ENSURE THAT THESE INSTRUCTIONS ARE LEFT

FOR THE USER AFTER COMPLETION OF THE

UK BENCHMARK SECTION

EI

Format
System
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 optimi-
se safety, efficiency and performance.

Benchmark is managed and promoted by the Heating and Hotwater Industry Council.
For more information visit www.centralheating.co.uk
 Format System 24:
IPX4D Gas Council number 47-719-15

Format System 30:

Gas Council number 47-719-16

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

Important Information
IT IS A STATUTORY REQUIREMENT THAT ALL GAS APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, IN
ACCORDANCE WITH THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION). The manu-
facturer’s instructions must not be taken as overriding any statutory requirements, and failure to comply with these
regulations may lead to prosecution.

No modifications to the appliance should be made unless they are fully approved by the manufacturer.

GAS LEAKS: DO NOT OPERATE ANY ELECTRICAL SWITCH, OR USE A NAKED FLAME. TURN OFF THE GAS SUPPLY
AND VENTILATE THE AREA BY OPENING DOORS AND WINDOWS CONTACT THE GAS EMERGENCY SERVICE ON
0800111999.

Please refer to commissioning instructions for filling in the checklist of this installation guide.

Note: All Gas Safe registered installers carry a ID Card.

You can check your installer is Gas Safe Registered by calling 0800 408 5577

SIME COMBINATION BOILERS

Installer checklist
Please remember to carry out the following checks after installation. This will achieve complete customer satis-
faction, and avoid unnecessary service calls. A charge will be made for a service visit where the fault is not due to
a manufacturing defect.
– Has a correct by-pass been fitted and adjusted?
– Has the system been flushed in accordance with the guidelines given in BS7593 “Treatment of water in domes-
tic hot water central heating systems”?
– Is the system and boiler full of water, and the correct pressure showing on the pressure gauge?
– Is the Auto Air Vent open?
– Has the pump been rotated manually?
– Is the gas supply working pressure correct?
– Is the boiler wired correctly? (See installation manual).
– Has the customer been fully advised on the correct use of the boiler, system and controls?
– Has the log book provided been completed?
 1 TECHNICAL FEATURES AND DIMENSIONS

1.1 INTRODUCTION instructions for the boiler models: “FORMAT SYSTEM 24”
- “FORMAT SYSTEM 30” with following features:
The Sime “FORMAT SYSTEM” are wall mounted, fan assisted – electronic ignition,
balanced flue combination boilers. – fully modulating,
The appliance is supplied suitable for use with natural gas, – built in mechanical time clock.
LPG and provide heat. Heat output is varied according to
demand by the modulating gas control.
The appliance is supplied with a telescopic air/flue duct suit- 1.1.1 Boiler operation
able for wall thicknesses up to 635 mm (25 in) although
extension duct kits are available (see details in section 3.4). If there is a call for heat the pump will start to circulate the pri-
The combined flue and air duct can exit the boiler from either mary heating water and the fan will run at full speed; once the
side or from the rear of the appliance. A vertical extension and air pressure switch has been proved the burner will light. The
additional flue elbow may be fitted. If required, the boilers can burner output then automatically adjusts to suit the system
also be fitted with a separate flues kit (see section 3 for details). demand; as the temperature of the heating water in the boiler
The boiler is designed for use with sealed primary water sys- approaches that set by the adjustable central heating control
tems and is supplied fully assembled and equipped with com- knob the burner output is reduced. When this set temperature
plete valve packs. is reached, the burner extinguishes and the fan stops. The
The boiler can be used with a 240V room thermostat pump continues to run for 30 seconds to prevent residual heat
(class II according to EN 60730.1). This booklet provides build up in the boiler.

1.2 DIMENSIONAL DETAILS

K 165

55 55
110

22
ø 60/100
700

718

G A B C

R M G
125 60
L 335 60 70 70 200

24 30
L mm 400 450
K mm 180 205
Fig. 1

TABLE 1 - Connections TABLE 2 - Minimum clearances

A C.H. return 22 mm Compression For servicing

B C.H. flow 22 mm Compression ABOVE THE APPLIANCE CASING 300 mm
C Gas connection 15 mm Compression AT THE R.H.S. 15 mm
AT THE L.H.S. 15 mm
BELOW THE APPLIANCE CASING 200 mm
IN FRONT OF THE APPLIANCE 500 mm

6
1.3 GENERAL DATA

TABLE 3a - Nominal boiler ratings (5 minutes after lighting) for “FORMAT SYSTEM 24”

MODE OUTPUT INPUT (G.C.V.) BURNER PRESS. (Nat. gas) BURNER PRESS. (Butane/Propane)
kW Btu/h kW Btu/h mbar inwg mbar inwg
CENTRAL HEATING RANGE 9.0 31,000 12.0 42,000 2.4 0.9 5.9/7.7 2.4/3.1
10.6 36,000 14.1 48,000 3.2 1.3 7.9/10.3 3.2/4.1
12.3 42,000 16.2 55,000 4.1 1.7 10.2/13.2 4.1/5.3
14.1 48,000 18.2 62,000 5.2 2.1 12.7/16.3 5.1/6.5
X* (G20-G31) 15.9 54,000 20.3 69,000 6.3 2.5 15.4/19.6 6.2/7.9
X* (G30) 17.7 60,000 22.4 76,000 7.5 3.0 18.4/23.2 7.4/9.3
19.6 67,000 24.5 84,000 8.9 3.6 21.5/26.9 8.6/10.8
21.5 73,000 26.6 90,000 10.3 4.1 24.8/30.8 10.0/12.4
23.4 80,000 28.7 98,000 11.8 4.7 28.5/36.5 11.4/14.7
* Factory setting

TABLE 3b - Nominal boiler ratings (5 minutes after lighting) for “FORMAT SYSTEM 30”

MODE OUTPUT INPUT (G.C.V.) BURNER PRESS. (Nat. gas) BURNER PRESS. (Butane/Propane)
kW Btu/h kW Btu/h mbar inwg mbar inwg
CENTRAL HEATING RANGE 11.4 39,000 15.0 51,000 2.6 1.0 5.5/7.1 2.2/2.9
13.5 46,000 17.5 60,000 3.5 1.4 7.4/9.4 3.0/3.8
15.6 53,000 20.0 68,000 4.5 1.8 9.7/12.1 3.9/4.8
17.7 60,000 22.5 77,000 5.6 2.3 12.2/14.9 4.9/6.0
X* (G20-G31) 19.8 68,000 25.0 86,000 6.8 2.7 14.9/18.0 6.0/7.2
X* (G30) 22.0 75,000 27.6 94,000 8.2 3.3 17.9/21.3 7.2/8.6
24.2 83,000 30.1 103,000 9.6 3.8 21.2/24.8 8.5/10.0
26.5 90,000 32.6 111,000 11.1 4.5 24.7/28.5 9.9/11.4
28.8 98,000 35.1 120,000 12.7 5.1 28.5/36.5 11.4/14.7
* Factory setting

TABLE 4 - General specifications

24 30
Main burner injectors No off 12 14
Dia for Natural gas mm 1.3 1.3
Dia for LPG mm 0.77 0.78
Water capacity l (gal) 3.4 (0.75) 4.7 (1.00)
Static head Minimum bar (psi) 0.5 (7.3) 0.5 (7.3)
Maximum bar (psi) 3.0 (43.5) 3.0 (43.5)
Weight Empty kg (lb) 38 (84) 40 (88)
Total (full) kg (lb) 41.4 (91) 44.7 (98)
Electrical supply 230 V - 50 Hz, Fused at 3 A
Internal fuse Line: F 1.6 A
Maximum power consumption Watt 150 160
Maximum gas consumpt. (Natural gas) m3/h (ft3/h) 2.73 (96) 3.34 (118)
Maximum gas consumpt. (Butane - Propane) kg/h (lb/h) 2.02 - 1.99 (4.45 - 4.39) 2.48 - 2.44 (5.47 - 5.38)
Max. working temperature °C (F) 95 (203) 95 (203)
Integral exp. vessel capacity l (gal) 6 (1.32) 8 (1.76)

7
 1.4 HYDRAULIC CIRCUIT

KEY
1 Fan
2 Water-gas exchanger
3 Combustion chamber
4 Gas valve
5 Limit thermostat 85 °C
6 102 °C safety thermostat
7 NTC sensor
8 Hydrometer
9 Water flow switch
10 Air relief valve
11 Circulation pump
12 Expansion vessel
13 Safety valve
14 Drain plug
15 Automatic by-pass
16 Gas cock
17 C.H. flow cock
18 C.H. return cock

GAS FLOW RETURN

Fig. 2

1.5 INTERNAL VIEW

6 5
7
8

KEY
4 1 Control panel
9 2 Ignition transformer
3 Combustion chamber
10 4 Fan
5 Combustion analysis intakes
11 6 Negative pressure intake
7 Positive pressure intake
8 Smoke pressure switch
3 9 C.H. sensor (SM)
10 Limit thermostat
11 Main exchanger
12 Gas valve
13 Flow water switch
2 14 102°C resettable safety stat
12

13
14
1
Fig. 3

8
2 GENERAL REQUIREMENTS FOR INSTALLATION

2.1 STATUTORY REQUIREMENTS – A compartment used to enclose the appliance MUST be

designed and constructed specifically for this purpose. An
GAS SAFETY (INSTALLATION AND USE) REGULATIONS (as existing cupboard, or compartment, may be used provid-
amended). It is the law that all gas appliances are installed by ed it is modified accordingly.
a registered person, in accordance with the above regula- – Where installation will be in an unusual location, special
tions. Failure to install appliances correctly could lead to pros- procedures may be necessary. BS6798 gives detailed
ecution. It is in your own interest, and that of safety, to ensure guidance on this aspect.
that the law is complied with.
In addition to the above regulations, this appliance must be
installed in accordance with the current IEE Wiring 2.3 FLUE TERMINAL POSITION
Regulations (BS 7671), Local Building Regulations, the
Building Standards (Scotland) (Consolidation) Regulations, Detailed recommendations for flue installation are given in
Byelaws of the local water undertaking, and Health and Safety BS5440:1. The following notes are for general guidance:
Document No 635 “The Electricity at Work Regulations – The boiler MUST be installed so that the terminal is
1989”. It should also be in accordance with the relevant rec- exposed to the external air.
ommendations in the current editions of the following British – It is important that the position of the terminal allows free
Standards and Codes of Practice: BS5449, BS5546, passage of air across it at all times.
BS5440:1, BS5440:2, BS6798, BS6891, and BG.DM2, – It is ESSENTIAL TO ENSURE, in practice that products of
BS7074, and BS5482 for propane installations. combustion discharging from the terminal cannot re-
enter the building, or any other adjacent building, through
Manufacturer’s instructions must NOT be taken in any way ventilators, windows, doors, other sources of natural air
as over-riding statutory obligations. infiltration, or forced ventilation/air conditioning. If this
does occur, the appliance MUST be turned OFF IMMEDI-
ATELY and the gas supplier consulted.
2.2 BOILER POSITION – The minimum acceptable dimensions from the terminal to
obstructions and ventilation openings are specified in fig. 4.
In siting the combination boiler, the following limitations MUST – If the terminal discharges into a pathway or passageway
be observed: check that combustion products will not cause nuisance
– The boiler is not suitable for external installation. The posi- and that the terminal will not obstruct the passageway.
tion selected for installation should be within the building, – Where the lowest part of the terminal is fitted less than 2
unless otherwise protected by a suitable enclosure, and m (78 in) above ground, above a balcony or above a flat
MUST allow adequate space for installation, servicing, and roof to which people have access, the terminal MUST be
operation of the appliance, and for air circulation around it protected by a purpose designed guard.
(section 2.4). – Where the terminal is fitted within 850 mm (34 in) of a
– This position MUST allow for a suitable flue termination to plastic or painted gutter, or 450 mm (18 in) of painted
be made. The combination boiler must be installed on a eaves, an aluminium shield at least 1,500 mm (59 in) long
flat vertical wall which is capable of supporting the weight must be fitted to the underside of the painted surface.
of the appliance, and any ancillary equipment. – The air inlet/outlet flue duct MUST NOT be closer than
– If the combination boiler is to be fitted in a timber framed 25 mm (1 in) to combustible material.
building it should be fitted in accordance with the Institute – In certain weather conditions the terminal may emit a
of Gas Engineers document for Gas Installations In Timber plume of steam. This is normal but positions where this
Frame Housing, Reference 16E/UP/7: 1998. If in doubt, would cause a nuisance should be avoided.
advice must be sought from the gas supplier.
– If the appliance is installed in a room containing a bath or
TABLE 5
shower, any electrical switch or control utilising mains
electricity must be so situated that it cannot be touched Terminal position Minimum spacing in mm
by a person using the bath or shower. Attention is drawn A Directly below an openable window, 300
to the requirements of the current I.E.E. Wiring Regula- air vent or any other ventilation opening
tions (BS 7671), and in Scotland the electrical provisions B Below guttering, drain pipes or soil pipes 25*
of the Building Regulations applicable in Scotland. 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
Fig. 4 P Above an openable window or other opening 300
* With “heat shield” installed in accordance to BS 5440 Pt1.

9
 2.4 VENTILATION REQUIREMENTS problems.
– For optimum performance after installation this boiler
Detailled recommendations for air supply are given in and its associated central heating system must be
BS5440:2. The following notes are for general guidance: flushed in accordance with the guidelines given in BS
– It is not necessary to have a purpose provided air vent in the 7593 “Treatment of water in domestic hot water central
room or compartment in which the appliance is installed. heating systems”.
– This must involve the use of a proprietary cleanser, such
as BetzDearborn Sentinel X300 or X400, or Fernox
2.5 GAS SUPPLY Superfloc. Full instructions are supplied with the products,
but for immediate information please contact BetzDear-
– The gas installation should be in accordance with born (0151 420 9563) or Fernox (01799 550 811)
BS6891. The gas required for the boiler is specified in directly.
Table 4. – For long term protection against corrosion and scale,
– Ensure that the pipework from the meter to the appliance after flushing it is recommended that an inhibitor such as
is of adequate size. BetzDearborn Sentinel X100, or Fernox MB-1 or Copal is
– The governor at the meter must give a constant outlet dosed in accordance with the guidelines given in BS
pressure of 20 mbar (8 inwg) for natural gas and 30 - 37 7593.
mbar (12 - 15 inwg) for LPG, when the appliance is running. Failure to flush and add inhibitor to the system may
– The gas supply line should be purged. invalidate the appliance warranty.
NOTE: Before purging open all doors and windows, also – It is important to check the inhibitor concentration after
extinguish any cigarettes, pipes, and any other naked installation, system modification and at every service in
flames. accordance with the manufacturer’s instructions. (Test
– The complete installation must be tested for gas soundness. kits are available from inhibitor stockists).

2.6 ELECTRICITY SUPPLY 2.9 REQUIREMENTS FOR SEALED WATER SYSTEMS

The appliance MUST be earthed. A mains supply of 230 V - The heating system design should be based on the following
50 Hz single phase is required. All external controls and information:
wiring MUST be suitable for mains voltage. a) The available pump head is given in fig. 5.
b) The appliance is equipped with an internal by-pass that
Wiring should be in 3 core PVC insulated cable NOT LESS operates with system heads (H) greater than 3 m. The
than 0.75 mm2 (24 x 0.2 mm) to BS6500, Table 16. Wiring maximum flow through the by-pass is about 300 l/h. If
external to the boiler MUST be in accordance with current thermostatic radiator valves are to be installed, at least
l.E.E. Wiring Regulations (BS 7671) and local regulations. The one radiator should be without a thermostatic valve (usu-
supply connection to the flying lead provided MUST be made ally the bathroom radiator).
to a fused double pole switch, having a 3 mm (1/8 in) contact c) A sealed system must only be filled by a competent per-
separation in both poles, serving only the boiler and system son using one of the approved methods shown in fig. 7.
controls; the fuse rating should be 3 amp. This connection The system design should incorporate the connections
should be readily accessible and be made adjacent to the boil- appropriate to one of these methods.
er (except in the case of bathroom installations for domestic d) The following paragraphs outline the specifications of the
boilers where the point of connection to the mains MUST be items fitted to the boiler.
outside of the bathroom).

2.7 EXTERNAL CONTROLS (Refer to section 3.9)

600
Format.zip - Format.zip 5

The boiler is intended for use with a 240 V room thermostat.

(mbar)

The connection is made inside the control box as described in 30-35 By-pass
By-passinserito
on
head(mbar)

500 By-pass
By-passescluso
off
section 3.9. 1
25
RESIDUA

400
Available

2.8 WATER SYSTEMS - GENERAL 300

PREVALENZA

– This appliance is designed for connection to sealed cen- 200

25
1
tral heating water systems.
100
30-35
2.8.1 Treatment of Water Circulating Systems
0 200 400 600 800 1000 1200 1400 1600

– All recirculatory systems will be subject to corrosion FlowPORTATA

rate (l/sec)
(l/h)
unless an appropriate water treatment is applied. This KEY
means that the efficiency of the system will deteriorate as 1 Available Head for “FORMAT SYSTEM 24”
corrosion sludge accumulates within the system, risking and “FORMAT SYSTEM 30” models Fig. 5
damage to pump and valves, boiler noise and circulation
10
 TYPICAL SYSTEM DESIGN

NOTE: A drain cock should be installed at the lowest point of the heating circuit and beneath the appliance.
Fig. 6

ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM

Fig. 7

11
 2.9.1 Pump TABLE 6

The available head shown in fig. 5 is that in excess of the Vessel charge and initial system bar 0.5 1.0 1.5
appliance hydraulic resistance, i.e. that available for the pressure psi 7.3 14.5 21.8
system at any given heating load up to the maximum out- Total water content of system
l 96 74 51
put in C.H. mode. Never reduce the pump speed below using 8 l (1.76 gal) capacity expan-
gal 21.1 16.2 11.2
maximum. The pump speed is indicated on the side of the sion vessel supplied with appliance
pump speed selector switch (if fitted). For systems having a larger capaci-
ty multiply the total system capacity
in litres (gal) by the factor to obtain .0833 .109 .156
2.9.2 System volume (total water content) the total minimum expansion vessel
capacity required litres (gal)
The following Table gives the maximum system volume that
the integral expansion vessel can sustain under different 2.9.3 Pressure gauge
charge pressure conditions.
If the system volume exceeds that shown, an additional A pressure gauge is mounted on the appliance facia panel.
expansion vessel must be fitted and connected to the heat-
ing system primary return pipe as close as possible to the
appliance. 2.9.4 Safety valve
If an extra vessel is required, ensure that the total capacity of
both vessels is adequate. Further details are available in the A safety valve set at 3 bar (43.5 psi) is fitted to the appliance
current issues of BS5449 and BS6798. and a discharge pipe is routed to outside of the appliance. This
discharge pipe should be extended to terminate safely away
NOTE: If the pressure gauge indicates 2.65 bar or greater from the appliance and where a discharge would not cause
when the appliance is at maximum temperature with all damage to persons or property but would be detected. The
radiators in circulation an extra expansion vessel is pipe should be able to withstand boiling water, be a minimum
required. of 15 mm in diameter, and installed with a continuous fall.

12
3 INSTALLING THE BOILER

Appliance package:
KEY 3 Woodscrew (2 Off)
– boiler (assembled); 1 Wall mounting bracket 4 Washer (2 Off)
– installation and servicing instructions; 2 Plastic wall plug (2 Off) 5 Adjustment screw (2 Off)
– users instructions;
– wall mounting templates (paper);
– wall mounting bracket;
– fixing screws with wall plugs;
– plastic bags containing:
– gas service cock;
– C.H. F/R isolation valves;
– associated fixing screws;
– associated gaskets;
– safety valve discharge pipe.

Fig. 8
3.1 FIXING THE WALL MOUNTING BRACKET

Before installing the appliance ensure that the chosen loca-

tion is suitable (section 2.2) and that the requirements for
flue position, (section 2.3), and minimum clearances, (Table 2)
are satisfied. These minimum clearances are essential to pro-
vide access for servicing, and are included on the wall mount-
ing templates.
– Open the paper wall mounting templates. If a rear flue is
to be used, discard the side templates and secure the
rear template in the desired position. For a side flue appli-
cation, secure both the rear and appropriate side tem-
plate in position.
– Mark the position of the two wall mounting bracket fixing
holes and the flue/air duct hole on the appropriate wall(s). Fig. 9
– Remove the template(s) and drill the two fixing holes using
a 10 mm masonry drill. Fit the plastic plugs provided.
– Cut the hole in the wall for the flue/air duct. The diame-
ter should not be less than 100 mm (4 in) and must be – Push an air duct in to the clamp. Join the air ducts (larger
horizontal. Refer to fig. 12-14. ducts) and tighten the screws an the clamp to connect them.
– Accurately measure the wall thickness, and note this
dimension for later use.
– Secure the wall mounting bracket in position using the 3.3.2 Cutting the flue/air duct extension
screws provided. Ensure that it is the correct way up, as to the correct length
indicated in fig. 8.
Rear flue outlet (Only - fig. 10)

3.2 HANGING THE BOILER – Select the air duct (larger duct) and starting at the formed
end, ‘mark off’ the length to be cut which is the wall thick-
– Lift the appliance into position. The upper cross member ness X + 70 mm.
locates onto the wall mounting bracket.
– Screw in the wall mounting bracket adjusting screws until
the appliance is secure and vertical.

3.3 FLUE DUCTS PREPARATION

3.3.1 Flue/air duct lenghts

– Determine whether an extension duct is required with ref-

erence to the Z dimension shown in figs. 10-11.
– If no extension ducts are required, procede to 3.4.
– If an extension duct or ducts is/are to be used, the flue and
air ducts should be joined before proceeding to the next sec-
tion. 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 stan-
dard and (if using two or three extensions) extension duct Fig. 10
into the swaged end of the extension duct(s).

13
 Side flue outlet (Only - fig. 11) tion of a PVC pipe 130 mm ø of the same length as the
thickness of the wall it has to pass through. Then fix the
Right hand side PVC pipe in place using cement mortar.
– Select the air duct (larger duct) and starting at the formed – Before to insert the duct in the wall hole fit in position the
end, ‘mark off’ the length to be cut which is the wall thick- outer wall seal (D).
ness X + the clearance Y plus 85 mm for the “FORMAT – Push the tube outwards until the gasket comes out. Pull the
SYSTEM 24” model and 110 mm for the “FORMAT SYS- pipe inwards bringing the ring to rest on the wall.
TEM 30” model. – Slide the inner ring (C).
– Insert the inner/outer duct into the elbow (A) until the
Left hand side ducts touch the inner part of the elbow where the diameter
– Select the air duct (larger duct) and starting at the formed becomes smaller.
end, ‘mark off’ the length to be cut which is the wall thick- – Fit the sponge-rubber gasket (B) to the collar (E).
ness X + the clearance Y plus 125 mm for the “FORMAT – Secure the collar (E) to the sealed chamber using the four
SYSTEM 24” model and 150 mm for the “FORMAT SYS- screws provided.
TEM 30” model. – Insert the elbow (A) into the collar (E) tightening the screw
(F).

NOTE: The air intake-flue outlet assembly must slope sligh-

tly downwards to prevent rain water getting into the boiler.

KEY
A Elbow 90°
B Sponge-rubber gasket ø 125/95
C White inner duct
D Grey outer duct
E Junction collar
F Screw

NOTE: The kit can be extended to a maximum

measure of 800 mm horizontal. Fig. 12

Fig. 11
3.4.2 Standard flue

– Push the flue duct assembly into the air duct until the
external swaged ring on the flue terminal stops against
All installations the internal swage on the air duct (fig. 13).
– Fit the rubber sealing ring into the swaged groove in the air duct
– Cut the air duct square to the mark and remove all burrs as shown in fig. 14. Ensure that it is the correct way around.
and sharp edges. – From inside or outside the building, slide the duct assem-
– Hold the air duct at the plain end, and slide the flue duct bly into the wall until the sealing ring forms a good seal
(small duct) inside the air duct (terminal first) until it stops against the outside wall.
against the terminal, then mark off the length to be cut – With reference to fig. 14, slide on the rubber retention ring
which leaves 20 mm protruding flue duct. (D), check that the rubber sealing ring (E) is pulled up to the
– Remove and cut the flue duct square to the mark and wall and that the duct assembly is horizontal, then secure
remove all burrs and sharp edges. 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
3.4 FLUE AND TERMINAL INSTALLATION duct touches the inner part of the collar where the diame-
ter becomes smaller.
3.4.1 Telescopic flue – Push the elbow socket into the junction collar and onto the
flue duct.
For the assembly follow what is indicated in figure 12: – Fit the jointing clamp (I) over the junction collar.
– Make a hole in the wall sufficiently large to allow an inser- – Remove the six fixing screws securing the sealed chamber
14
 Each additional 90° elbow installed reduces the available
lenght by 0.9 metres, each additional 45° elbow reduces
the available lenght by 0.45 metres.
NOTE: Sime flue systems are suitable for installation with
SE-duct systems.

Push flue duct and terminal into air duct from this end.

DIAPHRAGM

Fig. 13

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 HORIZONTAL FLUE DUCTS:
install diaphragm ø 87.5 only if the coaxial flue is less than
must be checked from inside the sealed chamber.
1.8 metres long for model “FORMAT SYSTEM 24” or 1.5
– Secure the elbow onto the top of the appliance using the metres long for model “FORMAT SYSTEM 30”.
four screws and washers provided, and refit the sealed
chamber front panel. VERTICAL FLUE DUCTS
Use the following diaphragms, depending on flue length
and without any additional elbow:
Flue ducts lenght Diaphragm to be used
Z From 1.3 to 2.5 m optional ø 86
From 2.5 to 4 m standard ø 87.5
From 4 to 5 m none

Fig. 15

IMPORTANT: each additional

90°elbow reduces the avail-
KEY able length by 0.9 metres.
min 1,3 m - max 5 m

A Elbow flange F Inner duct c/w terminal

B Junction collar G Gasket ø 95/125 x 2
C Outer duct H Fixing screw
D Aluminium ring I Protective jointing clamp
E Rubber sealing ring J Inner “O” ring
Fig. 14

3.4.3 Coaxial flue diaphragm

The boiler is normally supplied with a Ø 87.5 diaphragm. Way

of use and optional diaphragm to be used with vertical ducts
is shown in fig. 15.
max 3,5 m "80 C TS - 24 TS”
max 3,0 m "100/110 C TS - 30 TS”

3.4.4 Coaxial flue specifications

With the elbow supplied in the kit the maximum length of the
flue must not exceed following measures:

Horizontal Vertical
FORMAT SYSTEM 24 3.4 5.0 Fig. 16
FORMAT SYSTEM 30 3.0 5.0

15
 3.5 SEPARATE DUCTS tion failure. In such cases, provide for condensate drainage.
(Optional alternative twin pipe system) – If a segment of the flue passes through a flammable wall,
this segment must be insulated with a glass wool pipe insu-
When installing the separate ducts, comply with the require- lator 30 mm thick, with a density of 50 kg/m3.
ments of the current standards, as well as the following prac-
tical pointers: The maximum overall length of the intake and exhaust ducts
– With direct intake from outside, when the pipe is longer depends on the head losses of the single fittings installed
than 1 m, you are recommended to insulate the piping so (excluding the adaptors) and can reach approximately the
as to prevent the formation of condensation on the outside following horizontal measures:
of the piping during particularly cold periods of the year. – 30 m for “FORMAT SYSTEM 24” model,
– With the outlet pipe outside the building or in cold indoor – 35 m for “FORMAT SYSTEM 30” model
environments, insulation is necessary to prevent burner igni- For head losses in the fittings, refer to Table 7.

K
100
2

ø 80
ø 80
3

165
1

110
6
4 KEY
1 Sponge-rubber gasket ø 125/95
2 Fixing screw
3 Smoke outlet flange

165
4 Air intake diaphragm
6 Air/smoke manifold with intakes

24 30

92
K mm 180 205

Fig. 17

Model “FORMAT SYSTEM 24” Model “FORMAT SYSTEM 30”

N° segments Total horizontal lenght N° segments Total horizontal lenght
to remove (inlet+outlet) in metres to remove (inlet+outlet) in metres
none 0 ÷ 3.2 none 0 ÷ 3.3
n° 1 3.2 ÷ 6.4 n° 1 3.3 ÷ 6.7
n° 1 and 2 6.4 ÷ 9.6 n° 1 and 2 6.7 ÷ 10.0
from n° 1 to 3 9.6 ÷ 12.4 from n° 1 to 3 10.0 ÷ 13.3
from n° 1 to 4 12.4 ÷ 15.2 from n° 1 to 4 13.3 ÷ 16.7
from n° 1 to 5 15.2 ÷ 18.0 from n° 1 to 5 16.7 ÷ 19.7
from n° 1 to 6 18.0 ÷ 20.8 from n° 1 to 6 19.7 ÷ 22.7
from n° 1 to 7 20.8 ÷ 23.2 from n° 1 to 7 22.7 ÷ 25.7
from n° 1 to 8 23.2 ÷ 25.6 from n° 1 to 8 25.7 ÷ 28.7
from n° 1 to 9 25.6 ÷ 28.0 from n° 1 to 9 28.7 ÷ 31.7
without diaphragm 28.0 ÷ 30.4 without diaphragm 31.7 ÷ 34.7
Fig. 18

16
TABLE 7 3.7 GAS CONNECTIONS

Twin flue Head loss – Screw the gas cock into the internal thread in the gas
accessories ø 80 metres inlet connection using a suitable jointing compound.
90° elbow MF 1.5 – Connect the gas supply pipe.
45° elbow MF 0.7
Extension L. 1000 (horizontal) 1.0
Extension L. 1000 (vertical) 1.0 3.8 SAFETY VALVE CONNECTION
Outlet terminal 1.0
Intake terminal 0.3 – The appliance safety valve is located towards the R.H.S. of
Junction twin/concentric 0.7 the boiler and the discharge pipe is supplied loose.
Roof outlet terminal L.1240 2.0 Remove the two selftapping screws and lower the control
Tee condensation outlet 4.0 box to improve access.
– Connect the discharge pipe to the valve outlet, and extend
the pipe to ensure that any discharge from the safety valve
3.5.1 Separate flue accessories is safely routed to a drain. The pipe should be able to with-
stand boiling water, be a minimum of 15 mm in diameter,
Part No 8089904 is supplied for this purpose. and installed with a continuous fall.
The sectored diaphragm is to be used according to the max-
imum head loss allowed in both pipes, as given in fig. 18.
3.9 WIRING INSTRUCTIONS
(Refer to sections 2.6 - 2.7 and fig. 20)
3.5.2 Use of air intake (fig. 19)
– Disconnect the electric power supply before performing
To use the air intake in this type of outlet you must per- any work. Warning: all components in the control panel
form the following operations: are fed with 240V.
- Remove the base of the air intake, using a tool to cut it off (a); – Remove the three screws (9) locking the control panel in place
- Overturn the air intake (b) and replace the seal (5) with and pull the panel forward until it can be tilted downward.
the seal supplied in the kit code 8089904; – To access the components of the electrical panel, unscrew
- Inser t the intake diaphragm supplied in the kit code the four screws holding the protective guard in place (6).
8089904, pushing it in until it is in contact with the beat; – To gain access to connector “TA”, remove the control
You can now insert the extension or curve in its housing panel cover (7) and connect the room stat to the termi-
to complete the intake (you need not use any seal or nals 10-11 after having removed the jumper.
sealant). The thermostat or timer-thermostat, recommended for
better room temperature control, must be class II as
specified by standard EN 60730.1 (clean contact).
3.6 WATER CONNECTIONS – Carry out electrical system checks through a suitable test
meter: earth continuity, polarity, resistance to earth and
– Fit the two C.H. isolation valves using the gaskets supplied short circuit.
to the flow and return connections as shown in fig. 2. The – Re-secure control box.
pipe connections are labelled on the lower part of the boiler. – Ensure sufficient length of cable to allow access to control
– Connect the C.H. pipework as required. panel.

IMPORTANT: The three housings on the

diaphragm permit assembly of the air
intake in one position only (with numbers
a toward inside the boiler).

5
Fig. 19

17
 KEY
1 Pressure gauge
2 Time programmer housing
3 Earth faston
4 Main PCB
5 Control panel protection
6 7 6 Terminal strip
7 Fixing screws

ATTENTION: After having removed

5 the three fixing screws, tilt the
3 4 panel downward to gain access.

1 2
Fig. 20

18
4 COMMISSIONING AND TESTING

SIME SUPPORT THE BENCHMARK INITIATIVE 4.3 SETTING THE HEAT OUTPUT

All relevant sections of the logbook must be filled in at the – Turn the rotary switch to the ON position and ensure that
time of installation and thereafter service information on the the room thermostat of heating programmer (if fitted) is
back page of the logbook. Commissioning of the boiler is not calling for heat. Turn the heat thermostat knob to maxi-
complete until the logbook is filled in. Before commissioning mum (fully clockwise) and the burner will light.
the appliance, the whole gas installation including the meter – Allow the boiler to run for at least 5 minutes and check
MUST be purged and tested for gas soundness in accor- the burner pressure. The heating output is factory set as
dance with BS6891. stated in Table 3.
IMPORTANT: open all doors and windows, extinguish naked – If the heating output is to be adjusted, proceed as follows:
lights, and DO NOT SMOKE whilst purging the gas line. – refer to section 1.3 and establish the desired burner
Before commencing the commissioning procedure, ensure pressure;
that the gas service cock is turned on, the electricity sup- – remove (pull forwards) the rotary switch knob protect-
ply is isolated, and that the C.H. isolation valves are in the ing the potentiometer;
closed position. – set the burner pressure as required using a small
screwdriver on potentiometer (1 fig. 22). Rotate the
screw anti-clockwise to reduce the burner pressure;
4.1 FILLING THE WATER SYSTEM – operate the rotary switch between ON and OFF a few
times and check that the correct burner pressure is
– Open the flow and return valves (17 - 18 fig. 2). maintained.
– Loosen the automatic air vent cap (10 fig. 2). – To set the time clock proceed as follows:
– Open all radiator valves and system air vents. Fill the sys- – push in the setting tabs around the clock dial at the
tem with water using one of the approved methods times corresponding to when the heating is desired ON;
described in section 2.9 to about 0.5 bar greater than – set the clock to the correct time by rotating the dial clock-
the system design pressure. Close all air vents. Do not wise until the arrow corresponds to the current time.
close the A.A.V. near the pump!
– Check the system for water soundness.
– Completely drain the appliance and heating system, thorough-
ly flush the system, and refill the system design pressure.

4.2 COMMISSIONING THE BOILER

– Loosen the screw and connect a pressure gauge to the

burner pressure test point on the gas valve (fig. 21).
– Remove (pull forwards) the rotary switch knob to gain
access to the potentiometer of the heating output and
rotate the potentiometer fully clockwise with a screwdriv- 1
er (refer to fig. 22). KEY
– Ensure that heating programmers or room thermostats are 1 “Heating output” trimmer
calling for heat and that there is an adequate circulation in the
NOTE: To gain access to trimmer, take off the
system. Turn the heat output knob to maximum and the rotary switch knob. Fig. 22
rotary switch to ON. Turn on the electrical supply 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. If the 4.4 FINAL CHECKS
burner pressure is low, check that the appliance has not
begun to modulate. Check also the inlet pressure with the – Re-light and test for gas soundness.
burner alight; this should be 20 mbar (8 in.wg) +/- 2.5 – Re-fit the casing front panel and securing brackets.
mbar (1 in.wg) for natural gas and 30 - 37 mbar (12 - 15 – Set the heat potentiometer to the required settings.
in.wg) +/- 2.5 mbar (1 in.wg) for LPG. – Ensure that the time clock (if fitted) is set at the desired
time periods. Set the room thermostat (if fitted) to the
required setting.

4.5 USER’S INSTRUCTIONS

Upon completion of commissioning and testing the system,

the installer should:
– Give the “Users Instructions” to the householder and
emphasise their responsibilities under the “Gas Safety
BURNER PRESSURE (Installation and Use) Regulations 1996 (as amended)”.
TEST POINT – Explain and demonstrate the lighting and shutdown proce-
Fig. 21 dures.
– Advise the householder on the efficient use of the system,
19
 including the use and adjustment of all system controls. how to reset it. Emphasise that if cut-out persists, the boil-
– Advise the user of the precautions necessary to prevent er should be turned off and the installer or service engi-
damage to the system, and to the building, in the event of neer consulted.
the system remaining inoperative during frost conditions. – Stress the importance of an annual service by a regis-
– Explain the function of the boiler overheat thermostat, and tered heating engineer.

20
Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This
does not affect the customer’s statutory rights.

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

CONDENSING BOILERS ONLY

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

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

21
 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:

22
5 ROUTINE SERVICING INSTRUCTIONS

To ensure continued efficient operation of the appliance, it is – Unscrew the burner manifold union and locking nut. Lift
recommended that it is checked and serviced as necessary the front of the burner to disengage manifold thread and
at regular intervals. The frequency of servicing will depend then lift the burner clear.
upon the particular installation conditions and usage but in – Remove the burner manifold by disconnecting the four
general once a year should be adequate. screws.
It is the law that any service work must be carried out by reg- – Inspect and if necessary, clean the injectors, electrodes,
istered personnel (Gas Safe Register). Before commencing and the main burner bars.
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 5.2 FAN ASSEMBLY
below.
– Disconnect the electrical connections to the fan. Note the
position of the earth conductor.
5.1 MAIN BURNER ASSEMBLY – Remove the three screws securing the fan.
– Tilt the fan forwards and remove in a downwards direction.
– Remove the casing as showed in fig. 23. – Inspect the fan assembly and clean if necessary.
– Remove the 8 fixing screws securing the sealed chamber
front panel then remove the panel.
– Unscrew the 7 screws securing the combustion chamber 5.3 HEAT EXCHANGER
front panel and remove the panel, taking care not to dam-
age the insulation. – Inspect the heat exchanger, and clean if necessary.
– Remove the electrode by unscrewing it from the burner
manifold.

8 SEALED CHAMBER SCREWS

3 FAN FIXING SCREWS

1 MAIN EXCHANGER

BURNER MANIFOLD
SCREWS UNION

7 COMBUSTION CHAMBER
Fig. 23 FRONT PANEL SCREWS Fig. 24

23
 5.4 RE-ASSEMBLY 5.5 RE-COMMISSIONING

– Re-assemble all the components in reverse order and – Turn on the gas supply, and check for gas soundness
replace all the gaskets fitted in the gas line. whilst the appliance is running.
Ensure that all seals are correctly fitted and that the pres- – Check the operation of the appliance in both C.H. and
sure sensing line is correctly fitted. D.H.W. mode and ensure in both cases that the burner
Check that the fan earth connection is correctly re-fitted. pressure after at least 5 minutes running is as stated on
Note that the fan polarity (Line and Neutral) is immaterial. the data plate or in Table 3.
– Check for gas soundness before fitting the casing. Adjust if necessary as described in section 8.

6 FAULT FINDING
When any service or replacement of electrical components 6.4 RESISTANCE TO EARTH CHECK
which has required the breaking and re-making of electrical
connections has taken place, the following tests must be Appliance must be disconnected from main supply and meter
repeated: on Ω (ohm) x 100 scale. All switches including thermostat on
– earth continuity; test leads from L to E - if meter reads other than infinity (∞)
– short circuit; there is a fault which should be isolated. A detailed continuity
– polarity; check is required to trace the faulty component.
– resistance to earth.
IMPORTANT: These series of checks are the first electrical
checks to be carried out during a fault finding procedure.
6.1 EARTH CONTINUITY CHECK On completion of the service/fault finding task which has
required the breaking and remaking of electrical connec-
Appliances must be electrically disconnected, meter set on Ω tions then the checks 6.1 Earth continuity, 6.3 Polarity and
(ohm) x 1 scale and adjust zero if necessary. Tests leads from 6.4 Resistance to earth must be repeated.
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 6.5 FAULT FINDING LEDS
(ohm) check all earth wires for continuity and all contacts are
clean and tight. If the resistance to earth is still greater than The indicator leds signalling irregular and/or incorrect oper-
1 Ω (ohm) then this should be investigated futher. ation of the equipment are indicated in fig. 25.
Before commencing any service operation, ISOLATE the
mains electrical supply, and TURN OFF the gas supply at the
6.2 SHORT CIRCUIT CHECK main service cock. It is the law that any service work must be
carried out by registered personnel (Gas Safe Register).
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. Bi-colour green led off if power is cut-off
Meter set on Ω (ohm) x 100 scale. Repeat it with leads from Bi-colour orange led: C.H. sensor fault
L to E. If meter reads less than infinity (∞) there is a fault. Green led flashing: fan/smoke pressure switch failure
Bi-colour orange led flashing: insufficient system pressure
NOTE: Should it be found that the fuse has failed but no
fault is indicated, a detailed continuity check (i.e. by discon-
necting 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 evi-
dence of burning around the fault.

6.3 POLARITY CHECK Red led on, ignition lock-out/smokes stats tripped: turn
the selector switch to the position marked (|) until both
Appliance reconnected to mains supply and meter set on leds on the facia panel flash, then turn it back to the
300 V ac scale. Test at appliance terminal block. previous position to restore functioning
– Test leads from L to N meter reads approx.: 240 V ac.
– Test leads from L to E “ ” meter reads approx. 240 V ac. Fig. 25
– Test leads from N to E “ ” meter reads from 0 to 15 V ac.

24
6.6 C.H. MODE - FAULT FINDING

Start from cold Selector switch set to ON position.

Room thermostat (if fitted) calling for heat.
C.H. thermostat set to maximum position.
Clock in the ON position.

Yes

Is there power
No Make Does Yes Does No Check air pressure No
switch and his Replace air Is there a spark
at the external power the pump the fan
connections, are pressure switch at the electrode? Yes
socket? available start? start?
they OK?

Yes No Yes No
Is fuse Yes Is there power Yes No Is there 230V AC No No Yes
Is the green Replace fuse Check: gap
at mains at L and N available at the Replace the PCB
led on? on the PCB between the
plug OK? terminals? fan terminals?
electrode and
burner, conditions
No No Yes Yes of the electrode
and ignition
Check wire
Is the clock in No Turn the clock
transformer.
Replace fuse in connections Replace Does it spark
the correct to the right
mains plug to L and N the fan now?
band time? position
terminals

Yes
Close room
thermostat
contact Check the
time clock.
Do the contact
No open and close
when the clock
Is the room
No Is there voltage Yes turns? No
Replace
thermostat available
the clock
contact closed? to the pump?

Yes Yes
Yes
Check pump Is pump shaft Replace
connection free to rotate? the pump

No

Make it free to
rotate

No
No Yes Yes Yes Can the burner Yes Does the burner No
Check: gap pressure be pressure reduce
Has the PCB between the reduced by the as the temperature Check:
Has the PCB After two minutes
ignition electrode and C.H. adjuster? rises towards max.?
ignition (safety time +
locked-out after burner, conditions 1) C.H.
locked-out after C.H. delay time),
10 seconds of the electrode Yes thermistor
10 seconds is the burner
with flame and ignition
without flame pressure set to
at the burner?
at the burner transformer.
the maximum? No Is there No Does the boiler No 2) PCB control
before lock? Does it now switch off before board
voltage at the
detect the flame? achieving the tem-
modulator?
perature?

Yes No Yes Yes

No Yes
Is the gas Open the Is L and N Replace the Boiler is
Replace the PCB
available? gas cock polarity correct? modulator satisfactory

Yes No
No Reset* the
Is the safety Replace the
safety Correct
thermostat OK? C.H. thermistor
thermostat

Yes

Is there
Yes * To reset the overheat thermostat
Replace the
voltage available
to the gas valve?
gas valve The appliance is fitted with a safety cut-out thermostat. In the
event of overheating this will interrupt the power supply and pre-
No vent the appliance from functioning.
If this occurs, allow the appliance to cool, reinstate the thermostat
Check the button as shown in figure, turn the rotary switch to “|“ position
connection until both leds on the facia panel flash; then turn it back to the pre-
vious position. If the cut-out condition is repeated, turn off the elec-
trical supply and consult your installer or service engineer.

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.
25
 7 WIRING & FUNCTIONAL DIAGRAMS

7.1 ILLUSTRATED FLOW WIRING DIAGRAM

WIRING DIAGRAM
24 VAC

5 VDC 240 VAC

JUMPERS N

see the table

240 VAC
ROOM
THERMOSTAT

240 VAC

NOTE:
240 VAC
To incorporate a room thermo-
17 VDC stat remove the link between
H.L.
2 and 4 and wire the room
STAT stat to terminals 2 and 4.

240 VAC
240 VAC
SAFETY
STAT

240 VAC 240 VAC

WIRING DIAGRAM WITH THE TIME PROGRAMMER BUILT-IN

24 VAC

240 VAC
5 VDC 240 VAC

JUMPERS N

see the table

240 VAC

240 VAC
ROOM
THERMOSTAT

240 VAC
NOTE:
17 VDC
To incorporate a room thermo-
H.L. stat remove the link between
STAT
2 and 6 and wire the room
stat to terminals 2 and 6.
240 VAC
240 VAC
SAFETY
STAT

240 VAC 240 VAC

JUMPERS POSITION AND FEATURES

JUMPER POSITION AND FEATURE SUPPLY POSITION

CLOSED OPEN
J7 - POT. ACC.* Ignition power from 50% to max. Ignition power from min. to max. Open
J8 - METANO/GPL Ready to function with LPG Ready to function with natural gas Open

* The jumper modify the ignition pressure (STEP) of the gas valve. With the jumper not inserted during the ignition phase the gas pressure varies linearly
from minimum to maximum of the heating power. With the jumper inserted the gas pressure varies linearly from the 50% to the maximum heating
power. When functioning with butane (G30) or propane (G31) gas it is recommended to insert the jumper in case is necessary to improve the ignition. Fig. 26

26
7.2 TIME PROGRAMMER (optional)

The control panel is designed to allocate a timer-program-

mer, code 8092208, 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. 27).
Connect the unit as shown in the wiring diagram (fig. 26).

Fig. 27

7.3 FUNCTIONAL DIAGRAM WITH TWO ZONE VALVES OR THREE WAY VALVE

Fig. 28

7.4 SYSTEM USING MID POSITION ZONE VALVE

KEY
HW Hot water request
HTG Heating request
HWP Hot water program
HTGP Heating request program

Fig. 29

27
 7.5 SYSTEM USING A THREE WAY VALVE

KEY
HW Hot water request
HTG Heating request
HWP Hot water program
HTGP Heating request program

Fig. 30

7.6 SYSTEM USING TWO ZONE VALVES

KEY
HW Hot water request
HTG Heating request
HWP Hot water program
HTGP Heating request program

Fig. 31

28
8 REPLACEMENT OF PARTS

8.1 HEAT EXCHANGER (fig. 32) and test for gas soundness.
– Re-commission the appliance as described in section 4.
– 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 8.5 IGNITION/DETECTION ELECTRODE
the hood.
– Isolate the C.H. flow and return valves. – Remove the casing front panel and sealed chamber front
– Drain the heat exchanger using the drain cock (at the bot- panel as described in section 5.1.
tom RHS of the appliance) – Unscrew the single screw securing the electrode in posi-
– Unclip the heat exchanger securing clips and unscrew tion, and release the electrode from the burner.
completely the expansion vessel nut. – Remove the electrode and disconnect its cable from the
– Disconnect the pipes from the exchanger and lift out the ignition transformer.
heat exchanger. – Replace the electrode and re-assemble in reverse order.
– 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

4 ± 0.5
which is marked on the appliance). IGNITION/DETECTION
– Refill, and re-commission the system as described in sec- ELECTRODE
tion 4.

8.2 COMBUSTION CHAMBER INSULATION

The design of this appliance is such that the rear and side
insulation should not require replacement unless mechanical-
ly damaged.
IMPORTANT: When handling insulation panels, take care to
avoid producing or inhaling dust particles. When removing
Fig. 32
old or damaged insulation panels, dampen with water to
minimise dust.
To replace the insulation front panel, proceed as follows:
– r emove t he combus tion chamber fr ont panel as 8.6 GAS VALVE
described in section 5.1;
– replace the front insulation panel and glue it into position – Remove the casing front panel as described in section 5.1.
on the front panel using the glue supplied. Re-assemble in – Disconnect the two leads from the modulating solenoid
reverse order. and disconnect the valve connector (one screw).
Should the rear or side panels become damaged, replace – Unscrew the nut between the inlet pipe and the valve.
them as follows. – Unscrew the burner manifold nut underneath the
– remove the heat exchanger as described in section 8.1; sealed chamber, and withdraw the gas valve complete
– remove the side insulation panels followed by the rear with outlet pipe.
panel; – Transfer the outlet pipe onto the new gas valve, using a
– re-assemble in reverse order, refill, and recommission the new gasket (supplied with the valve).
system as described in section 4. – 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.
8.3 FAN ASSEMBLY – Re-light the appliance, check for gas soundness, and re-
commission in accordance with section 4.
– Remove the casing front panel and sealed chamber front
panel as described in section 5.1. In addition it will be necessary to set the C.H. heat output,
– Disconnect the electrical connections and the pressure with reference to fig. 33, as follows:
sensing pipes to the fan. Note the position of the earth Note that it is necessary to set the MAXIMUM PRESSURE FIRST.
conductor. – Connect a pressure gauge to the burner pressure
– Unscrew the three screws securing the fan. test point.
– Drop and tilt the fan forwards and remove in a down- – Remove the sealing cap of the proportioning unit (C) by
wards direction. rotating it ⁄ turn anticlockwise.
– Re-assemble in reverse order. Ensure that the earth con- – Remove (pull forwards) the C.H. knob to gain access to the
nection is correctly refitted. Note that the polarity (Line potentiometer of the heating output and rotate the poten-
and Neutral) is immaterial. tiometer fully clockwise with a screwdriver (refer to fig. 22).
8.4 MAIN BURNER – Ensure that heating programmers or room thermostats are
calling for heat and that there is an adequate circulation in
– Remove the main burner by following section 5.1. the system. Turn the C.H. knob to maximum and the rotary
– Transfer the ignition electrode onto the new burner switch to ON. Turn on the electrical supply and the burner will
assembly. light.
– Re-assemble in reverse order. Check the electrode gaps – Using a 10 mm spanner, turn nut (B) to attain the maxi-
29
 mum pressure in Table 3. 8.8 RESETTABLE OVERHEAT THERMOSTAT 102 °C
Turn the nut clockwise to increase or anti-clockwise to
decrease the burner pressure. The overheat thermostat is situated on the flow pipe, in the
– Turn the rotary switch on and off a few times and check lower part of the boiler (14 fig. 3).
that the pressure returns to the correct (set) maximum – Remove the casing front panel as described in section 5.1.
value (as in Table 3). – Tilt downward the control panel.
– Set the minimum burner pressure by first isolating the – Disconnect the plug from the safety thermostat.
electricity supply and disconnecting one of the modulat- – Unscrew the two limit thermostat fixing screws and
ing solenoid leads, then restore the electricity supply and remove the thermostat.
let the boiler start. – Replace the thermostat and spread heat sink compound
– Set the minimum pressure with reference to Tables 3 by (supplied) over the base of the new one.
holding nut (B) in position with a 10 mm spanner and rotat- – Re-assemble in reverse order. (Polarity is immaterial).
ing 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 8.9 LIMIT THERMOSTAT 85 °C
that the max pressure has been set prior to adjusting the
minimum pressure. Check that the minimum pressure is The limit thermostat is situated onto the main exchanger, in
correctly set by turning on and off the rotary switch several the left part of the boiler (10 fig. 3).
times and ensuring that the pressure returns to that previ- – Remove the casing front panel and the sealed chamber
ously adjusted; front panel as described in section 5.1.
– Isolate the power supply, re-connect the modulation lead, – Remove the left air deflector over the main exchanger to
restore the power and re-check the maximum pressure, gain access to the limit thermostat.
then re-fit the plastic cover (1). – Disconnect the plug from the thermostat.
– Adjust the Central Heating maximum pressure as – Unscrew the two limit thermostat fixing screws and
described in section 4.3, then complete the re-commis- remove the thermostat.
sioning as described in 4.4. – Replace the thermostat and spread heat sink compound
(supplied) over the base of the new one.
– Re-assemble in reverse order. (Polarity is immaterial).

8.10 THERMISTOR

The thermistor is placed over the main exchanger.

– Remove the casing front panel as described in section 5.1.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2), and
drain the appliance through the drain plug (14 fig. 2).
– Pull off the electric connection, and unscrew the thermis-
tor from the exchanger.
– Replace the thermistor and re-assemble in reverse order.
Table 8 shows the resistance values (Ω) that are obtained
on the sensor as the temperature varies.

TABLE 8

Temperature (°C) Resistance (Ω)

20 12,090
KEY
A Plastic screw 30 8,313
B Nut 40 5,828
C Sealing cap 50 4,161
Fig. 33 60 3,021
70 2,229
80 1,669

8.7 AIR PRESSURE SWITCH

8.11 DRIVER PCB
– Remove the casing front panel and sealed chamber front
panel as described in section 5.1. – Remove the casing front panel as described in section 5.1.
– Disconnect the pressure sensing pipe from the switch. – Open the control panel protecting cover by removing the
– Remove the switch (two screws) and fit the new one. three fixing screw and remove the cover protecting the
– Transfer the electrical connections one at a time (to ensure wirings (two screws).
that they are not incorrectly re-fitted) to the new switch. – Pull off the knobs.
– Re-assemble in reverse order referring to the wiring dia- – Release the PCB (four screws), transfer all connections
grams (section 7) if necessary. Ensure that the pressure onto the new PCB, and re-assemble in reverse order.
sensing lead is correctly connected to the low pressure – Ensure jumper links are fitted correctly (see fig. 26).
connection on the pressure switch (marked P2). – Re-set the CH burner pressure as described in section 4.3.
30
8.12 PUMP MOTOR – Remove the circlip securing the valve to the hydraulic
group and remove the valve assembly.
– Remove the casing front panel as described in section 5.1. – Mount the olive, locking nut and discharge pipe onto the
– Unplug the electrical connection plug. new valve.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2), and – Fit the new safety valve assembly and re-assemble in
drain the appliance through the drain plug (14 fig 2). reverse order. Refill and re-commission the system as
– Unscrew the four fixing screws on the motor. described in section 4.1.
– Replace the pump motor and re-assemble in reverse order.
– Refill and commission the system as described in section 4.1.
8.17 AUTOMATIC AIR VENT

8.13 C.H. EXPANSION VESSEL – Remove the casing front panel as described in section 5.1.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2).
Replacement is not recommended if a rear flue outlet is used – Drain the appliance through the drain point (14 fig. 2).
or if the clearance above the casing is less than 300 mm; in – Remove the circlip securing the automatic air vent to the
this cases is advisable to fit an external expansion vessel. hydraulic group.
– Remove the casing front panel as described in section 5.1. – Fit the new automatic air vent and re-assemble in reverse
– Isolate the C.H. flow and return valves (17 - 18 fig. 2), and order. Refill and re-commission the system as described
drain the appliance through the drain plug (14 fig. 2). in section 4.1.
– Unscrew the expansion vessel union on the C.H. return pipe.
– If a rear flue outlet is used it is necessary to disengage
the flue and air duct temporarily. Refer to section 3.5. 8.18 TIME CLOCK (if fitted)
– Remove the adjusting screws on the wall mounting brack-
et thereby allowing the appliance to move slightly for- – Remove the casing front panel as described in section 5.1.
wards at the top. – Tilt downward the control panel.
– Lift the expansion vessel out of the appliance through – Open the control panel protecting cover by removing the
the top. three fixing screw and remove the cover protecting the
– Replace the expansion vessel and re-assemble in reverse wirings (two screws).
order. Re-pressurise and re-commission the system as – Pull off the electrical connections at the back of the
described in section 4.1. clock.
– Remove the two screws securing the time clock to the
facia panel and pull out the time clock.
8.14 WATER PRESSURE SWITCH – Re-assemble in reverse order and test the operation of
the new clock.
– The water pressure switch is situated on the flow pipe, in – Set it to the desired settings as described in section 4.3.
the lower part of the boiler.
– Remove the casing front panel as described in section 5.1.
– Tilt downward the control panel.
– Isolate the C.H. flow and return valves (17 - 18 fig. 2).
– Drain the appliance through the drain point (14 fig. 2).
– Disconnect the plug from the water pressure switch.
– Remove the water pressure switch by unscrewing it.
– Replace it and eassemble in reverse order. Refill and re-
commission the system as described in section 4.1.

8.15 PRESSURE GAUGE

– 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 (14 fig. 2).
– Remove the circlip securing the pressure sensor to the
hydraulic group and pull out the sensor.
– 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 sec-
tion 4.1.

8.16 SAFETY VALVE

– 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 (14 fig. 2)
31
 9 EXPLODED VIEWS

COD. 3820050/683 TYPE FORMAT SYSTEM DATE 25.11.2002 PAGE 1/3

32
 COD. 3820050/683 TYPE FORMAT SYSTEM DATE 25.11.2002 PAGE 2/3

POSITION CODE DESCRIPTION MODEL NOTE POSITION CODE DESCRIPTION MODEL NOTE

1 6138570 Side frame part 27 A • 6174235 Heat exchanger 30

2 6138770 Frame assembly upper support 24 28 • 6231351 Plunged sensor
2 A 6138771 Frame assembly upper support 30 29 • 6022010 Sensor gasket
3 6255430 Expansion vessel lower support 24 30 5190600 Smoke chamber assembly 24
3 A 6255431 Expansion vessel lower support 30 30 A 5190610 Smoke chamber assembly 30
4 • 5139140 Expansion vessel l.7 - 3/8” M 24 31 2016020 Locked nut M4
4 A • 5139130 Expansion vessel l.8 - 3/8” M 30 32 • 6225621 Fan 24
5 6146305 Brass Nut 3/8” 32 A • 6225622 Fan 30
6 6288100 Sealed chamber rear panel 24 33 2000705 Screw M4x12
6 A 6288110 Sealed chamber rear panel 30 34 6288700 Combustion chamber front panel 24
7 6223202 Burner centering pin 34 A 6288710 Combustion chamber front panel 30
8 5190700 Main burner assembly 24 35 6257511 Air deflector
8 A 5190750 Main burner assembly 30 36 6139770 Combustion chamber front insulation 24
9 6022004 Copper washer Ø 6 36 A 6139771 Combustion chamber front insulation 30
10 6154402 Main burner nozzle NP 130 natural gas 37 6264825 C.H. return pipe 24
10 A 6154410 Main burner nozzle NP 77 GLP 24 37 A 6264826 C.H. return pipe 30
10 B 6154414 Main burner nozzle NP 78 GLP 30 38 • 6226412 O-ring 3068
11 • 6235929 Ignition-ionisation electrode 39 • 6226601 Spring for heat exchanger connection
12 6146301 Brass nut 1/2” 40 2030226 Gasket Ø 10,2x14,8x2
13 6288400 Combustion chamber rear panel 24 41 6264734 C.H. flow pipe 24
13 A 6288410 Combustion chamber rear panel 30 41 A 6264735 C.H. flow pipe 30
14 6288500 Combust. chamber right hand side panel 24 42 6146720 102°C safety stat
14 A 6288510 Combust. chamber right hand side panel 30 43 • 6226602 Pipe fixing spring
15 6288600 Combust. chamber left hand side panel 24 44 6119370 Plastic plug
15 A 6288610 Combust. chamber left hand side panel 30 45 • 6226414 O-ring 117 Ø 13,1x2,62 EP851
16 6139772 Combustion chamber rear insulation 24 46 6138870 Frame assembly lower side 24
16 A 6139773 Combustion chamber rear insulation 30 46 A 6138880 Frame assembly lower side 30
17 6139774 Combustion chamber side insulation 47 6100202 Ogive for pipe Ø 15
18 6287900 Air/smoke manifold 48 • 6037502 Water pressure switch
19 6147406 Air/smoke manifold plug M14x1.5 49 • 6013101 Automatic air vent
20 • 6226417 O-ring 3043 50 • 6017210 Manual air vent 1/4”
21 6242602 Air/smoke manifold screw 51 6281500 Straight fitting 3/4”
22 6248803 Lip seal for Ø 60 pipe 52 2030225 Gasket Ø 5,5x11x2
23 6028706 Air/smoke manifold gasket 53 6247326 Cap for knob hole
24 6028707 Air intake gasket 54 6247327 Cap for time programmer
25 6288000 Air intake 55 • 6146700 Limit stat auto reset
26 6257512 Air deflector for separate ducts 56 6168401 Locking nut for pipe Ø 15
27 • 6174234 Heat exchanger 24 57 6226607 Pipe fixing spring
• Recommended stock parts - Componenti da tenere a scorta
Fonderie Sime S.p.A. - Via Garbo, 27 - 37045 Legnago (Verona) - Tel. +39-0442-631111 - Fax +39-0442-631292 - www.sime.it

33
34
COD. 3820050/683 TYPE FORMAT SYSTEM DATE 25.11.2002 PAGE 3/3

POSITION CODE DESCRIPTION MODEL NOTE POSITION CODE DESCRIPTION MODEL NOTE
58 • 6272301 Circulating pump VA 55 Dab motor 94 6287321 Casing 24
59 • 6028705 Gasket EP709 for Dab 94 A 6287331 Casing 30
60 6281521 Flange + OR for Dab pump 95 • 2013302 Fastener for self tapping screw
61 2000201 Screw M5x40 96 2004510 Screw 8Px7/8”
62 • 6040201 Pressure relief valve 97 6112420 Control panel screw
63 6288200 Sealed chamber side panel 98 6028624 Air diaphragm Ø 87.5
64 6280511 3-ways junction 99 5192200 Gasket for sealed chamber
65 • 5192100 Air pressure switch 100 6263905 Fan pressure test point
66 2013303 Fastener for self tapping screw 101 6223351 Venturi 24
67 • 6243810 SIT gas valve type 845 SIGMA 101 A 6223352 Venturi 30
68 6226856 Gas inlet pipe 102 6157602 Pressure relief valve drain pipe
69 6226945 Pipe connecting gas valve-main burner
70 2030228 Gasket Ø 17x24x2 1010100 Anti-condensing pipe Ø 8.9x17
71 6146302 Brass nut 3/4” 5187351 Technyl hydraulic group
72 2030227 Gasket Ø 12x18x2 5191112 Complete control panel
73 6289810 Control panel 6031206 Main cable L=2000
74 6273210 Guidelight - 2 ways out 6245335 845 Sigma gas valve connector
75 6146130 Hydrometer 6278675 5 pole Stocko cable connector J5
76 6230690 Main PCB with ignition 6293521 6 pole Stocko cable connector J5
77 • 6201501 Trimmer spindle Ø 5 6293523 4 pole Stocko cable connector J3
78 • 6201505 Trimmer spindle Ø 6 6293528 8 pole Stocko cable connector J2
79 2211004 Terminal strip • 5144712 Conversion kit to LPG 24
80 2211610 Earth faston • 5144713 Conversion kit to LPG 30
81 • 6098305 Ignition transformer 5185403 Convers. kit to the nat. gas 25-30 kW
82 6289900 Control panel protecting cover • 6281506 O-ring kit for hydraulic group
83 6290300 Control panel cable cover 6281507 Split pin kit for hydraulic group
84 6290200 Room stat connection cover • 6233506 Fuse T1,6A 250V
85 6290100 Knob Ø 40
86 6009585 Control panel bracket Products reference:
87 6290003 Flap door
88 6290350 Terminal strip protection cover 8098470 Format System 24 Natural gas
89 6266902 Anti-jamming filter 8098471 Format System 24 LPG
90 6177505 Ball cock 3/4” x 22 UK 8098472 Format System 30 Natural gas
90 A 6177523 Ball cock 3/4” EIRE 8098475 Format System 24 EI Natural gas
91 6177504 Gas cock 1/2” x 1/2” 8098476 Format System 24 EI LPG
92 6288350 Sealed chamber front panel 24 8098477 Format System 30 EI Natural gas
92 A 6288360 Sealed chamber front panel 30
93 6001210 Peephole Check the correspondence with the boiler data plate.
• Recommended stock parts - Componenti da tenere a scorta
Fonderie Sime S.p.A. - Via Garbo, 27 - 37045 Legnago (Verona) - Tel. +39-0442-631111 - Fax +39-0442-631292 - www.sime.it
 GAS CONVERSION

A kit is supplied upon request complete with the necessary change-over materials for operation with butane
gas (G30) or propane gas (G31). Operate in the following manner for changing over from one gas to anoth-
er:
– Close the gas cock.
– Slide out the burner unit.
– Replace the main nozzles (6) supplied in a kit, inserting the copper washer (4). Use a ø 7 spanner to
perform this operation.
– Remove the “MET/GPL” connector link on the main board and set it on “GPL”.
– To set the values of maximum and minimum gas pressure, follow the instructions given in section 8.6.
When the working pressures have been adjusted, reseal the regulators.
– After the conversion of the boiler, please stick onto the casing panel the plate showing the relevant feed-
ing gas which is included in the kit.

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

KEY
1 Swivel connection 1/2”
2 Locknut 1/2”
3 Burner manifold
4 Washer ø 6.1
5 Burners
6 Nozzle M6
7 Screw

WARNING: To ensure a per-

fect seal, always use the
washer (4) supplied in the
kit when replacing nozzles,
even in burner units for
which it is not specified.
 Cod. 6272255A - 06/12 - 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: [email protected]