Sime Format B, Installation And Servicing Instructions

Page 1: ...tion 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 ...

Page 2: ...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 eng...

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Page 4: ...ndards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimi se safety efficiency and performance Benchmark is managed and promoted by the Heating and Hotwater Industry Council For more information visit www centralheating co uk ...

Page 5: ...al 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 m...

Page 6: ...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 mo...

Page 7: ... s 15 6 16 9 20 2 22 0 Losses after shutdown to 50 C W h 78 79 Category II2H3 II2H3 Type 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 m3 h 2 70 3 49 Butane...

Page 8: ...er 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 ...

Page 9: ...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...

Page 10: ...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 impo...

Page 11: ...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 after installation this boiler and its associated central heating system must be flushed in ...

Page 12: ...12 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 ...

Page 13: ...ressure 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 wate...

Page 14: ...ill 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 BOILE...

Page 15: ... 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 optio nal diaphragm separately ø 87 5 cod 6028624 and use it in accordance with the instructions provided in figure 11 C12 C32 C42 3 1 2 7 6 4 3 2 min 1 3 m max 5 m 8 x y 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 K...

Page 16: ...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 usi...

Page 17: ...ondenses 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 ...

Page 18: ...e insulated with a glass wool pipe insulator 30 mm thick with a density of 50 kg m3 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 1 2 3 4 6 165 110 165 K ø 80 ø ...

Page 19: ...e 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 ...

Page 20: ...ontact 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 8 1 2 5 4 7 6 Fig 20 KEY 1 Temperature and pressure gauge 2 Easy Stat Receiver housing 8092221 4 Main PCB 5 Earth faston 6 Control panel protection 7 Cover TA 8 Connector TA A...

Page 21: ...alve 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 ...

Page 22: ... 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...

Page 23: ...ffect 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 ...

Page 24: ...o 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...

Page 25: ... 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 a...

Page 26: ...ral 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 ...

Page 27: ...ds 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 ...

Page 28: ...e 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 continu ity between ignition electrode and igni tion transformer The gap betwe...

Page 29: ...ctrode 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 Rep...

Page 30: ...SSEMBLY 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 CL...

Page 31: ...ews 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 ...

Page 32: ...iring 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 remov...

Page 33: ...he 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...

Page 34: ...COD TYPE DATE PAGE 3820086 318 FORMAT 80B 100B 26 04 2007 1 4 34 9 EXPLODED VIEWS ...

Page 35: ...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 62256...

Page 36: ... 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 ...

Page 37: ...tocko 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...

Page 38: ...e 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 Convers...

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Page 40: ...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 ...