fig. 29, as follows: Note that it is necessary to set the MAXIMUM PRESSURE FIRST. – Connect a pressure gauge to the burner pressure test

point. – Remove the sealing cap of the proportioning unit (C) by

rotating it ⁄ turn anticlockwise. – Adjust DHW potentiometer to maximum, then fully open

any DHW tap to light the boiler. – Using a 10 mm spanner, turn nut (B) to attain the

maximum pressure in

Table 3

. Turn the nut clockwise to increase or anti-clockwise to decrease the burner pressure.

8 REPLACEMENT OF PARTS

Fig. 28

± 0.5

IGNITION/DETECTION

ELECTRODE

– Turn the main selector switch on and off a few times (with

the hot tap still open) and check that the pressure returns to the correct (set) maximum value (as in

Table 3

– Set the minimum burner pressure by first isolating the

electricity supply and disconnecting one of the modulating solenoid leads, then restore the electricity supply and fully open a DHW tap to light the appliance at minimum gas rate.

– Set the minimum pressure with reference to

Tables 3

by holding nut (B) in position with a 10 mm spanner and rotating the plastic screw (A) with a screwdriver until the correct pressure is obtained. Turn the screw clockwise to increase the pressure or anti-clockwise to decrease it. It is essential that the max pressure has been set prior to adjusting the minimum pressure. Check that the minimum pressure is correctly set by turning on and off the D.H.W. inlet valve several times and ensuring that the pressure returns to that previously adjusted;

– Isolate the power supply, re-connect the modulation lead,

restore the power and re-check the maximum pressure, then re-fit the plastic cover (1).

– Reduce the D.H.W. draw off rate to the minimum nec-

essary to maintain the burner alight by carefully adjusting the D.H.W. Inlet valve and check that the burner pressure decreases in response to D.H.W. temperature rise. Fully open the inlet valve;

– Close the D.H.W. tap and ensure that the burner is

extinguished and the pump stops.

– Adjust the Central Heating maximum pressure as

described in section 4.3, then complete the recommissioning as described in 4.4 and 4.5.

8.7 AIR PRESSURE SWITCH

– Remove the casing front panel and sealed chamber front

panel as described in section 5.1.

– Disconnect the pressure sensing pipe from the switch. – Remove the switch (two screws) and fit the new one. – Transfer the electrical connections one at a time (to

ensure that they are not incorrectly re-fitted) to the new switch.

– Re-assemble in reverse order referring to the wiring

diagrams (section 7) if necessary. Ensure that the pressure sensing lead is correctly connected to the low pressure connection on the pressure switch (marked P2).

8.8 SAFETY THERMOSTAT

The safety thermostat is situated on the flow pipe (3 fig. 3). – Remove the casing front panel as described in section 5.1. – Disconnect the two limit thermostat wires. – Unscrew the two limit thermostat fixing screws and

remove the thermostat.

– Replace the thermostat and spread heat sink compound

(supplied) over the base of the new one.

– Re-assemble in reverse order (Polarity is immaterial).

8.9 THERMISTOR

The thermistor is placed over the main exchanger. – Remove the casing front panel as described in section 5.1. – Isolate the C.H. flow and return valves (20 - 19 fig. 2), and

drain the appliance through the drain plug (16 fig. 2).

– Pull off the electric connection, and unscrew the

thermistor from the exchanger.

– Replace the thermistor and re-assemble in reverse order.

Table 8

shows the resistance values (Ω) that are obtained on

the sensor as the temperature varies.

8.10 DRIVER PCB

– Remove the casing front panel as described in section 5.1. – Open the control panel protecting cover by removing the

four fixing screw. – Pull off the potentiometer knobs. – Release the PCB (6 screws), transfer all connections onto

the new PCB, and re-assemble in reverse order.

8.11 PUMP MOTOR

– Remove the casing front panel as described in section 5.1. – Unplug the electrical connection plug. – Isolate the C.H. flow and return valves (20 - 16 fig. 2), and

drain the appliance through the drain plug (16 fig 2). – Unscrew the four fixing screws on the motor. – Replace the pump motor and re-assemble in reverse

order. If the new pump is fitted with a speed adjuster,

ensure that the speed is set to maximum. –

Refill and commission the system as described in section 4.1.

8.15 C.H. EXPANSION VESSEL

Replacement is not recommended if a rear flue outlet is used or if the clearance above the casing is less than 300 mm. – Remove the casing front panel as described in section 5.1.

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

TABLE 8

KEY A Plastic screw BNut C Sealing cap

Fig. 29

– Isolate the C.H. flow and return valves (20 - 19 fig. 2), and

drain the appliance through the drain plug (16 fig. 2).

– Unscrew the expansion vessel union on the C.H. return

pipe.

– If a rear flue outlet is used it is necessary to disengage the

flue and air duct temporarily. Refer to section 3.5.

– Remove the adjusting screws on the wall mounting

bracket thereby allowing the appliance to move slightly forwards at the top.

– Lift the expansion vessel out of the appliance through the

top.

– Replace the expansion vessel and re-assemble in reverse

order. Re-pressurise and re-commission the system as described in section 4.1.

8.16 PRESSURE/TEMPERATURE GAUGE

– Remove the casing front panel as described in section 5.1. – Isolate the C.H. flow and return valves (20 - 19 fig. 2). – Drain the appliance through the drain point (16 fig. 2). – Remove the circlip securing the pressure sensor to the

hydraulic group and pull out the sensor.

– Remove the fixing spring of the thermometer bulb from

the C.H. flow pipe.

– Squeeze the gauge to depress the retaining clips, then

ease the gauge forwards.

– Reassemble in reverse order.

Refill and re-commission the system as described in section 4.1.

8.17 SAFETY VALVE

– Remove the casing front panel as described in section 5.1.

– Isolate the C.H. flow and return valves (20 - 19 fig. 2). – Drain the appliance through the drain point (16 fig. 2) – Remove the circlip securing the valve to the hydraulic

group and remove the valve.

– Fit the new safety valve and re-assemble in reverse order.

Refill and re-commission the system as described in section 4.1.

8.18 AUTOMATIC AIR VENT

hydraulic group.

– Fit the new automatic air vent and re-assemble in reverse

order. Refill and re-commission the system as described in section 4.1.

8.19 TIME CLOCK

– Pull off the electrical connections at the back of the clock. – Remove the two screws securing the plastic frame of the

time clock to the facia panel. – Remove the plastic frame and pull out the time clock. – Re-assemble in reverse order and test the operation of

the new clock. – Set it to the desired settings as described in section 4.3.

COD. TYPE DATE PAGE

3820086/318 FORMAT 80B - 100B 26.04.2007 1/4

9 EXPLODED VIEWS

POSITION CODE DESCRIPTION MODEL NOTE

COD. TYPE DATE PAGE

• Recommended stock par ts - Com ponenti da tenere a scorta

POSITION CODE DESCRIPTION MODEL NOTE

1 6138570 Side frame part

2 6138770 Frame assembly upper support 80

2 A 6138771 Frame assembly upper support 100

3 6255430 Expansion vessel lower support 80

3 A 6255431 Expansion vessel lower support 100

4 • 5139140 Expansion vessel l.7 - 3/8” M 80

4 A • 5139130 Expansion vessel l.8 - 3/8” M 100

5 6146305 Brass Nut 3/8”

6 6288105 Sealed chamber rear panel 80

6 A 6288115 Sealed chamber rear panel 100

7 6119313 Plastic cap

8 6287900 Air/smoke manifold

9 6147406 Air/smoke manifold plug M14x1.5

10 • 6226417 O-ring 3043

11 6242602 Air/smoke manifold screw

12 6248803 Lip seal for Ø 60 pipe

13 6028706 Air/smoke manifold gasket

14 2000716 Screw T.C.B. M4x8

15 5190700 Main burner assembly 80

15 A 5190752 Main burner assembly 100

16 • 6235931 Ignition-ionisation electrode

17 6146301 Brass nut 1/2”

18 6288415 Combustion chamber rear panel 80

18 A 6288416 Combustion chamber rear panel 100

19 6288500 Combust. chamber right hand side panel 80

19 A 6288510 Combust. chamber right hand side panel 100

20 6288600 Combust. chamber left hand side panel 80

20 A 6288610 Combust. chamber left hand side panel 100

21 6139789 Combustion chamber rear insulation 80

21 A 6139790 Combustion chamber rear insulation 100

22 6139774 Combustion chamber side insulation 80

22 A 6139792 Combustion chamber side insulation 100

23 6028707 Air intake gasket

24 6288000 Air intake

25 6257512 Air deflector for separate ducts

26 6174249 Gas/Water heat exchanger 80

26 A 6174250 Gas/Water heat exchanger 100

27 6231356 Temperature sensor

28 6272504 Temperature sensor fixing spring

29 5190601 Smoke chamber assembly 80

29 A 5190611 Smoke chamber assembly 100

30 2016020 Locked nut M4

31 • 6225632 Fan 80

31 A • 6225624 Fan 100

32 2000715 Screw TCB M4x10 AISI 304

33 6288701 Combustion chamber front panel 80

33 A 6288711 Combustion chamber front panel 100

34 6139787 Combustion chamber side insulation 80

34 A 6139788 Combustion chamber side insulation 100

35 6264836 C.H. return pipe 80

35 A 6264837 C.H. return pipe 100

36 • 6226412 O-ring 3068

37 • 6226601 Spring for heat exchanger connection

38 6264767 C.H. flow pipe 80

38 A 6264768 C.H. flow pipe 100

39 2030226 Gasket Ø 10,2x14,8x2

40 • 6146701 100°C safety stat

41 6227012 D.H.W. outlet pipe 80

41 A 6227013 D.H.W. outlet pipe 100

42 • 6226444 O-Ring Ø 13,64x 2,62

43 • 6226617 Spring for heat exchanger connection

44 6227111 D.H.W. inlet pipe 80

44 A 6227112 D.H.W. inlet pipe 100

45 6131430 Magnetic sensor

46 6226612 Pipe fixing double spring

47 6017310 Flexible pipe

48 6226414 O-ring 117 Ø 13,1x2,62 EP851

49 6138870 Frame assembly lower side 80

49 A 6138880 Frame assembly lower side 100

50 6146302 Brass nut 3/4”

51 • 6037504 Water pressure switch

52 6226611 Water rate adjuster fixing spring

53 6281410 Water rate adjuster 11 l/min 80

53 A 6281411 Water rate adjuster 15 l/min 100

54 • 6040201 Pressure relief valve

55 6100202 Ogive for pipe Ø 15

3820086/318 FORMAT 80B - 100B 26.04.2007 2/4

POSITION CODE DESCRIPTION MODEL NOTE

COD. TYPE DATE PAGE

• Recommended stock par ts - Com ponenti da tenere a scorta

POSITION CODE DESCRIPTION MODEL NOTE

56 6168401 Locking nut for pipe Ø 15

57 • 6226602 Pipe fixing spring

58 6120510 Nipple 1/2”x1/2” OT

59 2030228 Gasket Ø 17x24x2

60 2030227 Gasket Ø 12x18x2

61 • 6231357 D.H.W. temperature sensor

62 6028705 Gasket EP709 for Dab

63 2000201 Screw M5x40

64 6288200 Sealed chamber side panel

65 6215220 Cables protection bracket

66 6229101 Smoke pressure switch bracket

67 6225724 Air pressure switch 52-62 Pa 80

67 A • 6225710 Air pressure switch 35-45 Pa 100

68 6280500 3-ways junct. with press. test nipple

69 6243820 SIT gas valve type 845 SIGMA

70 6226873 Gas inlet pipe

71 6226952 Pipe connecting gas valve-main burner

72 6146303 Brass Nut 1/8”

73 6289817 Control panel

74 6247360 Cap for time programmer

75 2005201 Screw “HI-LO” TSP 3x12

76 6273210 Guidelight - 2 ways out

77 6217005 Temperature and pressure gauge

78 6230630 Main P.C.B.

79 • 6201505 Trimmer spindle Ø 6

80 • 6201502 Trimmer spindle Ø 6

81 2211610 Ear th faston

82 • 6269810 Ignition cable

83 6289900 Control panel protecting cover

84 6290300 Control panel cable cover

85 6290200 Room stat connection cover

86 6290100 White knob Ø 40

87 6009585 Control panel bracket

88 6290015 Flap door 80

89 2051100 Retaining spring

90 6226605 Fixing spring

91 6288300 Sealed chamber front panel 80

91 A 6288310 Sealed chamber front panel 100

92 6001210 Peephole

93 6287321 Casing 80

93 A 6287331 Casing 100

94 2013302 Fastener for self tapping screw

95 2004510 Screw 8Px7/8”

96 6112420 Control panel screw

97 • 6028623 Air diaphragm Ø 86

98 6142330 Quarter bend 1/2” x 15

99 6177505 Ball cock 3/4” x 22

100 6177506 Ball cock 1/2” x 15

101 6177530 Gas cock 3/4” F x 15

102 6157602 Pressure relief valve drain pipe

103 6257523 Air deflector 100

104 6263911 Fan pressure test point 80

104 A 6263906 Fan pressure test point 100

105 5192200 Gasket for sealed chamber

106 • 5192600 Dab VA55 pump kit 80

106 A • 5192601 Dab VA65 circulating pump kit 100

107 6022004 Copper washer Ø 6

108 6154402 Main burner nozzle NP 130 natural gas

108 A 6154410 Main burner nozzle NP 77 GLP 80

108 B 6154406 Main burner nozzle NP 0,80 100

109 6281521 Flange + OR for Dab pump

111 6281500 Straight fitting 3/4”

112 6281501 Straight fitting 1/2”

113 • 6013101 Automatic air vent

114 • 6149316 Flow water switch assembly

115 6226446 O-ring Dalmar R7

116 • 6017250 Manual air vent 1/4”

117 6296916 By-pass

118 • 6226421 O-ring Dalmar R12

119 6281529 Flow manifold group + OR

120 6281530 Flow/return manifold group

121 6301900 Flow water switch-flow manifold pipe

5187352 Technyl hydraulic group

5191210 Control panel assembly

6127210 Main cable L=2000

3820086/318 FORMAT 80B - 100B 26.04.2007 3/4

POSITION CODE DESCRIPTION MODEL NOTE

COD. TYPE DATE PAGE

• Recommended stock par ts - Com ponenti da tenere a scorta

POSITION CODE DESCRIPTION MODEL NOTE

6299973 14 pole Lumberg cable connector CN6

6299974 6 pole Stocko connector CN7

6299977 4 pole Lumberg cable connector CN2

• 5144712 Conversion kit to LPG 80

• 5144716 Conversion kit to LPG 100

• 6233500 Fuse 1.6A main P.C.B.

5184817 Fitting cocks kit

Products reference:

8105400: Format 80B Natural gas

8105401: Format 80B L.P.G.

8105402: Format 100B Natural gas

8105403: Format 100B L.P.G.

Check the correspondence with the boiler data plate.

3820086/318 FORMAT 80B - 100B 26.04.2007 4/4

GAS CONVERSION

A kit is supplied upon request complete with the necessary change-over materials for operation with butane gas (G30) or propane gas (G31). Operate in the following manner for changing over from one gas to another: – Close the gas cock. – Slide out the burner unit. –

Replace the main nozzles (6) supplied in a kit, inserting the copper washer (4). Use a ø 7 spanner to per form this operation.

–

Remove the “MET/GPL” connector link on the main board and set it on “GPL”.

– To set the values of maximum and minimum gas pressure, follow the instructions given in section 8.6.

When the working pressures have been adjusted, reseal the regulators.

– After the conversion of the boiler, please stick onto the casing panel the plate showing the relevant feeding gas

which is included in the kit.

NOTE: When reassembling components which you have removed, replace gas seals; test all gas connections after assembly using soapy water or a product made specifically for the purpose, being sure not to use open flame. Conversion must be performed by authorised personnel only.

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

Cod. 6272297 - 02/11 - Documentation Dpt.

Sime Ltd

1a Blue Ridge Park Thunderhead Ridge Glasshoughton, Castleford, WF10 4UA

Phone: 0845 9011114 Fax: 0845 9011115

www.sime.ltd.uk Email: enquiries@sime.ltd.uk

Sime Format B Installation And Servicing Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual