advertisement
GB
Format 30 HE
Installation and servicing instructions
IPX4D
Form at 30 HE:
Gas Council number
47-719-21
These appliances comply with the S.E.D.B.U.K. scheme, band “A”
CONTENTS
5
6
7
3
4
1
2
DESCRIPTION OF THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
5
CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
11
USE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
14
FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
17
REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
20
EXPLODED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . pag.
22
Please refer to commissioning instructions for filling in the log book
Note: All CORGI registered installers carry a CORGI ID Card.
You can check your installer is CORGI Registered by calling 01256 372300
SIME COMBINATION BOILERS
Installer checklist
Please remember to carry out the following checks after installation. This will achieve complete customer satisfaction, and avoid unnecessary service calls. A charge will be made for a service visit where the fault is not due to a manufacturing defect.
– Has a correct by-pass been fitted and adjusted?
– Has the system and boiler been flushed?
– Is the system and boiler full of water, and the correct pressure showing on the pressure gauge?
– Is the Auto Air Vent open?
– Has the pump been rotated manually?
– Is the gas supply working pressure correct?
– Is the boiler wired correctly? (See installation manual).
– Has the D.H.W. flow rate been set to the customer requirements?
– Has the customer been fully advised on the correct use of the boiler, system and controls?
– Has the log book provided been completed?
– Has the Aquaguard Filter been cleaned (see 4.9)?
1 DESCRIPTION OF THE BOILER
1.1 INTRODUCTION
“FORMAT 30 HE” boilers are high efficiency premix condensating thermal appliances which use microprocessor technology for function control and management.
The boiler is equipped as standard with frost protection and circulating pump antijamming system.
The instructions given in this manual are provided to ensure proper installation and perfect operation of the appliance.
1.2
DIMENSIONS
157
133
=
335
=
S3
100
S3
400
30
125 60
335
=
R M
G E U
70 70 70 70
=
Fig. 1
TABLE 1 - Connections
R C.H. return
M C.H. flow
G Gas connection
E D.H.W. inlet
U D.H.W. outlet
S3 Condensation outlet ø 22
22 mm
22 mm
1/2 in
15 mm
15 mm
Compression
Compression
Bsp
Compression
Compression
TABLE 2 - Minimum clearances
ABOVE THE APPLIANCE CASING
AT THE R.H.S.
AT THE L.H.S.
BELOW THE APPLIANCE CASING
IN FRONT OF THE APPLIANCE
For ventilation For servicing
200 mm
15 mm
300 mm
15 mm
15 mm
200 mm
350 mm
15 mm
200 mm
500 mm
1
1.3
TECHNICAL FEATURES
Heat output nominal (80-60°C)
FORMAT 30 HE
kW (kcal/h) 27.3 (23,480)
Heat output nominal (50-30°C) kW (kcal/h) 29.8 (25,630)
Heat output minimum (80-60°C) kW (kcal/h) 10.2 (8,770)
Heat output minimum(50-30°C) kW (kcal/h)
Heat input nominal kW (kcal/h)
11.3 (9,720)
27.9 (24,000)
Heat input minimum
Nominal D.H.W. heat input kW (kcal/h) kW (kcal/h)
10.5 (9,030)
30.0 (25,800)
Minimum D.H.W. heat input kW (kcal/h)
Efficiency nom./min. output (80-60°C) %
Efficiency nom./min. output (50-30°C)
Seasonal efficiency rating (SEDBUK)
Termal efficiency (CEE 92/42 directive)
Class NOx
10.5 (9,030)
97.9/97.0
% 106.9/107.4
90.2% (A)
★★★★
5
Smokes temperature maximum (80-60°C) °C
Smokes temperature minimum(80-60°C) °C
Smokes temperature maximum (50-30°C) °C
Smokes temperature minimum (50-30°C) °C
63
56
42
41
Smokes flow
CO
2 maximum/minimum G20
CO
2 maximum/minimum G31
Adsorbed power consumption
Electrical protection grade
CE certification
Category
Type kg/h
%
%
W
47
9.0/9.0
10.0/9.9
145
IP X4D n° 1312BP4098
II
2H3P
B
23-53
C
13-33-43-53-83
CENTRAL HEATING
Maximum water head
Maximum temperature
Water content boiler
C.H. setting range
Expansion vessel capacity
Expansion vessel pressure
DOMESTIC HOT WATER
Minimum/maximum pressure
D.H.W. flow rate (EN 625)
Continuous D.H.W. flow rate
∆ t 30°C
Continuous D.H.W. flow rate
∆ t 35°C
Minimum D.H.W. flow rate
D.H.W. setting range bar l/min l/min l/min l/min
°C
GAS PRESSURE AND NOZZLES
Gas supply pressure G20
Gas supply pressure G31
Nozzles quantity
Nozzles diameter G20
Nozzles diameter G31
C.H gas consumption nom./min. G20 mbar mbar n°
ø
ø m 3 /h
C.H. gas consumption nom./min. G31 kg/h
D.H.W. gas consumption nom./min. G20 m 3 /h
D.H.W. gas consumption nom./min. G31 kg/h
WEIGHT
kg bar
°C
°C l bar l
FORMAT 30 HE
3
80
5.3
20/75
8
1
0.5/7.0
13.4
14.3
12.3
2
30/60
20
37
1
7.0
5.0
2.95/1.11
2.17/0.82
3.17/1.11
2.33/0.82
43
2
1.4
FUNCTIONAL DIAGRAM
29 22
5
4
24
25
23
26
6
16
17
27
3
1
2
12
8
9
10
11
13
7 15
14
18
28
U E G M R
21
S3
19
20
KEY
1 Fan
2 Air-gas mixer
3 Main exchanger
4 Gas flow rate adjuster (shutter)
5 Gas valve
6 D.H.W. exchanger
7 Divertor valve
8 Water flow switch
9 Thermometer sensor
10 SM sensor (thermister)
11 Aqua Guard Filter System
12 Safety stat 100°
13 Auto air vent
14 Circulating pump
15 Automatic by-pass
16 Temperature/pressure gauge
17 Boiler drain
18 Safety valve
19 Expansion vessel
20 Condensation water trap
21 Upper automatic air vent
22 Limit stat 90°
23 D.H.W. filter
25 D.H.W. inlet cock
26 Gas cock
27 C.H. flow cock
28 C.H. return cock
29 Smoke stat 95°
Fig. 2
1.5
MAIN COMPONENTS
KEY
1 Control panel
2 Wate flow switch
3 SM sensor (thermister)
4 Gas valve
5 Gas flow rate adjuster (shutter)
6 Gas test point
7 Air test point
8 Fan
9 Main exchanger
10 Smoke stat 95°
11 Upper automatic air vent
12 Limit stat 90°
13 Ignition/ionization electrode
14 Ignition transformer
15 Safety stat 100°
16 Aqua Guard Filter System
17 Automatic air vent
Fig. 3
3
2 INSTALLATION
The boiler must be installed in a fixed location and only by specialized and qualified person in compliance with all instructions contained in this manual. Furthermore, the installation must be in accordance with current standards and regulations.
2.1
VENTILATION REQUIREMENTS
Detailled recommendations for air supply are given in BS5440:2. The following notes are for general guidance:
– It is not necessary to have a purpose provided air vent in the room or compar tment in which the appliance is installed.
2.2
FIXING THE WALL
MOUNTING BRACKET
– Mark the position of the two wall mounting bracket fixing holes and the flue/air duct hole on the appropriate wall(s).
– Drill the top two fixing holes using a 10 mm masonry drill and fit the plastic plugs provided.
– Cut the hole in the wall for the flue/air duct. The diameter should not be less than 100 mm (4 in) and must be horizontal. If the hole is not accessible from the outside of the building, its minimum diameter should be sufficient to allow the insertion of the wall liner (130 mm -
5 1/4 in diameter) which will be sealed with mortar.
– Accurately measure the wall thickness, and note this dimension for later use.
– Secure the wall mounting bracket in position using the screws provided.
Ensure that it is the correct way up, as indicated in fig. 4.
4
2.3
CONNECTING UP SYSTEM
Before proceeding to connect up the boiler, you are recommended to flush out the system in order to eliminate any foreign bodies that might be detrimental to the operating efficiency of the appliance. When making the hydraulic connections, make sure that the clearances indicated in fig. 1 are respected. To facilitate the hydraulic connections the boiler is equipped with a valve pack code 5184803 complete with instructions sheet.
A safety valve set at 3 bar is fitted to the appliance, the discharge pipe provided should be extended to terminate safely away from the appliance and where a discharge would not cause damage to persons or property but would be detected.
The pipe should be a minimum of 15 mm Ø and should be able to withstand boiling water, any should avoid sharp corners or upward pipe runs where water may be retained.
The gas connection must be made using seamless steel or copper pipe
2 1
4
3
KEY
1 Wall mounting bracket
2 Plastic wall plug (2 Off)
3 Woodscrew (2 Off)
4 Washer (2 Off)
Fig. 4
(Mannesmann type), galvanized and with threaded joints provided with gaskets, excluding three-piece connections, except for initial and end connections. Where the piping has to pass through walls, a suitable insulating sleeve must be provided.
When sizing gas piping, from the meter to the boiler, take into account both the volume flow rates (consumption) in m
3
/h and the relative density of the gas in question. The sections of the piping making up the system must be such as to guarantee a supply of gas sufficient to cover the maximum demand, limiting pressure loss between the gas meter and any apparatus being used to not greater than 1.0 mbar for family II gases (natural gas). An adhesive data badge is sited inside the front panel; it contains all the technical data identifying the boiler and the type of gas for which the boiler is arranged.
2.3.1
Connection of condensation water trap
The drip board and its water trap must be connected to a civil drain through a pipe with a slope of at least 5 mm per metre to ensure drainage of condensation water.
The plastic pipes normally used for civil drains are the only type of pipe which is appropriate for conveying condensation to the building’s sewer pipes.
2.3.2
Requirements for sealed water systems
The heating system design should be based on the following information: a) The available pump head is given in fig. 16.
b) The 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).
2.4
CHARACTERISTICS
OF FEEDWATER
– All recirculatory systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.
– For optimum performance after installation this boiler and its associated central heating sys t em mus t be f lushed 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 Super floc. 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).
– At every service the Aquaguard Filter
(4.9) should be checked and cleaned.
2.5
COAXIAL DUCT ø 60/100
The air inlet-smoke outlet assembly, code
8096201, is included in the standard supply of the appliance complete with mounting instructions.
NOTE: to use only special accessories for condensing boilers.
2.5.1
Coaxial duct accessories
The accessories to be used for this type of installation and some of the connecting systems that may be adopted are illustrated in fig. 5. With the pipe bend included in the
kit, the maximum length of the piping should not exceed 4.6 meter. Where the supplementary bend code 8095800 is used, the total length of the piping can reach a maximum of 2.9 meter. When the vertical extension code 8086907 is used, the terminal part of the pipe must always
come out horizontally.
2.5.2
Positioning the outlet terminals
The outlet terminals for forced-draught appliances may be located in the external perimeter walls of the building.
To provide some indications of possible solutions, Table 3 gives the minimum distances to be observed, with reference to the type of building shown in fig. 6.
KEY
1a-b Coaxial duct kit code 8096201
2 Extension L. 1000 code 8096100*
3 Vertical extension L. 200 with take-off point code 8086907
4 90° additional bend code 8095800*
* Replace the gasket mounted on the outlet duct ø
60 with the ones supplied along with the accessory.
NOTE:
Place the duct horizontally.
max 4.6 m
Fig. 5
TABLE 3
Terminal position
A
Directly below an openable window, air vent
B
F
G
or any other ventilation opening
Below guttering, drain pipes or soil pipes
C/D Below eaves, balconies or carport roof
E
From vertical drain pipes or soil pipes
From internal or external corners
Above adjacent ground, roof or balcony level
I
H
From a surface facing the terminal
From a terminal facing the terminal
J
From an opening in the carport
(eg door, window into dwelling)
Minimum spacing
300 mm 12 in
75 mm 3 in
200 mm
75 mm
8 in
3 in
300 mm 12 in
300 mm 12 in
600 mm 24 in
1,200 mm 48 in
K
Vertically from a terminal on the same wall
L
Horizontally from a terminal on the same wall
1,200 mm 48 in
1,500 mm 60 in
300 mm 12 in
M
Horizontally from a vertical terminal to a wall 300 mm 12 in
N
Horizontally from an openable window or other opening 300 mm 12 in
P
Above an openable window or other opening 300 mm 12 in
– 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. Terminal guards are available from Quinnell, Barrett, and Quinnell, Old Kent
Road, London. State model C2, (G.C. Part No 382946).
– Where the terminal is fitted within 850 mm (34 in) of a plastic or 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.
Fig. 6
5
6
63,5
156,5
CS
CA
CA
3
4
134
2
5 3 1
KEY
CA Inlet
CS Outlet
KEY
1 Blind flange
2 Flue gas duct flange
3 Fixing screw
4 Gasket ø 125/95
5 Intake duct collar
TABLE 4
Accessories ø 80
90° elbow MF
45° elbow MF
Extension L. 1000 (horizontal)
Extension L. 1000 (vertical)
Outlet terminal
Inlet terminal
Doubler fitting
Roof outlet terminal L.1240
Inlet
0,30
0,20
0,20
0,30
–
0,10
0,30
–
Head loss (mm H
2
O)
Outlet
0,50
0,40
0,40
0,30
0,40
–
–
–
Roof outlet
–
–
–
–
–
–
–
0,60
Fig. 8
Fig. 7
2.6
SEPARATE PIPES ø 80
(Optional alternative twin pipe system)
A special kit may be used to separate the flue gas outlet from the fresh air intake.
The intake may be installed to the right or left of the flue gas outlet. Both ducts may be oriented in any direction. Refer to fig. 7 for positioning.
The maximum overall length of the intake and exhaust ducts depends on the head losses of the single fittings installed
(excluding the doublers) and must not be greater than 13 mm H
2
O. For head losses in the fittings, refer to Table 4.
NOTE:
To use only special accessories for condensing boilers.
2.6.1
Separate pipe accessories
Kit code 8089907 is supplied for this purpose (fig. 8).
2.8
ELECTRICAL CONNECTION
The boiler is supplied with an electric cable.
Should this require replacement, it must be purchased exclusively from SIME.
The electric power supply to the boiler must be 230V - 50Hz single-phase through a fused main switch, with at least 3 mm spacing between contacts.
Respect the L and N polarities and the earth connection.
NOTE:
SIME declines all responsibility for injury or damage to persons, animals or things, resulting from the failure to provide for proper earthing of the appliance.
2.8.1
Electrical board (fig. 12)
Prior to any operation, always turn off the power supply. Remove the three screws (7) fixing the control board, and pull forward the panel until it tilts downwards. In order to gain access to the electrical board components, unscrew the four screws (6) fixing the control panel cover.
2.8.2
Room thermostat
(fig. 12)
After having removed the jumper, connect electrically the room thermostat to terminals 1-2 of the junction box (5).
In order to have better room comfort and temperature control, we suggest you to use a room thermostat belonging to
Class II, as specif ied by s t andar d
EN60730.1 (clean contact).
ATTENTION: After having removed the three screws (7) tilt the panel downwards to gain access.
7
5
3 4
6
1 2
KEY
1 Pressure/temperature gauge
2 Heating programmer (optional)
3 Earth faston
4 Main electronic board
8
5 9 pole terminal strip
6 Control panel cover
7 Fixing screw
8 Selector OFF/SUMMER/WINTER/RESET
Fig. 12
7
2.8.3
Wiring diagram
90
°
LIMIT
THERMOSTAT
OPTIONAL
J9
J10 J13 J4
J8
J7
95
°
SMOKE
STAT
100
STAT
°
SAFETY
J3
J6 J5
8
NOTE:
– The room thermostat may be connected to the terminals 1-2 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
JP1 - DELAY CANCELLATION*
JP2 - DIVERTOR VALVE/D.H.W. PUMP
POSITION AND FEATURE
CLOSED OPEN
Ignition delay cancelled
Use with div. valve
Ignition delay operating
Use with boiler pump
SUPPLY POSITION
Open
Closed
*
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 overcome the problem of repeated ignitions and turning off with very short time intervals between. This could occur in particular in systems presenting high head losses. At each restart after the period of slow ignition, the boiler will set itself for about 1 minute at the minimum modulation pressure, and will then move to the heating pressure value set.
Fig. 13
2.9
TIME PROGRAMMER (optional)
The control panel is designed to allocate a timer-programmer, code 8092214 (digital time clock 1 channe) or code 8092213
(mechanical 24 Hour time clock), which can be supplied upon request.
To fit the timer, remove the housing blanking piece from the control panel and, with the panel open, fit the timer to the panel using the screws supplied therein (see fig.
13/a).
Fig. 13/a
3 CHARACTERISTICS
3.1 ELECTRONIC BOARD
The electronic board is manufactured in compliance with the EEC 73/23 low-voltage directives. It is supplied with 230V. The electronic components are guaranteed against a temperature range of 0 up to
+60° C. An aut omatic and continuous modulation system enables the boiler to adjust power to the various system requirements or the user’s needs.
3.1.1 Fault and malfunction signaling
The indicator LEDS signaling irregular and/or incorrect operation of the equipment are indicated in fig. 16.
3.1.2 Devices
The electronic board is equipped with the following devices (fig. 15):
– “POT. RISC.” trimmer (pos. 6)
Sets the maximum heating power value.
To increase the value turn the trimmer clockwise; to reduce the value turn the trimmer anticlockwise.
– “POT. ACC.” trimmer (pos. 3)
Trimmer to vary the pressure level upon ignition (STEP), of the gas valve. It has been factory set with ignition STEP at 95
Hz. To increase pressure, turn the trimmer clockwise; to reduce pressure, turn the trimmer counterclockwise. The slow
Bi-colour led 1
Bi-colour led 2
Operating mode
Stand-by
Flame presence
Flame detection circuit fault
Ignition lock
Water flow switch (FL) or limit stat (TL) intervention
Fan fault
C.H. sensor (SM) fault
Boiler off
Bi-colour led 1
green ON green ON green ON
OFF flashing orange flashing green steady orange
OFF
Bi-colour led 2
OFF orange ON flashing orange red ON
OFF
OFF
OFF
OFF
Fig. 14 ignition pressure level can be set during the first 7 seconds following burner ignition discharge. After setting the pressu-
re level upon ignition (STEP) according to the type of gas, check that the gas pressure for heating is still at the value previously set.
– “JP1” connector (pos.10)
In the heating phase, the electronic board is programmed to include a burner technical delay interval of approx.
180 seconds, which occurs at every ignition after a forced stop.
By “forced stop”, we indicate a stop due
8 6 4
2
5
3
1
9
7 11 2 10
NOTE: To gain access to the regulating trimmers (2-3-4-6) remove the C.H. potentiometer knob.
6 4 3
KEY
1 Bicolour led 1
2 MAX fan speed trimmer
3 Ignition power trimmer
4 MIN fan speed trimmer
5 Bicolour led 2
6 Heating power trimmer
7 D.H.W. potentiometer
8 Fuse (1,6 AT)
9 JP2 connector
10 JP1 connector
11 C.H. potentiometer
Fig. 15
9
10 to a sensor (SM) temperature difference of more than 5°C to temperature set at heating potentiometer.
The aim is to overcome the problem of repeated ignitions and turning off with very short time intervals between. This could occur in particular in systems presenting high load losses. At each restart after the period of slow ignition, the boiler sets itself for about 1 minute at the minimum modulation pressure, and then moves to the heating pressure value set.
When the jumper is inserted, both the programmed technical pause and the period of operation at minimum pressure in the startup phase are cancelled. In this case, the times elapsing between turning off and subsequent re-ignition will depend on a temperature difference of
5°C detected by the SM sensor (heating flow sensor).
– “JP2” connector (pos. 9)
Must be fitted.
– “MAX” fan maximum speed
trimmer (pos.2)
To set fan at a maximum speed.
– “MIN” fan minimum speed
trimmer (pos.4)
To set fan at a minimum speed.
ATTENTION: It is essential that all operations described above are carried out by authorized technical staff. If not, the warranty is invalid.
3.3.1 Operating cycle
Rotate the selector knob to summer or winter, and verify that green LED ( ) lights up to confirm the presence of voltage.
The burner must be ignited within 10 seconds max.
However, it is possible for ignition failures to occur, with consequent activation of “locked out” signal:
– Gas failure
The electrode continues spark discharge for a maximum of 10 sec. If the burner does not light, the board - after a 5 second ventilation stop - reactivates discharge for further 10 seconds. This cycle will be repeated 5 times, after that, the lock-out red LED will light up.
This may occur upon first ignition or after long periods of boiler lay-off when there is air in the pipes.
It may be caused by the gas cock being closed or by one of the valve coils having a break in the winding, so that the valve cannot open.
– Ignition electrode fails to spark
The electrode continues spark discharge for a maximum of 10 sec. If the burner does not light, the board - after a 5 second ventilation stop - reactivates discharge for further 10 seconds. This cycle will be repeated 5 times, after that, the lock-out red LED will light up.
This may be due to a break in the wire of the electrode or to the wire not properly fastened to the ignition transformer terminal.
The electrode itself may touch earth or may be heavily worn out and needs repla-
3.2 TEMPERATURE SENSOR
Antifreeze system managed by active heating NTC sensor when water temperature is 6°C. The heating sensor works also as a limit thermostat which switches off the burner when temperature is over 80°C. Reset temperature is set at 75°C. When sensor
(SM) is interrupted, neither of the boiler's heating services will function.
Table 5 shows the resistance values (
Ω
) obtained on the heating sensor as the temperature varies.
TABLE 5
Temperature (°C)
20
30
40
50
60
70
80
Resistance (
Ω
)
12.090
8.313
5.828
4.161
3.021
2.229
1.669
3.3 ELECTRONIC IGNITION
Ignition and flame detection is controlled by a sole electrode located on the burner. It guarantees maximum safety with intervention times, for accidental switching off or gas failure, within one second.
500
400
300
200
100
0
200 400
cing. The electronic board is defective.
When there is a sudden voltage failure, the burner shuts down immediately; when the power supply returns, the boiler will start up again automatically.
3.4 FLOW SWITCH
SAFETY VALVE
A flow switch safety valve (8 fig. 2) intervenes, blocking the operation of the burner if the boiler is without water due to the formation of air bubbles in the heat exchanger or if the circulator is not working correctly or because the “Aqua Guard” heating circuit filter is clogged.
3.5 SYSTEM
AVAILABLE HEAD
The head available for the heating plant is shown as a function of the flow in graph in fig. 16. To obtain the maximum head available to the system, turn off the by-pass by turning the union to the vertical position
(fig. 16/a).
3.6 ELECTRICITY
CONNECTION
FOR ZONE SYSTEMS
To realize this kind of system, use a separate electricity supply to connect the room thermostats and relative zone valves.
The micro or relay contact connection has to be made to 1-2 connectors of the 9-pole junction box after having removed the jumper (fig. 17).
600 800 1000 1200
FLOW RATE (l/h)
Fig. 16
D.H.W. FLOW RATE ADJUSTER
2 1
CR
CR
1
Fig. 16/a
L
TA TA
1
N
VZ
R VZ
1
R
1
KEY
TA-TA1 Zone room stat
VZ-VZ1 Zone valves
R-R1 Zone relay
CR-CR1 Zone microvalve or relay contact
Fig. 17
11
4 USE AND MAINTENANCE
SIME SUPPORT
THE BENCHMARK INITIATIVE
All relevant sections of the logbook must be filled in at the time of installation and thereafter service information on the back page of the logbook. Commissioning of the boiler is not complete until the logbook is filled in.
4.1
FILLING THE WATER SYSTEM
– Open the flow and return valves (27 -
28 fig. 2).
– Loosen the automatic air vent cap (13-
21 fig. 2).
– Open all radiator valves and system air vents. Fill the system with water using one of the approved methods described in section 2.3.2 t o about 0.5 bar greater than the system design pressure. Close all air vents. Do not close the A.A.V. (13-21 fig. 2).
– Check the system for water soundness.
– Completely drain the appliance and heating system, thoroughly flush the system, and refill the system design pressure.
– Before refillimg check and clean the Aquaguard filter (4.9).
4.2
GAS VALVE
The boiler, is equipped standard with the
HONEYWELL VK 4115V gas valve (fig. 18).
Puntatori tester inseriti sui morsetti "HS" per la terminals in order to measure Hz misura degli Hz al ventilatore
TABLE 6
Hertz
70
90
110
130
150
185
Pressure mbar
1.24
2.05
3.06
3.71
4.94
7.52
Heating output
(80/60°C) kW (50/30°C) kW
10.2
10.7
11.3
16.1
14.6
16.6
20.5
29.4
18.2
22.5
26.7
32.1
Fig. 19
1 5 2
4
3
KEY
1 Regulation intake
2 EV1-EV2 coils
3 Pressure inlet upstream
4 Pressure inlet downstream
5 OFF-SET
Fig. 18
12
4.3
ADJUSTMENT OF
HEAT OUTPUT
FOR HEATING
To adjust boiler heat output for heating purposes, i.e., modifying the setting made at the factory which is approximately 17 kW, use a screwdriver to adjust the heating heat output trimmer (6 fig. 15). To increase wor king pr essur e, tur n t he tr immer clockwise; to reduce pressure, turn the trimmer counterclockwise. To determine boiler heat output setting (for both natural gas and propane gas), check Hertz value shown in Table 6 (fig. 19) or check the pressure connect the positive of the manometer to the gas test point (6 fig. 3).
4.4 CALIBRATION PROCEDURE
IN HEATING PHASE
USING HERTZ (fig.20)
1) Turn heating manometer knob to maximum. Check that water temperature at heating system is lower than 75°C.
2) Turn the trimmer (6) anti-clockwise as far as it will go to minimum power.
3) Open completely the gas capacity step
(7) by turning the screw anti-clockwise until end of stroke.
4) Adjust trimmer (4) and check that Hertz value is between 68 and 72.
5) Adjust the gas valve OFF-SET (8) in order to achieve a C0
2 value of 10.8% for natural gas or of 10.9% for propane. To increase C0
2 value, turn the screw clockwise; to reduce it turn the screw anti-clockwise.
6) Adjust gas capacity step (7) in order to achieve a C0
2 value of 8.9% for natural gas or of 9.8% for propane. To reduce
C0
2 value, turn the screw clockwise.
7) Go to maximum power by turning clockwise trimmer (6) as far as it will go.
8) Adjust the trimmer (2) and check that the Hertz value of the fan is between
172 and 176b.
9) Check that C0
2 value is approx. 9.0% for natural gas or 10.0% for propane. In case the value would not be correct, repeat calibration procedure as mentioned in point 4.
4.5
CALIBRATION PROCEDURE
IN HEATING PHASE USING MBAR
1) Adjust air pressure (fan speed)
Connect the positive of the manometer to the positive test point of sealed chamber (7 fig. 3). Disconnect the SM sensor and connect a loose one free in air, or activate the chimney sweep function
(4.11).
Sequence (Fig. 20)
– Turn the heating output potentiometer to maximum output.
– Turn the heating output trimmer B to minimum.
– Adjust the minimum air pressure using fan speed trimmer A.
– Turn the DHW output potentiometer to maximum.
– Fully open a domestic hot water tap.
– Adjust the maximum air pressure using fan speed trimmer D (2 fig. 20).
AIR PRESSURE
Minimum Maximum
(mm H
2
O)
12.5/13.5
(mm H
2
86/88
O)
2
2) Adjust gas pressure
Connect the positive of the manometer to the gas test point (6 fig. 3).
Sequence (Fig. 20)
– Turn heating output potentiometer to maximum output.
– Turn the heating power trimmer B to minimum.
– Adjust the minimum gas pressure using the OFF-SET (8) on the gas valve.
– Turn the DHW output potentiometer to maximum output.
– Fully open a domestic hot water tap.
– Adjust the maximum gas pressure using the gas valve shutter (7).
GAS PRESSURE
Minimum Maximum
(mm H
2
O)
10.5/11.5
(mm H
2
69/71
O)
CO
2
VALUE %
Minimum output
Maximum output
Natural gas
8.7/9.3
8.7/9.3
LPG
9.7/10.3
9.7/10.3
– To adjust CO
2 at maximum output adjust the gas valve OFF-SET.
– To adjust CO
2 at minimum output to ajust the gas valve shutter.
VERY IMPORTANT:
It’s not necessary to adjust the gas pressure or the fan speed should the boiler be converted to another gas (ie natural gas to
LPG) only the injector will require changing.
4.6
GAS CONVERSION
A kit complete with instructions for transformation is supplied for G31 propane gas conversion.
4.7
DISASSEMBLY OF
EXPANSION VESSEL
To disassemble the expansion vessel, proceed as follows:
– Make sure that the water has been emptied out of the boiler.
– Unscrew the connection and the locknut.
– Remove the expansion vessel.
Before refilling the system, using a pressure gauge attached to the valve make sure that the expansion vessel is preloaded at a pressure of 0.8 to 1 bar.
7
1
6
8
4
KEY
2 MAX fan speed trimmer
4 MIN fan speed trimmer
6 Heating power trimmer
7 Shutter
8 OFF-SET
2
Fig. 20
Fig. 21
4.8
REMOVAL OF
OUTER CASING
It is possible to completely disassemble the shell for an easy maintenance of the boiler as showed in fig. 21.
4.9
CLEANING AND
MAINTENANCE
Preventive maintenance and checking of efficient operation of equipment and safety devices must be carried out exclusively by authorized technical personnel.
4.10
CLEANING THE C.H. WATER FILTER
“AQUA GUARD” (fig. 22)
To clean the filter, close the flow/return valves, turn off the power to the control panel, remove the casing and empty the boiler using the drain provided until the hydrome-
13
ter shows “zero”. Place a container for collection underneath the filter, unscrew the cap and proceed to clean the filter, removing impurities and limestone deposits.
Check the seal o-ring before reassembling the cap with the filter.
Fig. 23
Fig. 22
4.11
CHIMNEY SWEEP FUNCTION
(fig. 23)
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 hotwater service functioning.
To do so it is enough, after having activated the chimney sweep function, to take some hot water from one or more cocks.
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.
ATTENTION: After about 15 minutes, or once the hot water request has been fulfilled, the chimney sweep function automatically deactivates.
5 FAULT FINDING
If an electrical fault occurs on the appliance the preliminary electrical system checks contained in the British Gas Multimeter
Instruction Booklet must be carried out first. 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.
14
5.1
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 1
Ω
(ohm). If the resistance is greater than 1
Ω
(ohm) check all earth wires for continuity and all contacts are clean and tight. If the resistance to earth is still greater than 1
Ω
(ohm) then this should be investigated futher.
5.2
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.
5.3
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.
5.4
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 5.1 Earth continuity, 5.3 Polarity and 5.4 Resistance to earth must be repeated.
5.5
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 (if fitted).
Is there power at the external socket?
Yes
Is fuse at mains plug OK?
No
Replace fuse in mains plug
No
Put a jumper on the room thermostat connection
No
Is there a jumper on the room thermostat connection?
Yes
Yes
Check pump connection
Make power available
Yes
Replace the fuse
No
Is fuse
0,6 A OK?
No
Does the pump start?
Yes
No
Is the clock in the correct band time?
Yes
No
No
Check the time clock does his contacts open and close when the clock turns?
Yes
Is there voltage available to the pump?
Yes
Turn the clock in the right position
Replace the clock
Make it free to rotate
No
Is pump shaft free to rotate?
Replace the pump
Yes
No
Does the fan start?
Yes
No
Is there voltage available to the fan?
Yes
Replace the fan
Check the power supply cable
Does the boiler remain in pre-purge mode?
No
Yes
Is limit thermostat calling for heat?
Yes
Is the micro-switch on the diverter valve locked?
No
Does the micro-switch operate correctly?
No
No
Yes
Yes
Replace the microswitch
Replace the limit thermostat
Loose the screw on the flow switch cover
Check the connections of: limit thermostat and flow switch in the PCB control board
Fit correctly the ignition electrode
No
The gap between ignition electrode and hood is correct?
Yes
Check for continuity between ignition electrode and ignition transformer
No
Check the gas supply
Check the connection on the fan PCB
Does the boiler lock-out without starting the burner?
No
Yes
Is there a spark at the ignition electrode?
Yes
Is the gas available?
Yes
No
Is there voltage at the gas valve?
Yes
No
The boiler lock-out starting the burner
Yes reverse polarity between phase and neutral
No
The ignition of the burner is noisy
Yes
Check the settings of the gas valve and “POT. ACC.” trimmer
Replace the gas valve
No
No
Does the fan speed decrease reducing the flow temperature setting on the C.H. knob?
Check:
2) C.H. thermistor
3) PCB control board
Yes
No
Does the boiler switch
OFF before achieving the temperature?
Yes
Boiler is satisfactory
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.
15
5.6
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.
No
Is there power at the external socket?
Yes
Is fuse at mains plug OK?
No
Yes
Replace fuse in mains plug
Make power available
No
Clean or replace the divertor valve
Open any tap.
Is there an adequate flow rate of D.H.W.
available?
Yes
Does the microswitch of the divertor valve operate correctly?
No
Yes
Replace the microinterruptor
Yes
Check pump connection
Does the pump start?
No
Is there voltage available to the pump?
No
Is fuse
0,6 A OK?
Yes
Yes
Replace the fuse
No
Make it free to rotate
No
Is pump shaft free to rotate?
Replace the pump
Yes
No
Does the fan start?
Yes
No
Is there voltage available to the fan?
Yes
Replace the fan
Check the power supply cable
Does the boiler remain in pre-purge mode?
No
Yes
Is limit thermostat calling for heat?
Yes
Is the micro-switch on the diverter valve locked?
No
Does the micro-switch operate correctly?
No
No
Yes
Yes
Replace the microswitch
Replace the limit thermostat
Loose the screw on the flow switch cover
Check the connections of: limit thermostat and flow switch in the PCB control board
No
Fit correctly the ignition electrode
No
The gap between ignition electrode and hood is correct?
Yes
Check for continuity between ignition electrode and ignition transformer
No
Check the gas supply
Check the connection on the fan PCB
Does the boiler lock-out without starting the burner?
The boiler lock-out starting the burner
Yes
Is there a spark at the ignition electrode?
Yes
Yes
Yes
Is the ionisation probe connected to the main PCB?
No
No
Is the gas available?
No
Yes
Is there voltage at the gas valve?
Restore the connection
Fit correctly the ionistation probe
Yes
No
The ignition of the burner is noisy
No
Yes
Check the settings of the gas valve and “POT. ACC.” trimmer
Replace the gas valve
Does the fan speed decrease reducing the flow temperature setting on the
D.H.W. knob?
Yes
Does the boiler switch
OFF before achieving the temperature?
No
No
Yes
Check:
2) C.H. thermistor
3) PCB control board
Boiler is satisfactory
16
NOTE:
When commissioning the boiler, please check the polarity in case the pump and the fan are running but the burner does not fire.
6 REPLACEMENT OF PARTS
6.1
EXPANSION VESSEL
– Turn off power supply
– Remove boiler cover
– Isolate flow and return valve
– Drain boiler using fitted drain vent
– Disconnect expansion èipe
– Loosen top fixing screw and remove lower fixing screw
– Remove vessel
– Check new vessel for correct pressure
1-1.25 bar
– Refit in reverse order.
6.2
IGNITION/IONISATION
ELECTRODE
– Turn off power supply
– Remove boiler cover
– Remove sealed cover
– Disconnect electrode from ignition transformer
– Pull lead through grommet
– Remove electrode fixing screw
– Replace in reverse order.
6.3
MAIN BURNER
– Turn off power supply
– Isolate gas supply
– Remove boiler cover
– Remove sealed chamber cover
– Disconnect gas connection at injector
– Disconnect air sensing tube
– Disconnect two plugs to fan
– Remove ignition/ionisation electrode as described in 6.2
– Remove 6 x 10 mm nuts securing burner to heat exchanger
– Carefully lift out burner assembly
– Refit in reverse order
– Test for gas soundness.
6.4
FAN ASSEMBLY
– Remove burner assembly as described in 6.3
– Remove 4 x 8 mm bolts securing fan to burner assembly
– Refit in reverse ensuring injector assembly is fitted with arrow pointing from fan to burner
– Recommision boiler
– Test for gas soundness.
6.5
MAIN HEAT EXCHANGER
– Turn off power supply
– Isolate gas supply
– Isolate flow and return valves
– Drain boiler using drain vent
– Remove burner assembly as described in 6.3
– Remove flue connection
– Disconnect 95° stat
– Disconnect 90° stat
– Remove condensate drain connections
– Remove upper auto air vent
– Disconnect flow and return connections
– Remove two fixing brackets
– Lift out heat exchanger
– Refit in reverse order
– Recommission boiler
– Test for gas soundness:
6.6
95° SMOKE STAT
– Turn off power supply
– Remove boiler cover
– Remove sealed chamber cover
– Disconnect 95° stat
– Unscrew from smoke chamber
– Refit in reverse order.
6.12
PRINTED CIRCUIT BOARD (PCB)
– Isolate from power supply
– Remove screws securing control panel
– Lower panel to horizontal position
– Remove PCB cover
– Disconnect all wiring
– Remove heat control knobs
– Remove PCB fixing screws
– Transfer trimmer spindles to new board
– Ensure PCB links are matched to old board
– Refit in reverse order
– Recommission boiler.
6.7
90° LIMIT STAT
– Turn off power supply
– Remove cover
– Remove sealed chamber cover
– Disconnect 90° stat
– Unscrew stat
– Replace in reverse order.
6.8
100° SAFETY STAT
– Turn off power supply
– Remove cover
– Remove sealed chamber cover
– Disconnect 100° safety stat
– Remove fixing screws
– Refit in reverse order.
6.13
PUMP MOTOR
– Turn off power supply
– Remove boiler cover
– Isolate flow and return valves
– Drain boiler using drain vent
– Remove plug connection
– Remove 4 x fixing screws, catch any lost water
– Refit in reverse using new gasket.
6.14
DIVERTER VALVE MICROSWITCH
– Turn off power supply
– Remove boiler cover
– Pull off microswitch in direction of wiring
– Refit in reverse.
6.9
THERMISTOR
(SM SENSOR)
– Turn off power supply
– Remove cover
– Isolate flow and return valves
– Drain boiler using drain vent
– Disconnect thermistor
– Unscrew thermistor (catch any water lost)
– Refit in reverse.
6.10
GAS VALVE
– Turn off power supply
– Isolate gas supply
– Remove boiler cover
– Disconnect wiring from gas valve
– Disconnect sensing tube
– Remove gas valve complete with gas shutter
– Split gas shutter from gas valve
– Refit in reverse order ensuring seals are replaced as required
– Recommission boiler
– Check for gas soundness.
6.11
GAS SHUTTER
– As gas valve 6.10.
6.15
DOMESTIC HOT WATER
HEAT EXCHANGER
– Turn off power supply
– Isolate flow and return
– Turn on DHW tap
– Close cold water supply isolation valve
– Drain boiler using drain vent
– Remove diverter valve microswitch as described in 6.14
– Remove microswitch actuator from top of diverter valve
– Remove 3 x heat exchanger fixing screws
– Remove plate heat exchanger, catch any water lost
– Ensure that the four “0” rings are removed from the technil assembly
– Fit the new “0” ring supplied with the new heat exchanger to the heat exchanger
– Refit in reverse order.
6.16
DIVERTER VALVE
– Remove diverter valve microswitch as described in 6.14
– Remove plate heat exchanger as described in 6.15
– Remove plug securing clip at RHS of diverter assembly. NOTE: a internal spring will push off the plug. Retain.
– Remove internal bush from spindle
– Remove diverter valve head securing
17
18 clip
– Pull diverter valve head from assembly
– Remove spindle from assembly complete with bush and spacer
– Replace in reverse order replacing “0” rings as required.
– Drain boiler using drain vent
– Remove AAV
– Replace in reverse order.
6.17
TOP AUTO AIR VENT (AAV)
– Turn off power supply
– Isolate flow and return valves
– Drain boiler using drain vent
– Unscrew AAV
– Refit in reverse.
6.19
SAFETY VALVE
– Turn off power supply
– Isolate flow and return valves
– Remove boiler cover
– Drain boiler using drain vent
– Disconnect pipe from safety valve
– Remove safety valve securing clip
– Remove safety valve, catch any water lost
– Refit in reverse.
6.18
INTERNAL AUTO
AIR VENT (AAV)
– Turn off power supply
– Isolate flow and return valves
– Remove boiler cover
6.20
PRESSURE/TEMPERATURE
GAUGE
– Turn off power supply
– Isolate flow and return valves
– Remove boiler cover
– Drain boiler using drain vent
– Remove the clip securing the pressure sensor
– Remove the clip securing thermometer bulb
– Carefully remove the gauge
– Refit in reverse order.
7 EXPLODED VIEWS
7.1
HYDRAULIC CIRCUIT
27 36
17
Position Code
6 6226429
Description
O-ring 121
10
11
6277202
6146301
Water trap
Brass nut 1/2”
12
17
42
41
42
46
47
45
43
6
49
48
91
44
45
88
12
108
11
10
111
31
113
92
117
116
118
101
89
99
100
107
53
38
52
98
65
94
115
65
96
46
112
45
95
51
41
41
40
114
45
95
39
54
41
65
69
6281513 Flow water switch spare parts
6278906 Main exchanger body
27 6146721 Limit stat
31 • 6226414 O-ring 117 Ø 13,1x2,62 EP851
36
38
39
40
41 • 6226412 O-ring 3068
43
44
45
51
52
6013102 Automatic air vent 1/4”
6100202 Ogive for pipe Ø 15
5183711 Rectang. expansion vessel 8 l. 1/2” M
6227418 Heat exchanger outlet pipe
6277712
6295500
6277711
6226607
Pipe connect. exchanger-C.H filter
C.H. filter 3/4”M x 3/4”M
Pipe connect. C.H. filter-C.H. flow
2030228 Gasket Ø 17x24x2
46 • 6226601 Spring for heat exchanger connection
47 • 6146701 100°C safety stat
48 • 6022010 Sensor gasket
49 • 6231351 Plunged sensor
Pipe fixing spring
6168401 Locking nut for pipe Ø 15
53 • 6040201 Pressure relief valve
54 • 6226602 Pipe fixing spring
Fig. 24
Position Code
65 2030227
Description
Gasket Ø 12x18x2
69 6227652 Pipe connecting expansion vessel
88 • 6131401 Microswitch for flowmeter
89
91
92
94
5191900
2051100
6226605
6142330
Divertor valve microswitch + support
Retaining spring
Fixing spring
Quarter bend 1/2” x 15
95
96
98
99
6177505 Ball cock 3/4” x 22
6177506 Ball cock 1/2” x 15
6157602 Pressure relief valve drain pipe
6272304 Circulating pump VA 65 Dab motor
100 • 6028705 Gasket EP709 for Dab
101 2000201 Screw M5x40
107
108
6281521
6034152
Flange + OR for Dab pump
Condensate drainage rubber pipe
111
112
6226421 O-ring Dalmar R12
6281522 14 plate heat exchanger kit
113 • 6013101 Automatic air vent
114 6281500 Straight fitting 3/4”
115 • 6017210 Manual air vent 1/4”
116 6281501 Straight fitting 1/2”
117 6281512 Water rate adjuster
118 • 6281504 Divertor valve
19
7.2
COMBUSTION CIRCUIT
5
8
71
70
13
7
66
15
67
20
20
19
23
22
21
26
25
109
110
18
Position Code
5 6266037
Description
Sealed chamber rear panel
7
8
6266122
6266123
Sealed chamber left hand side panel
Sealed chamber right hand side panel
33
34
35
37
28
29
30
32
22
23
25
26
18
19
20
21
13
14
15
16
5192200
6278701
6248851
6248852
6269006
6278851
2010183
6278305
6174817
6278802
6174809
6221625
Gasket for sealed chamber
Smoke chamber
Smoke chamber outlet gasket
Smoke chamber/exchanger gasket
Combustion chamber door insulation
Main exchanger door
Nut for exchanger flange
Premix burner
Gasket for burner flange
Air-gas hose
Gasket for ignition electrode
Ignition-ionisation electrode
6174812 Mixer/hose gasket
6274307 Air/gas mixer
6274124 Burner nozzle ø 7,00 natural gas
6261403 Fan RG128/1300-3612
6028642 Air diaphragm
6174816 Gasket for fan flange
2000507 Screw TE M5x50
5191990 Smoke stat kit
37
68
34
35
28
106
16
14
28
64
57
30
29
45
65
63
62
61
58
56
60
59
80
33
32
55
50
97
Fig. 30/a
Position Code
45 2030228
Description
Gasket Ø 17x24x2
50
55
6146302
6120515
Brass nut 3/4”
Straight fitting 3/4”
56
57
6226861 Gas inlet pipe
6023100 Pressure test nipple Ø 1/8”
58 • 6162401 Square gasket
59 2000710 Screw TCB M4x10 Zn
64
65
66
67
60
61
6243821 Honeywell gas valve type VK4115V
6235802 Pressure test point M5
62 6216607 Gas shutter 1/2”
63 • 6226407 O-ring 130 ø 22,22x2,62 XP70
6277403
2030227
6280500
6280550
Pipe connecting gas valve-mixer
Gasket Ø 12x18x2
3-ways junct. with press. test nipple
Cap for 3-ways junction
97
106
109
110
68
70
6146303 Brass Nut 1/8”
6228847 Sealed chamber front panel
71 6001210 Peephole
80 • 6098304 Ignition transformer
6177504
6239206
6278968
6278967
Gas cock 1/2” x 1/2”
Mixer closing plate
Glass fibre sealing cord
Combustion chamber O-ring
7.3
STRUCTURAL COMPONENTS AND CONTROL & REGULATIONS
2
3
9
93
102
90
74
105
72 77
84 104
Position Code
1 6138532
Description
Right hand side frame part
2
3
6138632
6255430
Left hand side frame part
Expansion vessel lower support
4
9
72
73
6138870
6189543
6289803
6273210
Frame assembly lower side
Expansion vessel supporting bracket
Control panel
Guidelight - 2 ways out
74
75
6217005 Temperature and pressure gauge
6230692 Main PCB with ignition
76 • 6201501 Trimmer spindle Ø 5
77 • 6260701 Rotary switch
78 • 6201505 Trimmer spindle Ø 6
79 2211610 Earth faston
83
87
81
78
79 85
73 78
76
75
82
86
1
4
Position Code
81 6289900
Description
Control panel protecting cover
82
83
6290300
6290202
Control panel cable cover
Room stat cover
84
85
86
87
6290100
6009585
2211004
6290350
White knob Ø 40
Control panel bracket
Terminal strip
Terminal strip protection cover
90
93
6290010 Flap door
6287323 Casing
102 • 2013302 Fastener for self tapping screw
104 6112420 Control panel screw
105 2004510 Screw 8Px7/8”
Fig. 30/b
21
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: [email protected]
GB
PLEASE LEAVE THIS INSTRUCTION
WITH THE USER
Format 30 HE
User instructions
CONTENTS
OPERATING INSTRUCTIONS FOR THE USER
1.1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2
APPLIANCE OPERATION
1.3
OPERATING INSTRUCTIONS
1.4
MINIMUM CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5
ROUTINE SERVICING
1.6
GENERAL INFORMATION
1.7
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
These appliances comply with the S.E.D.B.U.K. scheme, band “D”
VERY IMPORTANT!
PLEASE MAKE SURE YOUR LOG BOOK ENCLOSED IS FILLED IN CORRECTLY.
ALL CORGI REGISTERED INSTALLERS CARRY A CORGI ID CARD.
BOTH SHOULD BE RECORDED IN YOUR CENTRAL HEATING LOG BOOK.
YOU CAN CHECK YOUR INSTALLER IS CORGI REGISTERED
BY CALLING ON 01256 372300
1
2
OPERATING INSTRUCTIONS FOR THE USER
THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS
1996. 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.
It is essential that the appliance is correctly earthed. An electricity supply of 240 V - 50 Hz fused at 3 A is required.
Read these instructions carefully before attempting to operate the appliance.
the draw off rate is near the maximum design flow rate the appliance will run continuously at full output until a tap is either turned off or the flow rate is reduced in which case the heat output will reduce accordingly to maintain a steady temperature.
Hot water is made available almost immediately at the appliance outlet, but the final temperature and time taken for the hot water to reach a tap depends upon the potentiometer setting, the rate at which water is drawn off, and the length of the pipe between the boiler and the tap.
When the tap is turned off, the appliance will revert to C.H.
mode (if set on winter position) otherwise the burner will be extinguished pending the next demand for hot water.
1.1
INTRODUCTION
The Sime “FORMAT 30 HE” family is a fully automatic, wall mounted, room sealed, fan assisted range of combination boilers. When operating in winter mode, the appliance provides central heating as required and produces instantaneous hot water upon demand.
When operating in summer mode, the central heating is not operational however the appliance continues to supply hot water whenever it is required. The heat output is automatically controlled by the fully modulating gas valve (within its preset limits), and there are user adjustable potentiometers to control the temperature of both central heating and domestic hot water. A temperature/pressure gauge is fitted and an overheat thermostat is incorporated to protect against fault conditions.
1.2
APPLIANCE OPERATION
A demand of hot water will be sensed by the appliance detecting water flow (providing that the flow rate is above 2 l/m - 0.5 gal/min).
The fan will start and the burner will light at full output. If
1.3
1.3.1
OPERATING INSTRUCTIONS
To light the appliance (see fig. 1)
– Check that the electricity supply is off and that the D.H.W.
isolation valve is in the open position (lever vertical). Check that the gas supply is on.
– Turn the selector switch summer/winter (C) to SUMMER
(water only) position “ ”.
– Switch on the electricity supply and full open any D.H.W.
tap. The burner will light.
Check that the burner has lit by looking through the viewing window (F). If the burner fails to light, turn the selector switch summer/winter to “ “ position and release it immediately; then turn it to the SUMMER position: the burner should now light. Turn off the tap.
– Check that the room thermostat and time clock are calling for heat. Turn the heating potentiometer (D) to maximum (fully clockwise).
– Turn the selector switch summer/winter to the WINTER position “❄" and the burner will light to serve the heating load.
F
A B C D E
KEY
A Temperature/pressure gauge
B Time clock (optional)
C Selector switch summer/winter
D D.H.W. thermostat
E C.H. thermostat
DHW
ISOLATION VALVE
Fig. 1
Set the required temperature for the C.H. and D.H.W. by rotating the potentiometers (D - E) clockwise to increase or anticlockwise to decrease the temperature.
NOTE: when operating in winter mode, priority is automatically given to providing hot water when the demand arises.
servicing the appliance:
ABOVE THE APPLIANCE CASING
AT THE R.H.S.
AT THE L.H.S.
BELOW THE APPLIANCE CASING
IN FRONT OF THE APPLIANCE
For ventilation For servicing
200 mm 300 mm
15 mm
15 mm
15 mm
15 mm
200 mm
350 mm
200 mm
500 mm
1.3.2 To turn off the appliance (see fig. 1)
– For short periods:
Set the selector switch (C) to the OFF position and urn off the DHW Isolation valve. When required, restore turn the selector switch to either the SUMMER or WINTER position and turn on the DHW Isolation valve.
– For longer periods:
Set the selector switch (C) to the OFF position, turn off the DHW Isolation valve, turn off the gas isolation cock.
When required, manually rotate the pump, open the gas isolation cock, turn on the DHW Isolation valve and turn the selector switch to either the SUMMER or WINTER position.
NOTE: If frost protection is required-turn the selector switch to the summer position, do not isolate the gas supply, turn off the DHW Isolation valve.
1.4
MINIMUM CLEARANCES
The following MINIMUM CLEARANCES must be available for
1.5
ROUTINE SERVICING
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 a registerd person (C.O.R.G.I.).
1.6
GENERAL INFORMATION
1.6.1
Fault finding indicators (LEDS)
The appliance is fitted with a safety cut-out thermostat. In the event of overheating this will interrupt the power supply and prevent the appliance from functioning.
If this occurs, allow the appliance to cool, turn the selector switch summer/winter to “ “ position and release it immediately, then turn it back to the previous position (see fig. 2).
If the cut-out condition is repeated, turn off the electrical supply and consult your installer or service engineer.
Bi-colour led 1
Bi-colour led 2
Operating mode
Stand-by
Flame presence
Flame detection circuit fault
Ignition lock
Water flow switch (FL) or limit stat (TL) intervention
Fan fault
C.H. sensor (SM) fault
Boiler off
Bi-colour led 1
green ON green ON green ON
OFF flashing orange flashing green steady orange
OFF
Bi-colour led 2
OFF orange ON flashing orange red ON
OFF
OFF
OFF
OFF
Fig. 2
3
4
1.6.2 Temperature/pressure gauge
The gauge (A fig. 1) on the facia panel indicates the approximate system pressure. If the normal running pressure is seen to decrease over a period of time there is a water leak and you should consult your installer or service engineer.
1.6.4 Ventilation
If the appliance is installed in a cabinet, the latter MUST NOT be used for storage purposes. Any ventilation provided for the appliance during installation MUST NOT be blocked and a periodic check must be made to ensure that the vents are free from obstructions.
1.6.3 Electrical supply
The mains plug used must be a 3 pin type to BS1363, and fused at 3 A. THIS APPLIANCE MUST BE EARTHED.
NOTE: an interruption in the electricity supply whilst the burner is alight may cause the overheat thermostat to operate. If this is suspected, turn the rotary switch to “ “ position and release it immediately, then turn it back to the previous position.
1.6.5 Cleaning
Use only a damp cloth and mild detergent to clean the appliance outer casing. DO NOT use abrasive cleaners.
TO CONNECT A PLUG
As the colour of wires in the mains lead of this appliance may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows: the wire which is coloured green and yellow must be connected to the terminal in the plug which is marked with the letter E or by the earth symbol - or coloured green and yellow; the wire which is coloured blue must be connected to the terminal marked with the letter N or coloured black; the wire which is coloured brown must be connected to the terminal marked with the letter L or coloured red.
1.7
SAFETY
It is essential that the instructions in this booklet are strictly followed for the safe and economical operation of this appliance. The appliance functions as a fan assisted balanced flue unit. The flue terminal MUST NOT BE OBSTRUCT-
ED under any circumstances. If damaged, turn off the appliance and consult the installer, service engineer, or gas supplier. If it is known or suspected that a fault exists on the appliance it MUST NOT be used until the fault has been rectified by a competent person.
WARNING: IF A GAS LEAK IS SUSPECTED OR EXISTS,
TURN OFF THE GAS SUPPLY TO THE APPLIANCE AT THE
GAS SERVICE COCK. DO NOT OPERATE ANY ELECTRICAL
SWITCHES. DO NOT OPERATE ANY ELECTRICAL APPLI-
ANCE. OPEN ALL WINDOWS AND DOORS. DO NOT
SMOKE. EXTINGUISH ALL NAKED LIGHTS. CONTACT THE
GAS SUPPLIER IMMEDIATELY.
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.
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: [email protected]
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