UK
ENSURE THAT THESE INSTRUCTIONS ARE LEFT
FOR THE USER AFTER COMPLETION OF THE
BENCHMARK SECTION
Super Mk.II
Installation and
servicing instructions
199838
Please read the Important Notice within
this guide regarding your boiler warranty
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.
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.
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
Super 90 Mk.II:
Gas Council number 47-719-14
Super 105 Mk.II:
Gas Council number 47-719-15
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
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?
CONTENTS
1
TECHNICAL FEATURES AND DIMENSIONS
1.1
1.2
1.3
1.4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIMENSIONAL DETAILS
GENERAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2
GENERAL REQUIREMENTS FOR INSTALLATION
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
STATUTORY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BOILER POSITION
FLUE TERMINAL POSITION
VENTILATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
GAS SUPPLY
ELECTRICITY SUPPLY
EXTERNAL CONTROLS
WATER SYSTEMS - GENERAL
REQUIREMENTS FOR SEALED WATER SYSTEMS
D.H.W. SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3
INSTALLING THE BOILER
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
UNPACKING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FIXING THE BOILER MOUNTING FRAME
WATER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
HANGING THE BOILER
FLUE AND TERMINAL PREPARATION
FLUE AND TERMINAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SEPARATE DUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GAS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SAFETY VALVE CONNECTION
WIRING INSTRUCTIONS
TIME-CLOCK INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4
COMMISSIONING AND TESTING (including BENCHMARK)
4.1
4.2
4.3
4.4
4.5
4.6
FILLING THE WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COMMISSIONING THE BOILER
SETTING THE C.H. INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SETTING THE D.H.W. FLOWRATE
FINAL CHECKS
USER’S INSTRUCTIONS
5
ROUTINE SERVICING INSTRUCTIONS
5.1
5.2
MAIN BURNER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
FAN ASSEMBLY
5.3
5.4
5.5
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RE-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RE-COMMISSIONING
6
FAULT FINDING
6.1
6.2
6.3
6.4
6.5
6.6
EARTH CONTINUITY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SHORT CIRCUIT CHECK
POLARITY CHECK
RESISTANCE TO EARTH CHECK
C.H. MODE - FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
D.H.W. MODE - FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7
INTERNAL WIRING DIAGRAMS AND VIEWS
7.1
7.2
FUNCTIONAL FLOW WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
8
REPLACEMENT OF PARTS
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
8.12
8.13
8.14
8.15
8.16
8.17
8.18
8.19
8.20
8.21
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
COMBUSTION CHAMBER INSULATION
FAN ASSEMBLY
MAIN BURNER
IGNITION/DETECTION ELECTRODES
GAS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
AIR PRESSURE SWITCH
LIMIT THERMOSTAT
OVERHEAT THERMOSTAT
THERMISTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
IGNITION CONTROL BOX
DRIVER PCB
PUMP
D.H.W. HEAT EXCHANGER
DIVERTOR VALVE - COMPLETE
DIVERTOR VALVE - MICROSWITCH ASSEMBLY
C.H. EXPANSION VESSEL
PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
SAFETY VALVE
AUTOMATIC AIR VENT
TIME CLOCK
9
9.1
9.2
9.3
9.4
EXPLODED VIEWS
DIVERTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
COMBUSTION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STRUCTURAL COMPONENTS AND CONTROL & REGULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1
TECHNICAL FEATURES AND DIMENSIONS
1.1
INTRODUCTION
The Sime “Super Mk.II” are wall mounted, fan assisted balanced flue combination boilers.
The appliance is supplied suitable for use with natural gas, (an
L.P.G. model is available) 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 concentric air and flue duct
suitable for wall thicknesses up to 740 mm (29 in) although
extension duct kits are available and may be used up to a total
flue length of 3.0 m (118 in).
The combined flue and air duct can exit the boiler from either
1.2
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.
If the wall thickness is less than 0.5 m (19 in) the appliance
can be installed from inside the room without access to the
external wall although a wall liner is required.
This is available as an optional extra, and full details are given
in section 3.
The boiler can be used with a 240V room thermostat (class
II according to EN 60730.1).
DIMENSIONAL DETAILS
REAR VIEW
L mm
90 Mk.II
450
105 Mk.II
500
Fig. 1
TABLE 2 - Minimum clearances
TABLE 1 - Connections
R
M
G
E
U
8
C.H. return
C.H. flow
Gas connection
Cold water
Hot water
22 mm
22 mm
1/2 in
15 mm
15 mm
Compression
Compression
Bsp
Compression
Compression
ABOVE THE APPLIANCE CASING
AT THE R.H.S.
AT THE L.H.S.
BELOW THE APPLIANCE CASING
IN FRONT OF THE APPLIANCE
200
5
5
200
450
mm
mm
mm
mm
mm
8
1/4
1/4
8
18
in
in
in
in
in
1.3
GENERAL DATA
TABLE 3a - Nominal boiler ratings (5 minutes after lighting) for “Super 90 Mk.II”
MODE
OUTPUT
INPUT (G.C.V.)
kW
Btu/h
kW
Btu/h
CENTRAL HEATING RANGE
10.5
35,700
13.5
46,200
12.5
42,600
15.9
54,200
14.5
49,500
18.2
62,200
16.5
56,400
20.6
70,200
18.5
63,300
22.9
78,200
X**
20.6
70,200
25.3
86,200
22.6
77,100
27.6
94,200
24.6
84,000
29.9
102,200
26.6
90,900
32.3
110,200
DOMESTIC HOT WATER
Max.
26.6
90,900
32.3
110,200
Min.
10.5
35,700
13.5
46,200
*Differential measure between downstream pressure in the gas valve and depression in sealed chamber
BURNER PRESSURE*
mbar
inwg
2.4
1.0
3.8
1.5
5.1
2.0
6.4
2.6
7.7
3.1
9.0
3.6
10.3
4.1
11.6
4.6
12.6
5.1
12.6
5.1
2.4
1.0
**Factory setting
TABLE 3b - Nominal boiler ratings (5 minutes after lighting) for “Super 105 Mk.II”
MODE
OUTPUT
INPUT (G.C.V.)
kW
Btu/h
kW
Btu/h
CENTRAL HEATING RANGE
11.5
39,250
15.0
51,150
13.9
47,400
17.7
60,400
16.2
55,300
20.4
69,600
18.6
63,500
23.1
78,800
21.0
71,600
25.9
88,400
X**
23.4
79,800
28.6
97,500
25.7
87,700
31.3
106,800
28.0
95,500
34.0
116,000
30.5
104,050
36.8
125,550
DOMESTIC HOT WATER
Max.
30.5
104,050
36.8
125,550
Min.
11.5
39,250
15.0
51,150
*Differential measure between downstream pressure in the gas valve and depression in sealed chamber
BURNER PRESSURE*
mbar
inwg
2.2
0.9
3.0
1.2
4.0
1.6
5.1
2.0
6.4
2.6
7.8
3.1
9.3
3.7
11.0
4.1
12.6
5.1
12.6
5.1
2.2
0.9
**Factory setting
TABLE 4 - General specifications
Main burner injectors
Water capacity
Minimum water flow
D.H.W. flow rate
at a temperature rise of
Static head
D.H.W. pressure
Weight
Electrical supply
Internal fuses
Maximum power consumption
Maximum gas consumpt. (G20)
Max. working temperature
Integral expansion vessel capacity
90 Mk.II
13
1.3
3.4 (0.85)
2
(0.5)
No off
Dia
l
D.H.W.
mm
(gal)
l/min
(gal/min)
30°C
35°C
Minimum
Maximum
Minimum
Maximum
Empty
Total (full)
l/min
l/min
bar
bar
bar
bar
kg
kg
(gal/min)
(gal/min)
(psi)
(psi)
(psi)
(psi)
(lb)
(lb)
12.7
10.9
0.5
3.0
0.5
7.0
43
46.5
Watt
m3/h
°C
l
(ft3/h)
(F)
(gal)
155
2.72
95
7
105 Mk.II
15
1.3
3.4
(0.85)
2
(0.5)
(2.8)
14.6
(3.2)
(2.4)
12.5
(2.7)
(7.3)
0.5
(7.3)
(43.5)
3.0
(43.5)
(7.3)
0.5
(7.3)
(102)
7.0
(102)
(95)
49
(108)
(102)
52.5
(116)
230 V - 50 Hz, Fused at 3 A
Line: F 1.6 A - P.C.B.: T 100 mA
160
(96)
3.50
(123.7)
(203)
95
(203)
(1.5)
10
(2.2)
9
1.4
HYDRAULIC CIRCUIT
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Fan
Water-gas exchanger
Combustion chamber
Gas valve
D.H.W. exchanger
Divertor valve with charging
NTC sensor
100°C safety thermostat
Air relief valve
Circulation pump
Expansion vessel
Safety valve
Drain plug
Manometer
Automatic by-pass
D.H.W. filter
C.H. return cock
C.H. flow cock
D.H.W. cock
Gas cock
Limit thermostat
Frost stat
Non-return valve
Fig. 2
10
2
GENERAL REQUIREMENTS FOR INSTALLATION
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.
– 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 re-enter
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. 3.
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.
Fig. 3
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)
K Vertically from a terminal on the same wall
1,500
L
Horizontally from a terminal on the same wall
300
M Horizontally from a vertical 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.
2.3
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.
– 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
11
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.
2.7
The boiler is intended for use with a 240 V room thermostat.
The connection is made inside the control box as described in
section 3.10.
VENTILATION REQUIREMENTS
2.8
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 internal space in which the appliance is
installed.
GAS SUPPLY
– The gas supplier should be consulted at the installation
planning stage in order to establish the availability of an
adequate supply of gas.
– An existing service pipe MUST NOT be used without prior
consultation with the gas supplier.
– A gas meter can only be connected by the gas supplier or
their contractor.
– An existing meter should be of sufficient size to carry the
maximum boiler input plus the demand of any other
installed appliance. (BS6891: 1988).The gas required for
the boiler is specified in Table 4.
– The governor at the meter must give a constant outlet
pressure of 20 mbar (8 inwg) for natural gas 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
lights.
– The complete installation must be tested for gas soundness.
– It is important to assure an adequate gas supply to the
appliance. No more than 3 m of 15 mm pipe should be
used. Where the supply exceeds 3 m the pipe should be
suitably sized only reducing to 15 mm for the last 3 m prior
to the appliance.
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 mm2 (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
12
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 (Table 4). If necessary, a
pressure reducing valve must be fitted to the mains supply
before the D.H.W. inlet connection.
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. 4.
b) A minimum flow rate corresponding to a heating differential of 11°C must be obtained at all times.
c) A heating by-pass is usually only required when microbore piping is used on the system. If however condition (b)
can not be satisfied a heating by-pass should be fitted. 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. 6. 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.
Available head
(mbar)
PREVALENZA
RESIDUA
(mbar)
2.5
EXTERNAL CONTROLS (Refer to section 3.10)
600
500
2
30
conboiler
by-pass
with
by-pass
senzaboiler
by-pass
without
by-pass
1
25
25 BFT
1
25
400
Format - Planet - Open
2.4
separation in both poles, serving only the boiler and system
controls. The fuse rating should be as per the original instructions. 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).
30
2
300
200
100
0
25 BFT
200
400
600
800 1000 1200 1400 1600
1 Available Head for “90 Mk.II” model
2 Available Head for “105 Mk.II” model
Flow
rate (l/h)
(l/sec)
PORTATA
Fig. 4
TYPICAL SYSTEM DESIGN
NOTE:
– A drain cock should be installed at the lowest point of the heating circuit and beneath the appliance.
Fig. 5
ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM
METHOD 1 (complies with BS6798.1987)
METHOD 2 (complies with BS6798.1987)
NOTES:
– When it is not possible to avoid a situation where the initial system pressure and static head are equal a manually fitted top up container should be fitted as shown above.
Take note of the requirements relative to container capacity: height above system, inclusion of a non-return
valve, stop cock and automatic air vent in the feed pipe, as shown in fig. 5.
Note also the feed pipe connection is made to the heating return as close to the appliance as possible.
– The Local Water Undertaking MUST approve ALL connections between the system and a water storage cistern or water main supplying D.H.W.
Fig. 6
13
2.9.1 Pump
The available head shown in fig. 4 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).
D.H.W. SYSTEMS
bar
psi
0.5
7.3
1.0
14.5
1.5
21.8
l
gal
87
19.1
64
14.0
44
9.7
l
gal
124
27.3
91
20.0
63
13.9
2.10.1 Domestic hot/cold water supply
taps and mixing taps
The Table 6 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.
TABLE 6
All equipment designed for use at mains water pressure is
suitable.
.0833
.109
.156
2.10.2 Showers
A pressure gauge is mounted on the appliance facia panel.
Any mains pressure shower is suitable, but if the unit has a
loose head which may become immersed in bath water either
an anti-syphonage device must be fitted, or the length of the
flexible hose must be reduced so that it cannot fall closer than
13 mm (1/2 in) to the top of the bath.
2.9.4 Safety valve
2.10.3 Bidets
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
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.
2.9.3 Pressure gauge
14
2.10
– The authority of the local Water Company should be
obtained before the appliance is connected to the cold
water mains supply.
Check that the mains supply pressure is within the prescribed limits (Table 4).
If necessary, a pressure reducing valve should be fitted to
the mains supply before the D.H.W. inlet connection.
– The final 600 mm (24 in) of the mains supply pipe to the
boiler must be copper.
– A maximum D.H.W. flow rate of 10.3 l/m (2.3 gpm) (13
l/m (2.9 gpm) for “Super 105 Mk.II”) 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.
2.9.2 System volume (total water content)
Vessel charge and initial system
pressure
Total water content of system
using 7 l (1.54 gal) capacity expansion vessel supplied with appliance
(“Super 90 Mk.II”)
Total water content of system
using 10 l (2.2 gal) capacity expansion vessel supplied with appliance
(“Super 105 Mk.II”)
For systems having a larger capacity multiply the total system capacity in litres (gal) by the factor to
obtain the total minimum expansion vessel capacity required litres
(gal)
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 not include any horizontal
runs prone to freezing.
3
INSTALLING THE BOILER
3.1
UNPACKING THE BOILER
The standard appliance is supplied in three separate cardboard cartons. In addition up to two extension duct kits may
be used. If the appliance is to be installed without access to
the outside wall, the wall liner will also be required.
Unpack each carton and check the contents against the following lists:
Appliance package:
– combination boiler (assembled);
– installation and servicing instructions;
– users instructions;
–
–
–
–
–
–
–
–
–
3.2
Flue package:
– inner duct (flue outlet) c/w flue terminal and centering
springs;
– outer duct (air inlet);
– junction collar with protective metal sleeve;
– flue elbow with gasket;
– rubber sealing ring;
– aluminium ring.
Fixing jig pack:
– boiler mounting frame;
– fixing bracket.
– flue template;
– fixing screws with wall plugs;
– cardboard containing:
gas service cock;
C.H. F/R isolation valves;
D.H.W. isolation valve;
D.H.W. elbow connection;
D.H.W. compression fitting;
flexible pipe;
extension for the gas cock;
safety valve discharge pipe;
associated gaskets;
FIXING THE BOILER MOUNTING FRAME (fig. 7)
Before installing the appliance ensure that the chosen location is suitable (section 2.2) and 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.
– For the rear flue application fix the flue template (14) to
the frame with the selftapping screws provided.
– Mark the position of the two upper installation frame fixing
holes, the two lower frame 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 the bottom two fixing holes using a 6 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. If the hole is not accessible from the outside of the
14
15
ø 15
1
7
2
ø 22
3
8
KEY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Gasket ø 13x18.6x1.5
D.H.W. outlet elbow
Extension for gas cock (if required)
Gas cock 1/2”
D.H.W. inlet isolation valve 1/2”
Fixing bracket
Gasket ø 17.5x23.9x1,5
C.H. flow isolation valve 3/4”
Flexible pipe
Non-return valve
Gasket ø 6x10.5x1
Safety valve discharge pipe
C.H. return isolation valve 3/4”
Flue template
Boiler inclination adjusting screw
9 4
5
10 12
11
Note: Item 6 can be discarded once boilier is on site
13
6
Fig. 7
15
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. Refer to fig. 13. (The
wall liner is available as an optional extra).
– Accurately measure the wall thickness, and note this
dimension for later use.
– Remove the flue template and secure the installation
frame in position using the screws provided.
3.3
WATER CONNECTIONS
Before installing the appliance it is possible to test the water
system by means of the frame kit. The water connections may
be done whether straight to the wall or in the vertical manner
as shown in fig. 7.
selftapping screws provided.
3.4
– Remove the outer casing front panel fixing screws (6 fig. 8)
and remove the front panel (5 fig. 8) by pulling forwards,
starting at the top corners.
– Lift the appliance into position. The upper cross member
locates onto the installation frame.
– Screw the adjusting screws (15 fig. 7) until the appliance
is secure and vertical.
– Connect the isolation valves to the boiler using the gaskets
provided.
3.5
3.3.1 Central heating connections (8-13 fig. 7)
– Fit the two C.H. isolation valves to the mounting frame as
shown in the figure. The pipe connections are labelled on
the mounting frame.
– Connect the C.H. pipework as required.
HANGING THE BOILER
FLUE AND TERMINAL PREPARATION
If the wall thickness is less than 0.5 m (19 in) the flue/air duct
may be fitted without access to the outside wall providing that
the optional wall liner kit is used. (This consists of a steel pipe,
0.5 m long and 129 mm outside diameter with a 1 mm wall
thickness).
3.5.1 Flue/air duct lengths
3.3.2 D.H.W. connections (5-2 fig. 7)
– Fit the D.H.W. isolation valve and the elbow connection to
the installation frame as shown in the figure.
– Connect the D.H.W. pipework as required.
3.3.3 Filling loop connections
– Fit the non-return valve to the C.H. return isolation valve
using the gasket provided (10-11 fig. 7).
– Fit the flexible pipe between the non-return valve and the
D.H.W. isolation valve.
– Fit the fixing bracket to lock the isolations valves using the
KEY
1 Self-tapping screw
2 Rear panel
3 L.H. side panel
16
4
5
6
R.H. side panel
Front panel
Fixing bracket Fig. 8
– Determine whether an extension duct is required with reference to the Z dimension shown in figs. 10-11-13. Alternatively
max. flue lengths information is given in Table 7.
Z Dimension UP TO 945 mm.
No extension duct required.
Z Dimension greater than 945 mm and up to 1,760
mm.
One extension duct kit required.
Z Dimension greater than 1,760 mm and up to 2,575
mm. Two extension duct kits required.
Z Dimension greater than 2,575 mm and up to 3,000
mm. Three extension duct kits required.
Z Dimension greater than 3,000 mm.
NOT PERMITTED.
– If no extension ducts are required, procede to 3.5.2.
– If an extension duct or ducts is/are to be used, the flue and
air ducts should be joined before proceeding to the next section. The extension ducts should be joined to each other and
to the standard ducts using the following procedure (fig. 9).
– For the flue ducts in turn, push the plain end of the standard and (if using two or three extensions) extension duct
into the swaged end of the extension duct(s).
– Push an air duct in to the clamp. Join the air ducts (larger
ducts) and tighten the screws an the clamp to connect them.
Fig. 9
3.5.2 Cutting the flue/air duct to the correct length
All installations
Rear flue outlet (Only - fig. 10)
– Cut the air duct square to the mark and remove all burrs
and sharp edges.
– Refer to fig. 12. Hold the air duct at the plain end, and slide
the flue duct (small duct) inside the air duct (terminal first)
until the external swage of the terminal stops against the
internal swage of the air duct, then mark off the length to
be cut which leaves 20 mm protruding flue duct.
– Remove and cut the flue duct square to the mark and
remove all burrs and sharp edges.
– Select the air duct (larger duct) and starting at the formed
end, ‘mark off’ the length to be cut which is the wall thickness X + 165 mm (6 1/2 in).
165
Push flue duct and terminal into air duct from this end.
Fig. 10
Side flue outlet (Only - fig. 11)
Fig. 12
– Select the air duct (larger duct) and starting at the formed
end, ‘mark off’ the length to be cut which is the wall thickness X + the clearance Y plus 155 mm (6 1/8 in) for
“Super 90 Mk.II” and 180 mm (7 in) for “Super 105 Mk.II”.
3.6
“90 Mk.II” models
“105 Mk.II” models
FLUE AND TERMINAL INSTALLATION
A diaphragm is normally supplied together with boiler version
“Super 105 Mk.II”. See fig. 13 for positioning.
ATTENTION: Install the diaphragm only when the length of
the ø 60/100 coaxial pipe is less than 1 m.
Fig. 11
Fig. 13
TABLE 7 - Maximum flue lengths
(measured from appliance casing to outside wall face)
“Super 90 Mk.II”
STANDARD FLUE KIT
WITH 1 EXTENSION KIT
WITH 2 EXTENSION KITS
WITH 2 1/2 EXTENSION KITS
“Super 105 Mk.II”
STANDARD FLUE KIT
WITH 1 EXTENSION KIT
WITH 2 EXTENSION KITS
WITH 2 1/2 EXTENSION KITS
Rear outlet
R.H./L.H. side outlet
mm
in
mm
in
710
28
715
28
1,525
60
1,530 601/4
1
2,340 92 /4
2,345 921/4
2,765 109
2,775 1091/4
Rear outlet
R.H./L.H. side outlet
mm
in
mm
in
740
28
690 271/4
1,555
60
1,505 591/4
1
2,370 92 /4
2,320 911/4
2,795 109
2,750 1081/4
3.6.1 Installations from inside the room
Wall thicknesses up to 0.5 m (19 in) only, Hole diameter sufficient to accept wall liner 130 mm (5 1/4 in) if optional kit is used.
– A wall liner, 127 mm (5 in) internal diameter, 500 mm (19
in) long is available as an optional extra for use when fitting
the flue/air duct from inside the building, (or where it is
required to seal the hole through a cavity wall). Cut the liner
to the wall thickness, insert into the hole, and seal with mortar at inner and outer wall faces. Access to the outside can
be made by inserting one’s hand through the liner.
– Fit the rubber sealing ring into the swaged groove in the air
duct as shown in fig. 13/a. Ensure that it is the correct
17
way around and spray the outside surface with talcum
powder or soap solution to reduce friction.
– Push the flue duct assembly into the air duct until the
external swaged ring on the flue terminal stops against
the internal swage on the air duct (fig. 12).
– From inside the building slide the duct assembly into the
wall liner until the sealing ring passes completely through
the wall, then pull the air duct back until the ring is pulled
up to the wall surface.
– Procede to section 3.6.3.
Z
3.6.2 Installations from outside the building only
(Hole diameter 100 mm - 4in)
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 metal collar
J Inner “O” ring
– Push the flue duct assembly into the air duct until the
external swaged ring on the flue terminal stops against
the internal swage on the air duct (fig. 12).
– From inside or outside the building, slide the duct assembly into the wall until the sealing ring forms a good seal
against the outside wall.
– Fit the rubber sealing ring into the swaged groove in the air
duct as shown in fig. 13. Ensure that it is the correct way
around.
Fig. 13/a
3.6.3 Connecting the duct assembly - All installations
3.7
– With reference to fig. 13, slide on the aluminium retention ring (D), check that the rubber sealing ring (E) is
pulled up to the wall and that the duct assembly is horizontal, then secure the aluminium retention ring to the
air duct using the two screws (H) provided. Do not overtighten the screws.
– Push the junction collar (B) over the air duct until the air
duct touches the inner part of the collar where the diameter becomes smaller.
– Push the elbow socket into the junction collar and onto the
flue duct.
– Fit the protective metal collar (I) over the junction collar.
– Remove the six fixing screws securing the sealed chamber
front panel then remove the panel.
– Place the gasket (G) under the flange of the elbow and fit
the elbow onto the top of the appliance, taking care to
ensure that the silicon seal on the fan outlet correctly
engages and forms a seal at its joint with the elbow. This
must be checked from inside the sealed chamber.
– Secure the elbow onto the top of the appliance using the
four screws and washers provided, and refit the sealed
chamber front panel.
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:
– The temperature on the surface of the discharge pipe, in
the portions that pass through masonry and/or come into
contact with walls should not exceed room temperature by
more than 60°C (pr EN 483).
– With direct intake from outside, when the pipe is longer
than 1 m, you are recommended to insulate the piping so
as to prevent formation of dew 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.
The maximum overall length of the intake and exhaust
ducts depends on the head losses of the single fittings
installed (excluding the adaptors) and must not be greater
than 9.00 mm H2O (“Super 90 Mk.II”) - 11.00 mm H2O
(“Super 105 Mk.II”).
For head losses in the fittings, refer to Table 8.
TABLE 8
Accessories ø 80
90° elbow MF
45° elbow MF
Extension L. 1000 (horizontal)
Extension L. 1000 (vertical)
Outlet terminal
Intake terminal
Doubler fitting
Roof outlet terminal L.1240
Tee condensation outlet
18
Head loss (mm H2O)
Inlet
0,30
0,20
0,20
0,10
–
0,10
0,50
–
–
“Super 90 Mk.II”
Outlet
0,40
0,30
0,30
0,20
0,30
–
1,50
–
0,90
Roof outlet
–
–
–
–
–
–
–
0,50
–
Inlet
0,30
0,20
0,20
0,10
–
0,10
0,50
–
–
“Super 105 Mk.II”
Outlet
0,50
0,40
0,40
0,30
0,40
–
1,80
–
1,10
Roof outlet
–
–
–
–
–
–
–
0,60
–
=
ø 80
160
KEY
1 Sponge-rubber gasket ø125/95
2 Fixing screw
3 Air-smokes flow splitting unit
with take-off point
4 Sectors diaphragm ø 38
=
120
Fig. 14
“Super 105 Mk.II” version
“Super 90 Mk.II” version
Sectores of diaphragm
to remove
1
2
3
4
5
Remove diaphragm
Total head loss
mm H2O
Pa
0 ÷2
2 ÷3
3 ÷4
4 ÷5
5 ÷6
6 ÷9
0 ÷ 19,6
19,6 ÷ 29,4
29,4 ÷ 39,2
39,2 ÷ 49,0
49,0 ÷ 58,8
58,8 ÷ 88,2
Sectores of diaphragm
to remove
1
2
3
4
5
6
Remove diaphragm
Example of allowable installation calculation (“Super 90 Mk.II”
model) in that the sum of the head losses of the single fittings
is less than 9.00 mm H2O:
7 meter horizontal pipe ø 80 x 0.20
7 meter vertical pipe ø 80 x 0.30
n° 2 90° elbows ø 80 x 0.30
n° 2 90° elbows ø 80 x 0.40
N° 1 terminal ø 80
Total head loss
Intake
1.40
–
0.60
–
0.10
Outlet
–
2.10
–
0.80
0.30
2.10
+ 3.20
= 5.3 mm H2O
With this total head loss, remove the ø 38 baffle from the
intake pipe.
3.7.1
Total head loss
mm H2O
Pa
0 ÷2
2 ÷3
3 ÷4
4 ÷5
5 ÷6
6 ÷7
7 ÷ 11
0 ÷ 19,6
19,6 ÷ 29,4
29,4 ÷ 39,2
39,2 ÷ 49,0
49,0 ÷ 58,8
58,8 ÷ 68,6
68,6 ÷ 107,8
SECTOR OF DIAPHRAGM
Fig. 15
Separate flue accessories
Part No 8093000 is supplied for this purpose (fig. 14).
The sectored diaphragm is to be used according to the maximum head loss allowed in both pipes, as given in fig. 15.
The complete range of accessories necessary for satisfying
all installation requirements is shown in fig. 16.
3.7.2 Separate-pipes roof outlet
The roof outlet terminal (1240 mm) cannot be shortened and
when positioning the tile, the minimum distance from the dis-
KEY
1 Air-smokes flow plitting unit
with take-off point
2a 90° elbow MF
2b Isolated 90° elbow MF
3a Extension L. 1000
3b Isolated extension L. 1000
4 Outlet terminal
5 Int.-est. ring kit
6 Intake terminal
7 45° elbow MF
8 Condensation outlet L. 135
9 Locking junction (n. 5)
code 8093000
code 8077404
code 8077408
code 8077303
code 8077306
code 8089501
code 8091500
code 8089500
code 8077406
code 8092800
code 8092700
Fig. 16
19
KEY
1
2
3
4
5
Tile with articulated joint
Lead panel
Collar
Locking screw
Reducing fitting
with gasket
Fig. 17
charge head terminal must not be less than 700 mm (fig. 17).
The accessories to be used for this type of installation and
some of the connecting systems that may be adopted are
illustrated in fig. 18. There is the possibility of separating the
air-intake and flue-outlet dusts and then bringing them back
together again so as to obtain a concentric discharge by
using the doubler fitting (7 fig. 18). In these cases, when
assembling, recover the silicone gasket used on the terminal
adapter (5 fig. 17), which is to be replaced by the doubler, and
insert it into the seat made in the doubler. For this type of
discharge the sum of the maximum rectilinear development allowed for the pipes must not exceed 9.00 mm H2O
(“Super 90 Mk.II”) - 11,00 mm H2O (“Super 105 Mk.II”).
When calculating the lengths of pipe, take into account the
parameters given in the Table 2.
3.8
GAS CONNECTIONS
– Screw the extension for the gas cock into the internal
thread of the gas inlet connection using a suitable jointing
compound.
– Screw the gas cock into the extension using a suitable
jointing compound.
– Connect the gas supply pipe.
3.9
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
panel to improve access.
– Fit the discharge pipe to the valve outlet using the ogive
inserted in the valve, 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 should avoid sharp corners or upward pipe
runs where water may be retained.
3.10
WIRING INSTRUCTIONS
(Refer to sections 2.6 - 2.7 and fig. 19)
The external wiring is connected to the boiler via a lead cable
situated behind the control box at the L.H.S.
– If a room thermostat is to be used, unscrew the two
screws at either side of the control box, pivot the box
downwards, then remove the room thermostat connection cover (one screw) to gain access to connector TA.
– Remove the pre-wired kink and connect the room thermostat to terminals 22 and 23.
– Re-fit the room thermostat connection cover.
The thermostat or timer-thermostat, recommended for
better room temperature control, must be class II as specified by standard EN 60730.1 (clean contact).
KEY
1 Air-smokes flow splitting unit
with take-off point
2 a 90° elbow MF
2 b Isolated 90° elbows MF
3 a Extension L. 1000
3 b Isolated extension L. 1000
4 Int.-est. ring kit
5 Intake terminal
6 Locking junction (n. 5)
7 Doubler fitting
8 Tile with articualted joint
9 Roof outlet terminal L. 1240
10 45° elbow MF
11 Condensation outlet L. 135
12 Tee condensation outlet
code 8093000
code 8077404
code 8077408
code 8077303
code 8077306
code 8091500
code 8089500
code 8092700
code 8091400
code 8091300
code 8091201
code 8077406
code 8092800
code 8093300
Fig. 18
20
Fig. 19
– Carry out electrical system checks through a suitable test
meter: earth continuity, polarity, resistance to earth and
short circuit.
– Re-secure control box.
sponding to the selected switching periods.
Function 1: segment set outwards (C.H. “ON”)
Function 2: segment set inwards (C.H. “OFF”)
Programming characteristics
3.11
TIME-CLOCK INSTRUCTIONS
Setting the time
Turn the programming dial in clockwise direction to set the
read off the 24-hour dial opposite the marking.
Program setting
Press inwards the segments on the program disk corre-
4
24 hour
Number of actions
Program time
Min. interval between
per cycle
per segment
two actions
96
15 min.
15 min.
Manual override
0 = “OFF” permanently
= automatic programmed operation
1 = “ON” permanently
COMMISSIONING AND TESTING
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.
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
Cycle
FILLING THE WATER SYSTEM
– Open the C.H. flow and C.H. return valves (17 and 18 fig. 2).
– Loosen the automatic air vent cap (9 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 forget
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.
– Open the D.H.W. inlet valve, open any hot tap, clear of air
bubbles. Close hot tap.
4.2
COMMISSIONING THE BOILER
– Remove the screw and connect a pressure gauge to the
burner pressure test point on the gas valve (fig. 20 “SIT gas
valve Tandem 837” - fig. 20/a “SIT gas valve Sigma 845”).
– 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 (8 in.wg) +/- 2.5 mbar (1
in.wg) 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
21
Fig. 20
2
3
4.4
1
4
KEY
1 Burner pressure test point
2 VENT pressure test point
3 Sealed chamber
4 Manometer
Fig. 20/a
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.
4.3
burner pressure. The heating input is factory set as stated in Table 3.
– If the heating output is to be adjusted, proceed as follows:
– refer to section 1.3 and establish the desired burner
pressure;
– remove (pull forwards) the C.H. knob protecting the
potentiometer;
– set the burner pressure as required i.e. 3,5 mbar (natural gas), 7 mbar (L.P.G.), using a small screwdriver on
potentiometer (1 fig. 21). Rotate the screw anti-clockwise to reduce the burner pressure;
– operate the rotary switch between SUMMER and WINTER position a few times and check that the correct
burner pressure is maintained.
– Replace the C.H. knob over potentiometer.
– To set the time clock proceed as follows:
– push in the setting tabs around the clock dial at the
times corresponding to when the heating is desired ON;
– set the clock to the correct time by rotating the dial clockwise until the arrow corresponds to the current time.
SETTING THE C.H. INPUT
– Turn the rotary switch to the WINTER position “❄" and
ensure that the room thermostat (if fitted) is calling for
heat. Turn the C.H. thermostat knob to maximum (fully
clockwise) and the burner will light.
– Allow the boiler to run for at least 5 minutes and check the
1
2
A restrictor lever is fitted into the diverting valve to reduce
the D.H.W. flow to that which will give an acceptable D.H.W.
temperature. To set the D.H.W. flow, procede as follows:
– select Summer position “ ” and turn the D.H.W. thermostat to max.;
– fully open the D.H.W. tap furthest from the boiler;
– check that the boiler is firing at maximum burner pressure;
– adjust the D.H.W. flowrate by turning the restrictor lever
on the divertor valve until a D.H.W. temperature rise of
approx 35°C is achieved. This corresponds to the
flowrates shown in Table 4;
– turn off the tap;
– remove the pressure gauge and refit the sealing screw;
Remember that the flow rates and corresponding temperatures of use of hot water, given in Table 4, have been obtained
by positioning the selector of the circulation pump on the maximum value.
Should there be any reduction in the D.H.W. flow rate, the
filter installed on the inlet to the pressure switch valve will
need cleaning. To gain access to the filter, first close the
cold water isolation valve (19, figure 2), drain the D.H.W.
circuit via the lowest tap, make provision to collect a small
discharge of water, then loosen the brass swivel connection to access the filter.
4.5
A
SETTING THE D.H.W. FLOWRATE
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.
B
KEY
1 “Ignition pressure” trimmer
2 “Heating output” trimmer
NOTE: To gain access to trimmers (1) and (2), unscrew
the central heating potentiometer knob.
4.6
USER’S INSTRUCTIONS
Fig. 21
Upon completion of commissioning and testing the system,
22
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.
23
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
24
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.
Service 1
Date:
Service 2
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
Service 3
Date:
Service 4
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
Service 5
Date:
Service 6
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Operative ID No.
Comments:
Comments:
Signature:
Signature:
Service 7
Date:
Service 8
Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
Service 9
Date:
Service 10 Date:
Engineer Name:
Engineer Name:
Company Name:
Company Name:
Telephone No.
Telephone No.
Gas Safe Register No.
Gas Safe Register No.
Comments:
Comments:
Signature:
Signature:
25
5
ROUTINE SERVICING INSTRUCTIONS
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
(Gas Safe Register). 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.
6 SEALED CHAMBER FIXING SCREWS
– Unscrew the 4 screws securing the combustion chamber
front panel and remove the panel, taking care not to damage the insulation.
– Unplug the HT lead from the ignition electrode, then remove
the detection electrode from the burner (one screw).
– 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 four screws securing the fan mounting plate.
– Tilt the fan assembly forwards and remove in a downwards direction.
– Inspect the fan assembly and clean if necessary.
PRESSURE
SENSING LINE
HEAT
EXCHANGER
5.3
BURNER
MANIFOLD UNION
5.1
COMBUSTION CHAMBER
FRONT PANEL SCREW
Fig. 22
HEAT EXCHANGER
– Pull off the pressure sensing line(s) from the flue hood.
– Lift the collector hood assembly, tilt forwards and remove
the hood.
– Inspect the heat exchanger, and clean if necessary.
MAIN BURNER ASSEMBLY
5.4
– Remove the front casing panel by unscrewing the retaining
screws and brackets situated above the front panel, and
pulling the panel forwards from the top corners.
– Remove the 6 fixing screws securing the sealed chamber
front panel then remove the panel.
“Super 90 Mk.II” model
FAN MOUNTING
PLATE SCREWS
PRESSURE
SENSING LINE
– 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 front panel.
5.5
COLLECTOR HOOD
ASSEMBLY
RE-ASSEMBLY
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.
ELECTRICAL
CONNECTIONS
“Super 105 Mk.II” model
FAN MOUNTING
PLATE SCREWS
COLLECTOR HOOD
ASSEMBLY
26
PRESSURE
SENSING LINES
ELECTRICAL
CONNECTIONS
Fig. 23
Fig. 24
6
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.
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 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 further.
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.
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).
27
6.5
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).
Yes
Is there power
at the external
socket?
No
Make
power
available
Does
the pump
start?
Yes
No
Yes
Is fuse
at mains
plug OK?
Is there power
at L and N
terminals?
No
No
Close room
thermostat
contact
Does
the fan
start?
Replace
the clock
Is smoke
pressure switch
connected right?
No
Is fuse
F1 OK?
Check smoke pressure switch and
fan
connection
Yes
Is there continuity
between
ignition probe
and ground?
No
Is the smoke
pressure switch
contact in open
position?
Is limit
thermostat
calling for heat?
Is pump shaft
free to rotate?
Replace the smoke
pressure switch
Yes
No
Replace the
limit thermostat
Check gap
between the
ignition electrode
and hood, check if
the electrode
lead and fit
are not damaged.
Does it now
spark?
Yes
Yes
Yes
No
Yes
No
No
Yes
Is there voltage
available
to the pump?
Is smoke
pressure switch
closed?
Make it free to
rotate
Yes
Replace
the pump
Yes
No
No
Yes
Check the
time clock does
his contacts
open and close
when the clock
turns?
No
Is there a spark
at the ignition
electrode?
Set properly
ignition probe
No
Is the clock in
the correct
band time?
No
No
Yes
Turn the clock
in the right
position
Yes
Replace
fuse F1
No
Is the room
thermostat
contact closed?
Yes
Check wire
connections
to L and N
terminals
Replace fuse in
mains plug
Yes
Is sensor
disconnected?
Connect
the sensor
Yes
No
Yes
No
No
Set right
the contacts
Check pump
connection
Yes
Replace the PCB
control board
Yes
Is there
230V AC
available between
11 and 4
terminals
and between
11 and 10
terminals of PCB
ignition?
Is there
continuity
between power
terminals of
PCB control
board and
PCB ignition?
No
Is sensor OK?
Yes
Is there 230V AC
available at the
fan terminals?
Yes
Replace
sensor
Replace
the fan
No
Yes
No
Has the PCB
ignition
locked-out after 10
seconds
with flame
at the burner
before lock?
Has the PCB
ignition
locked-out after
10 seconds
without flame
at the burner?
Check the gap
between the
ionisation probe
and hood;
check if the
electrode lead
and fit are not
damaged.
Does it now
detect the flame?
No
Yes
No
Is the gas
available?
Open
the gas
Yes
Turn the plug
Yes
Is the burner
pressure set to
the maximum?
Yes
No
Is there a
voltage at the
modulator?
Yes
Can the burner
pressure be
reduced by the
C.H. ajuster?
No
Yes
Does the burner
pressure reduce
as the temperature
rises towards max.?
No
Yes
No
No
Replace the
C.H. thermistor
Does the
boiler switch
OFF before
achieving the
temperature?
Check:
1) Limit
thermostat
2) C.H.
thermistor
3) PCB control
board
Replace the
modulator
Yes
No
Is the safety
thermostat OK?
Replace the
safety
thermostat
Boiler is
satisfactory
Yes
Yes
Is there
continuity
between the
PCB control
board and
the gas valve?
No
Replace the
gas valve
Set properly
the connection
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.
28
6.6
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.
Is there power
at the external
socket?
No
Make
power
available
Yes
Make it
free to
rotate
Replace
fuse in
mains plug
Is there power
at L and N
terminals?
Is there
voltage available
at the pump?
Yes
Yes
Are microswitches
of divertor valve
operated?
Is smoke
pressure switch
closed?
Yes
Check smoke
pressure
switch and fan
connection
Yes
Is there continuity
between
ignition probe
and ground?
No
Is the smoke
pressure switch
contact in open
position?
No
Yes
Replace the smoke
pressure switch
No
Is limit
thermostat
calling for heat?
Replace the
pump
Yes
No
Replace the
limit thermostat
Check gap
between ignition
electrode and
hood. Check the
electrode lead
and fit are not
damaged. Does it
now spark?
Yes
No
Yes
No
Replace
fuse F1
Replace the
divertor valve
Is fuse
F1 OK?
Yes
Check pump
connection
Yes
No
No
Yes
Is pump
shaft free
to rotate?
Yes
No
Yes
Open any
D.H.W. tap
to give flow
2.8 l/min.
Can you
get the desired
flow at the
D.H.W. taps?
Is smoke
pressure switch
connected right?
No
Check wire
connections
to L and N
terminals
Is there a spark
at the ignition electrode?
Set right ignition
probe
No
Yes
No
Yes
Does
the fan
start?
No
No
Is fuse
at mains
plug OK?
Yes
Does
the pump
start?
Is sensor
disconnected?
Connect
the sensor
Yes
No
No
No
Clean or replace
filter at inlet of
divertor valve
Set right
the contacts
Replace the
PCB control
board
Has the PCB
ignition
locked-out after 10
seconds
with flame
at the burner
before lock?
Yes
No
Open the
gas cock
Is the gas
available?
Is there
continuity
between
power terminals
of PCB control
board and PCB
ignition?
No
No
Has the PCB
ignition
locked-out after
10 seconds
without flame
at the burner?
Yes
No
Is there 230V AC
available between
11 and 4
terminals and
between
11 and 10
terminals of PCB
ignition?
Is the burner
pressure set to
the maximum?
Yes
Yes
Yes
Check the gap
between the
ionisation probe
and hood.
Check if the
electrode lead
and fit are not
damaged.
Does it now
detect the flame?
Yes
No
Yes
Yes
Yes
Is there 230V AC
available at
the fan terminal?
Can the burner
pressure be
reduced by the
D.H.W. ajuster?
No
No
Is there a
voltage at the
modulator?
No
Replace
sensor
Is sensor OK?
Yes
Replace
the fan
Yes
Does the burner
pressure reduce
as the temperature
rises towards max.?
No
Yes
No
No
Replace the
D.H.W. thermistor
Does
the boiler
swich OFF
before achieving
the temperature?
Check:
1) Limit
thermostat
2) D.H.W.
thermistor
3) PCB control
board
Replace the
modulator
Yes
No
Replace the
limit thermostat
Is the limit
thermostat OK?
Turn
the plug
Boiler is
satisfactory
Yes
Yes
Replace the
gas valve
Is there
continuity between
PCB control
board and
the gas valve?
No
Set right
the connection
NOTE:
When commissioning the boiler, please check the polarity in case the pump and the fan are running but the burner does
not fire.
29
7
INTERNAL WIRING DIAGRAM AND VIEW
7.1
FUNCTIONAL FLOW WIRING DIAGRAM
KEY
L
N
EV1
EV2
EA
ER
A
TS
OP
PF
Phase
Neutral
Gas valve coil
Gas valve coil
Ignition electrode
Detection electrode
SIT 503 control box
100°C safety thermostat
Time clock
Air pressure switch
V
P
VP
TAG
C
TA
M
SM
TL
F1
Fan
Circulation pump
Divertor valve
Frost thermostat
Rotary switch
Room thermostat
Modulator
C.H. sensor
Limit thermostat
Fuse
Note: The room thermostat must be connected to the terminals 22-23
Fig. 25
30
7.2
INTERNAL VIEW
“Super 105 Mk.II” model
KEY
1
2
3
4
6
7
10
11
12
13
14
15
16
17
Control panel
Divertor valve
Gas valve with control box
D.H.W. exchager
Combustion chamber
Water-gas exchager
100°C safety thermostat
NTC sensor
Limit thermostat
Air relief valve
Circulating pump
Fan
Smoke pressure switch
Frost stat
Fig. 26
31
8
REPLACEMENT OF PARTS
8.1
HEAT 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 heat exchanger using the drain cock (at the bottom RHS of the appliance)
– Unclip the heat exchanger securing clips, then lift out the
heat exchanger.
– Re-assemble in reverse order, ensuring that the heat
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.
– Transfer the ignition electrode onto the new burner
assembly.
– Re-assemble in reverse order. Check the electrode gaps
(fig. 27) and test for gas soundness.
– Re-commission the appliance as described in section 4.
8.5
IGNITION/DETECTION ELECTRODES
– 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.
Ignition electrode:
Pull off the HT lead from the base of the electrode, and
replace the electrode.
Detection electrode:
Follow the detection lead back to the control box. Unscrew
the two screws from the front of the control box and
remove the control box plastic front cover.
– Carefully remove the electrode and integral lead from the
appliance. Replace the electrode assembly, and carefully
route the lead through the grommet below the burner and
to the control box.
– Re-assemble in reverse order.
“Super 90 Mk.II” model
25 kW
IGNITION ELECTRODE
DETECTION ELECTRODE
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 to the fan. Note the
position of the earth conductor.
– Unscrew the four screws securing the fan mounting plate.
– Drop and tilt the fan assembly forwards and remove in a
downwards direction.
– Unscrew the three screws retaining the fan on the fan
plate. Remove the fan assembly.
– Transfer the fan outlet seal onto the new fan.
– Re-assemble in reverse order. Ensure that the earth connection is correctly refitted. Note that the polarity (Line
and Neutral) is immaterial.
8.4
“Super 105 Mk.II” model
30 kW
IGNITION ELECTRODE
DETECTION ELECTRODE
MAIN BURNER
Fig. 27
– Remove the main burner by following section 5.1.
32
8.6
GAS VALVE
– Remove the casing front panel as described in section 5.1.
– Unscrew the single screw securing the plastic ignition control box to the gas valve and pull off the control box in a forwards direction.
– Disconnect the two leads from the modulating solenoid.
– From underneath the appliance, unscrew the four posihead screws securing the gas valve inlet pipe flange.
– Remove the two screws securing the control box and pivot
the control box downwards
– Unscrew the burner manifold nut underneath the sealed
casing, 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 recommission 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. 28, as follows: (SIT gas
valve). 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.
– 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 of 1.5 mbar 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
KEY
A Plastic screw
B Nut
C Sealing cap
–
–
–
–
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 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.
Adjust the Central Heating maximum pressure as
described in section 4.3, then complete the re-commissioning as described in 4.4 and 4.5.
8.7
– Remove the casing front panel and sealed chamber front
panel as described in section 5.1.
– Disconnect the pressure sensing pipe from the switch.
– Unscrew and remove the two screws securing the mounting bracket.
– Remove the switch from the bracket (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
LIMIT THERMOSTAT
The limit thermostat is situated on the top, R.H.S. of the heat
exchanger (12 fig. 26).
– Remove the outer casing and the sealed chamber front
panel as described in section 5.1.
– Without disconnecting the wires, unscrew the two limit
thermostat fixing screws.
– Lift the thermostat and fixing screws out using the wires.
– Replace the thermostat and spread heat sink compound
(supplied) over the base of the new one. Connect the wires,
(polarity is immaterial) and position the screws in the
flange and re-fit using the wires to position the thermostat
before tightening the screws.
– Re-assemble in reverse order.
8.9
Fig. 28
AIR PRESSURE SWITCH
OVERHEAT THERMOSTAT
The overheat thermostat is situated on the flow pipe, below
the sealed chamber (10 fig. 26).
– Remove the casing front panel as described in section 5.1.
– Disconnect the two overheat 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).
33
8.10
THERMISTOR
8.14
The thermistor is clipped to the flow pipe below the overheat
thermostat.
The thermistor does not penetrate the waterways, therefore
it is not necessary to drain the appliance.
– Remove the casing front panel as described in section 5.1.
– Remove the thermistor securing clip from the pipe.
– Pull off the thermistor connection plug, and release the
thermistor from the clip.
– Replace the thermistor and re-assemble in reverse order
using the heat sink compound supplied.
TABLE 9
Temperature (°C)
Resistance (Ω)
20
30
35
40
45
50
55
60
70
80
12,764
8,579
7,102
5,915
4,955
4,173
3,533
3,006
2,208
1,650
– Remove the casing front panel as described in section 5.1.
– Remove the gas valve (to improve access) as described in
section 8.6.
– Isolate the C.H. flow and return valves, and the D.H.W. isolation valve (17 - 18 - 19 fig. 2).
– Drain the appliance through the drain plug (13 fig 2).
– Drain the D.H.W. circuit by opening any D.H.W. tap below
the level of the boiler.
– Remove the two screws pivot the control box downwards.
– Disconnect all union connections to the D.H.W. heat
exchanger and remove the heat exchanger.
– Fit new heat exchanger and re-assemble in reverse order
using the new gaskets supplied with the heat exchanger.
– Refill and re-commission the system as described in section 4.1.
8.15
DIVERTOR VALVE - COMPLETE
– Remove the casing front panel as described in section 5.1.
– Unscrew the single screw securing the plastic ignition control box to the gas valve and pull off the control box in a forwards direction.
– Unscrew the single screw securing the plastic control box
cover to reveal the electrical connections.
– Transfer the electrical connectors and wires etc to the
new PCB and re-assemble in reverse order.
– Remove the casing front panel as described in section 5.1.
– Remove the gas valve (to improve access) as described in
section 8.6.
– Isolate the C.H. flow and return valves, and the D.H.W. isolation valve (17 - 18 - 19 fig. 2).
– Drain the appliance through the drain plug (13 fig 2)
– Drain the D.H.W. circuit by opening any D.H.W. tap below
the level of the boiler.
– Remove the two screws pivot the control box downwards.
– Disconnect all union connections from the divertor valve.
Withdraw the valve and remove the circlip securing the
microswitch assembly.
– Transfer the electrical connections onto the new valve. If
necessary. refer to the wiring diagrams in section 7.
– Re-assemble in reverse order, using the new gaskets supplied with the valve.
– Refill and re-commission the system as described in section 4.1.
8.12
8.16
8.11
IGNITION CONTROL BOX
DRIVER PCB
– Remove the casing front panel as described in section 5.1.
– Pivot the control box downwards, by removing the two
screws.
– Open the plastic driver control box housing by removing the
room thermostat cover (one screw) and the single central
fixing screw then prising open the four locating tabs.
– Pull off the potentiometer knobs.
– Release the PCB (four screws), transfer all connections
onto the new PCB, and re-assemble in reverse order.
– Re-set the CH burner pressure as described in section 4.3.
DIVERTOR VALVE - MICROSWITCH
ASSEMBLY
– Remove the casing front panel as described in section 5.1.
– Remove the two screws pivot the control box downwards.
– Pull out the microswitch circlip, and lift off the microswitch
assembly.
– Transfer the electrical connections onto the new
microswitch assembly. If necessary. refer to the wiring diagrams in section 7.
– Re-assemble in reverse order.
8.17
8.13
C.H. EXPANSION VESSEL
PUMP
– Remove the casing front panel as described in section 5.1.
– Unplug the electrical connection plug.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2), and
drain the appliance through the drain plug (13 fig 2).
– Unscrew both union connections.
– Replace the pump, and re-assemble in reverse order, using
the new gaskets supplied with the pump. 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.
34
D.H.W. HEAT EXCHANGER
In the unlikely event of failure of the expansion vessel
diaphragm it is acceptable to leave the vessel in position and to
fit a replacement vessel (of similar or greater capacity) external to the appliance but as close as possible to the C.H. return.
Alternatively the vessel can be replaced as follows. Note
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.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2), and
drain the appliance through the drain plug (13 fig. 2).
– Unscrew the expansion vessel pipe union at its connec-
tion union.
– Remove the screw securing the expansion vessel bracket
at the top, rear of the appliance.
– 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.
8.18
PRESSURE GAUGE
–
–
–
–
–
Remove the casing front panel as described in section 5.1.
Remove the two screws and pivot the control box downwards.
Isolate the C.H. flow and return valves (17 - 18 fig. 2).
Drain the appliance through the drain point (13 fig. 2).
Unscrew the pressure sensor from the brass body near
the drain point.
– 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.
8.19
SAFETY VALVE
– Remove the casing front panel as described in section 5.1.
– Remove the two screws and pivot the control box downwards.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2).
– Drain the appliance through the drain point (13 fig. 2)
9
EXPLODED VIEWS
9.1
DIVERTOR VALVE
– Unscrew the union supporting the outlet pipe from the
valve, and remove the valve by unscrewing it from the
brass housing.
– Fit the new safety valve using a suitable jointing compound
and re-assemble in reverse order. Refill and re-commission
the system as described in section 4.1.
8.20
–
–
–
–
–
AUTOMATIC AIR VENT
Remove the casing front panel as described in section 5.1.
Isolate the C.H. flow and return valves (17 - 18 fig. 2).
Drain the appliance through the drain point (13 fig. 2).
Unscrew the automatic air vent.
Fit the new automatic air vent using a suitable jointing compound and re-assemble in reverse order. Refill and re-commission the system as described in section 4.1.
8.21
TIME CLOCK
– Remove the casing front panel as described in section 5.1.
– Remove the two screws and pivot the control box downwards.
– Open the plastic driver control box housing by removing the
room thermostat cover (one screw) and the single central
fixing screw then prising open the four locating tabs.
– Pull off the electrical connections at the back of the clock.
– Remove the four screws securing the plastic frame of the
time clock to the fascia 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
Fig. 29
Position
1
2
3
4
5
6
Code
6150700
6219701
6223800
6220601
6218500
6153101
Description
Divertor valve microswitch
Cap MPMV 3310 for microswitch
Washer MPMV 3318
O-ring R1 MPMV 3325
Clip Ø 17 for diverting valve
Diaphragm assembly for divertor valve
Position
7
8
9
10
11
12
Code
6231201
6223902
6222000
6220602
6223903
6153401
Description
Brass ring nut MPMV 3320
Teflon short spacer MPMV 3315
D.H.W. filter MPMV 3326
O-ring 4093 MPMV 18
Teflon long spacer MPMV 3316
Snap ring J26 MPMV 3323
35
9.2
HYDRAULIC CIRCUIT
59
17
20
19
18
45
21
57
110
6
107
49
63
56
55
54
46
43
42
45
45
45
49
64
60
56
47
87
41
62
61
48
58
45
53
40 52
98
106
99
88
100
108
44
49
19
30
21
51
116
39
49
119
45
102
101
103
Fig. 29/a
115
Position
6 •
6A •
17 •
17 A •
18 •
19 •
20 •
21
30
39
40
41 •
42 •
43 •
44
45
46 •
47
48
49
51 •
52
53 •
54 •
54 A
55 •
56 •
36
Code
5139110
5187700
6174221
6174223
6265101
6226412
6226601
6146302
6146301
6265701
6265801
6102806
6226417
6275900
6147403
2030228
6265600
6264900
6265000
2030227
6226403
6017211
6040201
6124803
6124810
6013100
2030229
Description
Model
Expansion vessel l.7 - 1/2” M
90
Expansion vessel l.10 - 1/2” M
105
Heat exchanger PR20326001
90
Heat exchanger PR24326004
105
Heat exchanger inlet/outlet pipe
O-ring 3068
Spring for heat exchanger connector
Brass nut 3/4”
Brass nut 1/2”
D.H.W. inlet/outlet manifold
C.H. flow/return manifold
Divertor valve
O-ring 3043
Restrictor lever
Plug for water pressure switch hole
Gasket Ø 17x24x2
Plate-type heat exchanger
D.H.W. exchanger-C.H. manifold pipe
D.H.W. exchanger-D.H.W. manifold pipe
Gasket Ø 12x18x2
O-ring 2031
Manual air vent 1/4”
Pressure relief valve
Myson CP51AS pump 1”
90
Myson CP61AS pump 1”
105
Automatic air vent 3/8”
Gasket Ø 22x30x2
Position
57
57 A
58
58 A
59 •
60 •
61 •
62 •
63
64
87
88 •
98
99
100
101
102
103
106
107
108
110
115
116
119
Code
6264812
6264822
6264712
6264721
6146700
6146701
6231352
6272500
6227621
2030226
6175400
6226411
6100202
6168401
6157607
6142341
6177511
6177513
2002302
6146330
6017403
6146702
6177512
6078612
2030239
Description
C.H. return pipe
C.H. return pipe
C.H. flow pipe
C.H. flow pipe
Limit stat auto reset
100°C safety stat
Temperature sensor
Temperature sensor fixing spring
Pipe connecting expansion vessel
Gasket Ø 10,2x14,8x2
Cover for micro switches
O-ring 2015
Ogive for pipe Ø 15
Locking nut for pipe Ø 15
Pressure relief valve drain pipe
Quarter bend 1/2” x 15
Ball cock 3/4” x 22
Ball cock 1/2” x 15
Hex. socket headless screw M4x6
Nut 1/2” for expansion vessel
Flexible pipe
Frost stat
Ball cock 3/4” x 22
Non-return valve
Gasket Ø 6x11x2
• Recommended stock parts
Model
90
105
90
105
9.3
COMBUSTION CIRCUIT
9
118
105 38
8
96
117
33
124
109
34
37
10
32
123
125
11
11
31
50
15
89
35
13
9
14
16
22
49
68
69
36
15
12
66
65
27
69
67
28
70
26
21
29
122
23
24
25
30
97
104
Fig. 29/b
Position
8
8A
9
10
11 •
12
13
13 A
14
14 A
15
16
21
22
22 A
23
24
24 A
25
25 A
26 •
26 A
27 •
28
29
30
31
31 A
32
33
33 A
34 •
34 A •
Code
6266001
6266020
6266110
6119313
2013302
6223200
6266601
6266620
6139721
6139722
6139410
6139720
6146302
5172700
5172720
6022004
6154402
6154401
6175103
6175104
6235920
6235927
6235916
2034000
2030015
6146301
5174510
5174511
6235800
6229209
6229210
6225615
6225613
Description
Model
Sealed chamber rear panel
90
Sealed chamber rear panel
105
Sealed chamber side panel
Plastic cap
Fastener for self tapping screw
Burner centering pin
Combustion chamber rear panel
90
Combustion chamber rear panel
105
Combustion chamber rear insulation
90
Combustion chamber rear insulation 105
Combustion chamber side panel
Combustion chamber side insulation
Brass nut 3/4”
Main burner assembly
90
Main burner assembly
105
Copper washer Ø 6
Main burner nozzle NP 130 natural gas
Main burner nozzle NP 75 M6 LPG
Protecting shield
90
Protecting shield
105
Ignition electrode
90
Ignition electrode
105
Ionisation electrode
Locking ring
90
Plane washer Ø 21x37
90
Brass nut 1/2”
Smoke chamber assembly
90
Smoke chamber assembly
105
Venturi pressure nipple
90
Fan mounting plate
90
Fan mounting plate
105
Fan
90
Fan with venturi
105
Position Code
Description
Model
35
6139606 Combustion chamber front panel
90
35 A
6139608 Combustion chamber front panel
105
36
6139754 Combustion chamber front insulation
90
36 A
6139756 Combustion chamber front insulation 105
37
6229101 Smoke pressure switch bracket
38 • 6225707 Air pressure switch
90
38 A
6225712 Air pressure switch
105
49
2030227 Gasket Ø 12x18x2
50
2000715 Screw TCB M4x10 AISI 304
65 • 6243802 SIT gas valve type Tandem 837
90
65 A
6243810 SIT gas valve type 845 SIGMA
105
66
2000716 Screw T.C.B. M4x8
90
67
6226832 Gas inlet pipe
90
67 A
6226849 Gas inlet pipe
105
68
6226932 Pipe connecting gas valve-main burner 90
68 A
6226944 Pipe connecting gas valve-main burner 105
69 • 6162401 Square gasket
90
70 • 6210203 Control box SIT 503
90
70 A
6210205 Control box SIT 537
105
89
6228871 Sealed chamber front panel
90
89 A
6228880 Sealed chamber front panel
105
96
6263903 Fan pressure test point
90
97
6070808 Extension MF 1/2”
104 • 6177504 Gas cock 1/2” x 1/2”
105
6028702 Gasket Ø 95x125x2
109
6028620 Air diaphragm Ø 81
117
6035906 Washer Ø 56,3x60
105
118
6231402 Silicon rubber flue ring
105
122
6070807 Extension MF 1/2”
105
123
6215109 Pressure switch sensor protect. shield 105
124
6223350 Venturi for fan
105
125
6263902 Fan pressure test point
105
• Recommended stock parts
37
9.4
STRUCTURAL COMPONENTS AND CONTROL & REGULATIONS
112
114
3
2
92
7
91
1
4
72 73
113
5
95
71
94
93
120
74
82
77
86
81
90
84
78
P
la
n
e
t
R
8
0
E
79
83
80
76
85
75
111
Fig. 29/c
Position
1
2
3
3A
4
4A
5
5A
7
7A
71
72
73
74
75
76
77 •
78 •
79 •
80 •
38
Code
6138521
6138621
6138700
6138701
6255420
6255421
6138856
6138857
6140004
6140005
6250010
6250110
6219571
6272910
6044022
6217003
6197707
6230679
6201501
6201502
Description
Model
Right hand side frame part
Left hand side frame part
Frame assembly upper support
90
Frame assembly upper support
105
Expansion vessel lower support
90
Expansion vessel lower support
105
Frame assembly lower side
90
Frame assembly lower side
105
Expansion vessel fixing bracket
90
Expansion vessel fixing bracket
105
Control panel R.H. side supp. bracket
Control panel L.H. side supp. bracket
Lower closing panel
Control panel
Gem
Temperature and pressure gauge
Time programmer
Control board
Trimmer spindle Ø 5
Trimmer spindle Ø 6
Position Code
Description
81
• 6260701 Rotary switch
82
2211610
Earth faston
83
6273010 Control panel protecting cover
84
6273110 Room stat connection cover
85
6230921 Knob Ø 40
86
2005101 Screw TCB 4x10 Zn
90
6271250 Casing right hand side panel
90 A
6274050 Casing right hand side panel
91
6271150 Casing left hand side panel
91 A
6273950 Casing left hand side panel
92
2003000 Pin M5 Zn
93
6273510 Casing front panel
94
2015000 Spring clip M0/A8
95
6250300 Front panel fixing bracket
111
6273300 Flap door
112
5185210 Boiler mounting frame
112 A
5185211 Boiler mounting frame
113
6280600 Isolation valves fixing bracket
114
6279500 Flue template
• Recommended stock parts
Model
90
105
90
105
90
105
Cod. 6274207A - 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
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