Sime Format 100 C, Installation And Servicing Instructions

Page 1: ...Supplied By www heating spares co Tel 0161 620 6677 Format C Installation and servicing instructions GB PLEASE LEAVE THIS INSTRUCTION WITH THE USER ...

Page 2: ...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 ...

Page 3: ...8 3 INSTALLING THE BOILER 3 1 FIXING THE WALL MOUNTING BRACKET 9 3 2 HANGING THE BOILER 3 3 FLUE DUCTS PREPARATION 3 4 FLUE AND TERMINAL INSTALLATION 10 3 5 SEPARATE DUCTS 12 3 6 WATER CONNECTIONS 13 3 7 GAS CONNECTIONS 3 8 SAFETY VALVE CONNECTION 3 9 WIRING INSTRUCTIONS 4 COMMISSIONING AND TESTING 4 1 FILLING THE WATER SYSTEM 15 4 2 COMMISSIONING THE BOILER 4 3 SETTING THE C H INPUT 4 4 SETTING T...

Page 4: ... 8 2 COMBUSTION CHAMBER INSULATION 8 3 FAN ASSEMBLY 8 4 MAIN BURNER 8 5 IGNITION DETECTION ELECTRODE 8 6 GAS VALVE 8 7 AIR PRESSURE SWITCH 24 8 8 OVERHEAT THERMOSTAT 8 9 THERMISTOR 8 10 DRIVER PCB 8 11 PUMP MOTOR 8 12 D H W HEAT EXCHANGER 25 8 13 DIVERTOR VALVE COMPLETE 8 14 DIVERTOR VALVE MICROSWITCH ASSEMBLY 8 15 C H EXPANSION VESSEL 8 16 PRESSURE TEMPERATURE GAUGE 8 17 SAFETY VALVE 8 18 AUTOMAT...

Page 5: ...e 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 sys tems and is supplied fully assembled and equipped with com plete 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 C FORMAT 100 C FORMAT 110 C wit...

Page 6: ...7 7 60 000 22 5 77 000 5 6 2 3 12 2 14 9 4 9 6 0 X G20 G31 19 8 68 000 25 0 86 000 6 8 2 7 14 9 18 0 6 0 7 2 X G30 22 0 75 000 27 6 94 000 8 2 3 3 17 9 21 3 7 2 8 6 24 2 83 000 30 1 103 000 9 6 3 8 21 2 24 8 8 5 10 0 26 5 90 000 32 6 111 000 11 1 4 5 24 7 28 5 9 9 11 4 28 8 98 000 35 1 120 000 12 7 5 1 28 5 36 5 11 4 14 7 DOMESTIC HOT WATER Max 28 8 98 000 35 1 120 000 12 7 5 1 28 5 36 5 11 4 14 7...

Page 7: ...in 2 0 5 2 0 5 2 0 5 D H W flow rate at a temperature rise of 30 C l min gal min 11 2 2 5 13 8 3 0 15 1 3 3 35 C l min gal min 9 6 2 1 11 9 2 6 12 9 2 8 Static head Minimum bar psi 0 5 7 3 0 5 7 3 0 5 7 3 Maximum bar psi 3 0 43 5 3 0 43 5 3 0 43 5 D H W pressure Minimum bar psi 1 0 14 6 1 0 14 6 1 0 14 6 Maximum bar psi 6 0 87 6 0 87 6 0 87 Weight Empty kg lb 38 84 40 88 40 88 Total full kg lb 41 ...

Page 8: ...er 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 tem perature is reached the burner extinguishes and the fan ...

Page 9: ...or compartment may be used provid ed 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...

Page 10: ...re 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 a...

Page 11: ...ing spares co Tel 0161 620 6677 7 TYPICAL SYSTEM DESIGN ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM NOTE A drain cock should be installed at the lowest point of the heating circuit and beneath the appliance Fig 6 Fig 7 ...

Page 12: ...hin the pre scribed limits Table 4 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 10 3 l m 2 3 gpm for FORMAT 80 C 13 l m 2 9 gpm for FORMAT 100 C and 14 l m 3 1 gpm for FORMAT 110 C is recom mended Higher flow rates will not damage the appliance but may lower the water temperature below an accept able leve...

Page 13: ...izontal 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 scre...

Page 14: ...ontal Push the junction collar B over the air duct until the air duct touches the inner part of the collar where the diame ter becomes smaller Push the elbow socket into the junction collar and onto the flue duct Fit the jointing clamp G over the juction collar Place the gasket F under the flange of the elbow and fit the elbow onto the flue manifold taking care to ensure that the silicon seal on t...

Page 15: ...tres each additional 45 elbow reduces the available lenght by 0 45 metres NOTE Sime flue systems are suitable for installation with SE duct systems 11 Push flue duct and terminal into air duct from this end Fig 13 KEY A Elbow flange B Junction collar C Outer duct D Aluminium ring E Rubber sealing ring F Inner duct c w terminal G Gasket ø 95 125 x 2 H Fixing screw I Protective jointing clamp J Inne...

Page 16: ...l 40 m for 110 C model For head losses in the fittings refer to Table 7 12 1 2 3 4 6 165 110 165 K ø 80 ø 80 100 92 Fig 17 KEY 1 Sponge rubber gasket ø 125 95 2 Fixing screw 3 Smoke outlet flange 4 Air intake diaphragm 6 Air smoke manifold with intakes 80 C 100 C 110 C K mm 180 205 Fig 18 Model FORMAT 100 C N segments Total horizontal lenght to remove inlet outlet in metres none 0 3 3 n 1 3 3 6 7 ...

Page 17: ...NECTIONS 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...

Page 18: ...30 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 14 4 1 2 3 5 6 7 8 9 Fig 20 KEY 1 Temperature and pressure gauge 2 Time programmer housing 3 Rotary switch 4 Main PCB 5 Earth faston 6 Control panel protection 7 C...

Page 19: ...f modulation is suspected open all D H W taps to maximise flow and recheck burner pres sure 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...

Page 20: ...alve may need cleaning To gain access to the filter first close the cold water isolation valve 20 figure 2 drain the D H W circuit via the low est tap make provision to collect a small discharge of water then loosen the brass swivel connection to access the filter 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 potentio...

Page 21: ...aking care not to dam age 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...

Page 22: ...mble 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 pres sure 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 suppl...

Page 23: ...t 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 ...

Page 24: ... the electrode and ignition transformer Does it spark now Turn the clock to the right position Close room thermostat contact Replace the fan Is there voltage available to the pump Replace the clock Check pump connection Is pump shaft free to rotate Replace the pump Make it free to rotate Has the PCB ignition locked out after 10 seconds without flame at the burner Has the PCB ignition locked out af...

Page 25: ...g Check pump connection Is there 230V ac available at the fan terminals Replace the PCB Replace the pump Replace the divertor valve Replace the fan Check filter at inlet of hydraulic group Has the PCB ignition locked out after 10 seconds without flame at the burner Has the PCB ignition locked out after 10 seconds with flame at the burner before lock Is the gas available Open the gas cock Is the sa...

Page 26: ... AND FEATURE SUPPLY POSITION CLOSED OPEN J7 METANO GPL Ready to function with LPG Ready to function with natural gas Open J8 ANN RIT Ignition delay cancelled Ignition delay operating Open In the heating phase the electronic board is programmed to include a burner technical delay interval of approx 3 minutes which occurs both at system cold starting and at subsequent re ignitions The aim is to over...

Page 27: ...the fan Drop and tilt the fan forwards and remove in a down wards direction Re assemble in reverse order Ensure that the earth con nection 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...

Page 28: ...itch Re assemble in reverse order referring to the wiring dia grams 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 OVERHEAT THERMOSTAT The overheat thermostat is situated on the flow pipe below the sealed chamber 11 fig 3 Remove the casing front panel as described in section 5 1 Disconnect the ...

Page 29: ...essel 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 brack et thereby allowing the appliance to move slightly for wards at the top Lift the expansion vessel out of the appliance through the top Replace the expansion vessel and re assemble in reverse order...

Page 30: ...15 48 6281502 Flow water switch spare parts 49 6013101 Automatic air vent 50 6017210 Manual air vent 1 4 51 6281500 Straight fitting 3 4 52 6281501 Straight fitting 1 2 53 6226421 O ring Dalmar R12 54 6281522 14 plate heat exchanger kit 80C 100C 54 A 6281525 16 plate heat exchanger kit 110C 55 6281504 Divertor valve 56 6168401 Locking nut for pipe Ø 15 57 6226607 Pipe fixing spring 58 6272301 Circ...

Page 31: ... Washer MPMV 3318 4 6220601 O ring R1 MPMV 3325 5 6218500 Clip Ø 17 for diverting valve 6 6153101 Diaphragm assembly for divertor valve Position Code Description 7 6231201 Brass ring nut MPMV 3320 8 6223902 Teflon short spacer MPMV 3315 9 6222000 D H W filter MPMV 3326 10 6220602 O ring 4093 MPMV 18 11 6223903 Teflon long spacer MPMV 3316 9 2 DIVERTOR VALVE Fig 30 a ...

Page 32: ...19 6147406 Air smoke manifold plug M14x1 5 20 6226417 O ring 3043 21 6242602 Air smoke manifold screw 22 6248803 Lip seal for Ø 60 pipe 23 6028706 Air smoke manifold gasket 24 6028707 Air intake gasket 25 6288000 Air intake 26 6257512 Air deflector for separate ducts 30 5190600 Smoke chamber assembly 80C Position Code Description Model 30 A 5190610 Smoke chamber assembly 100C 110C 31 2016020 Locke...

Page 33: ...apping screw 73 6289800 Control panel 74 6273210 Guidelight 2 ways out 75 6217005 Temperature and pressure gauge 76 6230687 Main PCB with ignition 77 6201501 Trimmer spindle Ø 5 78 6201505 Trimmer spindle Ø 6 79 6260701 Rotary switch 80 2211610 Earth faston Position Code Description Model 82 6289900 Control panel protecting cover 83 6290300 Control panel cable cover 84 6290200 Room stat connection...

Page 34: ...Supplied By www heating spares co Tel 0161 620 6677 ...

Page 35: ...ersion of the boiler please stick onto the casing panel the plate showing the relevant fee ding gas which is included in the kit NOTE When reassembling components which you have removed replace gas seals test all gas con nections 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...

Page 36: ...ting spares co Tel 0161 620 6677 Cod 6272251B Documentation Dpt Sime Ltd Unit D2 Enterprise Way Bradford Road Bradford West Yorkshire BD10 8EW Tel 0870 9911114 Fax 0870 9911115 www sime ltd uk e mail enquiries sime ltd uk ...