Sime FORMAT 34I BF User manual

Format
34I-34E BF
AUS

1
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.
– as a correct by-pass been fitted and adjusted?
– as the system 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?
– as the pump been rotated manually?
– Is the gas supply working pressure correct?
– Is the boiler wired correctly? (See installation manual).
– as the D. .W. flow rate been set to the customer requirements?
– as the customer been fully advised on the correct use of the boiler, system and controls?
1 TECHNICAL FEATURES AND DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 ENERAL REQUIREMENTS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 INSTALLIN THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 COMMISSIONIN AND TESTIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5 ROUTINE SERVICIN INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 FAULT FINDIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7 WIRIN & FUNCTIONAL DIA RAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
CONTENTS
Installation and servicing instructions

2
1.1 INTRODUCTION
The Sime Format series wall hung boilers are fully automatic
power flued, wall mounted boilers for central heating and
instantaneous production of D. .W.
Model “34I BF” is an internally installed boiler.
Model “34E BF” is an externally installed boiler.
They are provided with direct fired ignition, and modulating
temperature control, circulating pump and expansion tank.
The central heating output has an adjustable output of 11.2 –
34 kW.
NOTE: The boilers must not to be used for pool or spa
heating. The boilers must be installed only by an autho-
rised person.
1 TECHNICAL FEATURES AND DIMENSIONS
TABLE 2 - Minimum clearances
For ventilation For servicing
ABOVE THE APPLIANCE CASIN 400 mm 300 mm
AT THE R.H.S. 15 m m 15 m m
AT THE L.H.S. 15 m m 15 m m
BELOW THE APPLIANCE CASIN 200 mm 200 mm
IN FRONT OF THE APPLIANCE 100 mm 500 mm
TABLE 1 - Connections
1.2 DIMENSIONAL DETAILS
Fig. 1
“FORMAT 34I BF” model
“FORMAT 34E BF” model
R C.H. return 3/4
M C.H. flow 3/4
as connection 3/4
U Hot water 1/2
E Cold water 1/2

3
1.3 ENERAL DATA
TABLE 4 - eneral specifications
TABLE 3 - Heating data
FORMAT 34I - 34E BF
Main burner injectors No off 15
Dia for Naural gas mm 1.45
Dia for LPG mm 0.85
Water capacity l (gal) 4.7 (1.00)
Minimum water flow D.H.W. l/min (gal/min) 2 (0.5)
D.H.W. flow rate
at a temperature rise of 30°C l/min (gal/min) 15.1 (3.3)
35°C l/min (gal/min) 12.9 (2.8)
Burner pressure Natural gas Maximum kPa 0.71
Minimum kPa 0.09
Burner pressure LP (Propane) Maximum kPa 2.41
Minimum kPa 0.5
Static head Maximum bar (psi) 3.0 (43.5)
Minimum bar (psi) 0.5 (7.3)
D.H.W. pressure Minimum bar (psi) 1.0 (14.6)
Maximum bar (psi) 6.0* (87)
Weight Empty kg (lb) 40 (88)
Total (full) kg (lb) 44.7 (98)
Electrical supply 230 V - 50 z, Fused at 3 A
Internal fuse Line: F 1.6 A
Maximum power consumption Watt 160
Maximum gas consumpt. (Natural gas) m3/h 3.68
Maximum gas consumpt. (Propane) kg/h 2.74 - 2.70
Max. working temperature °C (F) 95 (203)
Integral exp. vessel capacity l (gal) 8 (1.76)
* For greater pressures it is necessary to install a pressure reducer in the inlet of D. .W.
Heat Output Input
(Adjustable) (Adjustable)
FORMAT 34I BF 11.2 - 34 kW 45 - 145 MJ/hr
FORMAT 34E BF 11.2 - 34 kW 45 - 145 MJ/hr

4
DHW MCW GAS FLOW RETURN
1.4 HYDRAULIC CIRCUIT
KEY
1Fan
2 Water-gas exchanger
3 Combustion chamber
4 Gas valve
5 D. .W. exchanger
6 Divertor valve
7 NTC sensor
8 100°C safety thermostat
9 C. . water filter
10 Air relief valve
11 Circulation pump
12 Expansion vessel
13 Safety valve
14 Drain plug
15 Water flow switch
16 Temperature and pressure gauge
17 Automatic by-pass
18 D. .W. filter
Fig. 2
6
12
11
10
9
8
7
5
4
3
2
1
13
14
19
1.5 INTERNAL VIEW
KEY
1 Control panel
2 Ignition transformer
3 Combustion chamber
4Fan
5 Combustion analysis intakes
6 Negative pressure intake
7 Positive pressure intake
8 Air pressure switch
9 C. . sensor (SM)
10 Main exchanger
11 100°C safety stata
12 Gas valve
13 Flow water switch
14 Divertor valve
19 C. . water filter
Fig. 3

5
2.1 INSTALLATION
Models “34E BF” with a hermetically sealed combustion cham-
ber and air supply circuit, may be installed outdoor.
Models “34I BF” with a hermetically sealed combustion cham-
ber and air supply circuit, may be installed in any room in the
home.
2.2 CONNECTIN UP SYSTEM
Wash all system pipes well before hooking them up with the
boiler to eliminate any residues which could compromise its
functioning.
The discharge pipe must be connected and extend the pipe
to ensure that any discharge is safety routed any.
THE BOILERS MUST BE INSTALLED STRICTLY IN ACCOR-
DANCE WITH THESE INSTRUCTIONS AND MEET THE
NATIONAL AS INSTALLATION STANDARD AS 5601.
AND ANY LOCAL WATER AND ELECTRICAL STATE AND
LOCAL OVERNMENT RE ULATIONS WHICH MAY BE
APPLICABLE.
For installations where the heater is connected to larger
systems, the additional volume will need to be taken into
account.
A temperature pressure relief valve may be needed.
An adhesive data plate is sticked inside the front panel; it con-
tains all the technical data identifying the boiler and the type
of gas for which the boiler is arranged.
2.3 CHARACTERISTICS OF FEEDWATER
To prevent lime scale and damage to the tap water exchan-
ger, the water supplied should have a hardness of no more
than 20°F. In all cases the water used should be tested and
adequate treatment devices should be installed.
2.4 FLUE TERMINAL POSITION MODEL “34I BF”
The outlet terminals for forced draught systems may be
located on the outer walls of the building. Fig 4 shows
approximate, non-binding minimum distances to be met for a
building of the type shown in fig. 4.
2 ENERAL REQUIREMENTS FOR INSTALLATION
Fig. 4

6
2.5 ELECTRICITY SUPPLY
The electrical connection is made to a standard 10 amp 3
pin outlet. It is essential that a positive earth be made for the
satisfactory operation of the boilers.
THIS MUST BE FITTED BY A QUALIFIED ELECTRICAN.
2.6 WATER SYSTEMS - ENERAL
– This appliance is designed for connection to sealed cen-
tral heating water systems.
– Check that the mains water pressure is sufficient to pro-
duce the required D. .W. flow rate, but does not exceed
the maximum D. .W. pressure (Table 4).
Where mains pressure exceed 6 bar a pressure reduc-
ing valve must be fitted in the D.H.W. inlet.
2.6.1 Treatment of Water Circulating Systems
The condition of the water in the system is of great impor-
tance. Treatment such as Fernox is recommended to reduce
the effect of sludge and scale on the efficiency of the heating
system.
2.7 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. 5.
b) The appliance is equipped with an internal by-pass that
operates with system heads ( ) greater than 3 m. The
maximum flow through the by-pass is about 300 l/h. If
thermostatic radiator valves are to be installed, at least
one radiator should be without a thermostatic valve (usu-
ally the bathroom radiator).
c) The following paragraphs outline the specifications of the
items fitted to the boiler.
2.7.1 Pump
The available head shown in fig. 5 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 out-
put in C. . mode.
Never reduce the pump speed below maximum as this will
reduce D. .W. output. The pump speed is indicated on the
side of the pump speed selector switch (if fitted).
2.7.2 System volume (total water content)
The following Table 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 expan-
sion 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.
0200 1600
140012001000800600400
Flow rate (l/h)
Available head (mbar)
500
400
100
200
300
Format 34I- 34E
Fig. 5

7
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.
2.7.3 Pressure gauge
A pressure gauge is mounted on the appliance facia panel.
2.7.4 Safety valve
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
cause damage to persons or property but would be detected.
The pipe should be able to withstand boiling water, be a mini-
mum of 15 mm in diameter, and installed with a continuous fall.
2.8 D.H.W. SYSTEMS
– Check that the mains supply pressure is within the pre-
scribed limits (
Table 4 ).
If necessary, a pressure reducing valve should be fitted to
the mains supply before the D. .W. inlet connection.
– A maximum D. .W. flow rate of: 14 l/m (3.1 gpm) is rec-
ommended. igher flow rates will not damage the appli-
ance but may lower the water temperature below an
acceptable level.
– If the appliance is installed in an area where the tempo-
rary 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. .W. circuit, consult the Local Water Undertaking, how-
ever the following information is given for guidance.
2.8.1 Domestic hot/cold water supply
taps and mixing taps
All equipment designed for use at mains water pressure is
suitable.
2.8.2 Showers
If a shower control is supplied from the appliance it should be
of the thermostatic or pressure balanced type.
Thermostatic type shower valves provide the best comfort
and guard against water at too high temperature.
Existing controls may not be suitable, refer to the shower
valve manufacturer.
Vessel charge and initial system
pressure
Total water content of system
using 8 l (1.76 gal) capacity expan-
sion vessel supplied with appliance
For systems having a larger capaci-
ty multiply the total system capacity
in litres (gal) by the factor to obtain
the total minimum expansion vessel
capacity required litres (gal)
bar
psi
l
gal
0.5
7. 3
96
21.1
.0833
1.5
21.8
51
11. 2
.15 6
1.0
14.5
74
16.2
.10 9
TABLE 6

C12
C32
C42
3
1
2
7
6
4
3
2
min 1,3 m - max 5 m
8
x
y
x + y = max 3,5 m "25"
x + y = max 3,0 m "30-35"
max 3,5 m "25"
max 3,0 m "30-35"
8
APPLIANCE PACKA E:
- boiler (assembled);
- installation and servicing instructions;
- users instructions;
- wall mounting bracket;
- fixing screws with wall plugs.
3.1 FIXIN THE WALL MOUNTIN 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 provide access
for servicing, and are included on the wall mounting tem-
plates.
– 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).
– 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
horizontal. Refer to fig. 12-14.
– Accurately measure the wall thickness, and note this
dimension for later use.
– Secure the wall mounting bracket in position using the
screws provided. Ensure that it is the correct way up, as
indicated in fig. 6.
3.2 HAN IN THE BOILER
– Lift the appliance into position. The upper cross member
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 MODEL “34I BF”
The air inlet-smoke outlet assembly ø 60/100 is supplied in a
kit code 8084811 complete with mounting instructions.
With the curve supplied in the kit the maximum horizontal
length of the flue must not exceed 3 metres.
When the extension code 8086908 is used, the end of
the flue must always have a horizontal outlet.
The diagrams in fig. 7 illustrate a number of examples of dif-
ferent coaxial outlets.
3 INSTALLIN THE BOILER
Fig. 6
KEY
1 Wall mounting bracket
2 Plastic wall plug (2 Off)
3 Woodscrew (2 Off)
4 Washer (2 Off)
5 Adjustment screw (2 Off)
KEY
1 Coaxial flue kit code 8084811
2 a Extension L. 1000 code 8096100
2 b Extension L. 500 code 8096101
3 Vertical extension L. 200 code 8086908
4 Additional 90° curve code 8095800
6 Articulated tile code 8091300
7 Roof outlet terminal L. 1284 code 8091200
8 Vertical condensation collector L. 200 code 8092803
Fig. 7
IMPORTANT:
– Each additional 90° curve installed reduces
the available length by 0.90 metres.
– Each additional 45° curve installed reduces
the available length by 0.45 metres.
– It is advisable to assemble the condensation
collector (8) on vertical segments exceeding
2.5 metres in length and to limit maximum
length to 4 metres.
max 3 m
min. 1,3 m - max. 3 m

9
3.3.1 Coaxial flue diaphragm
The boiler is normally supplied with ø 87.5 diaphragm. Insert
the diaphragm only if the length of the coaxial flue.
Refer to fig. 8 for positioning.
With outlet type C12, install diaphragm ø 87.5 only if the coaxial flue is less than
1.5 metres.
With outlet type C32, use the following diaphragms, depending on flue length and
without any additional curves:
Installations with vertical extension L. 200 Installations with condensation
code 8086908 collector code 8092803
Optional Standard Standard None
diaphragm ø 86 diaphragm ø 87,5 diaphragm ø 87,5 diaphragm
(cód. 6028623)
L min = 1,3 m L min = 2,5 m L max = 2,5 m L min = 2,5 m
L max = 2,5 m L max = 3 m L max = 3 m
Fig. 8

10
3.6 SAFETY VALVE CONNECTION
– The appliance safety valve is located towards the R. .S. of
the boiler and the discharge pipe is supplied loose.
Remove the two selftapping screws and lower the control
box to improve access.
– Connect the discharge pipe to the valve outlet, and extend
the pipe to ensure that any discharge from the safety valve
is safely routed to a drain.
The discharge pipe should be a minimum of 15 mm copper,
and must avoid sharp corners or upward pipe runs where
water may be retained.
3.7 WIRIN INSTRUCTIONS (fig. 12)
– Disconnect the electric power supply before performing
any work.
Warning: all components in the control panel are fed
with 240V.
– Remove the three screws (7) locking the control panel in place
and pull the panel forward until it can be tilted downward.
– To access the components of the electrical panel,
unscrew the four screws holding the protective guard in
place (5).
– To gain access to connector “TA”, remove the control
panel cover and connect the room stat to the terminals 2-
6 after having removed the jumper (6).
– Carry out electrical system checks through a suitable test
meter: earth continuity, polarity, resistance to earth and
short circuit.
– Re-secure control box.
– Ensure sufficient length of cable to allow access to control
panel.

11
4
12 3
56 7
8
9
Fig. 12
ATTENTION: After having removed the three fixing screws, tilt the panel downward to gain access .
KEY
1 Temperature and pressure gauge
2 Time programmer housing
3 Rotary switch
4 Main PCB
5 Earth faston
6 Control panel protection
7 Cover (TA)
8 Connector (TA)
9 Fixing screw

4.1 FILLIN THE WATER SYSTEM
– Loosen the automatic air vent cap (10 fig. 2).
– Open all radiator valves and system air vents. Close all air
vents. Do not close the A.A.V. the one 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.
– Open the D. .W. inlet valve, open any hot tap, clear of air
bubbles. Close hot tap.
4.2 COMMISSIONIN THE BOILER
–
Remove the screw and connect a pressure gauge to the
burner pressure test point on the gas valve (fig. 13).
– Ensure that the rotary switch on the facia panel is set to the
SUMMER position “ ” (D. .W. Only), turn the D. .W. ther-
mostat to maximum (fully clockwise), and turn on the electri-
cal supply. Fully open any D. .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. .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. .W. flow rate is low. If modulation is suspected, open
all D. .W. taps to maximise flow and recheck burner pres-
sure). If it is necessary to adjust the D. .W. burner pres-
sure the method is described in section 8.6.
– Reduce the D. .W. draw off rate to the minimum neces-
sary to maintain the burner alight by carefully adjusting
the D. .W. inlet valve and check that the burner pressure
decreases in response to D. .W. temperature rise. Fully
open the inlet valve.
– Close the D. .W. tap and ensure that the burner is extin-
guished and the pump stops.
4.3 SETTIN 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. . thermostat knob to maximum (fully
clockwise) and the burner will light.
– Allow the boiler to run for at least 5 minutes and check
the burner pressure. The heating input is factory set as
stated in
Table 4 .
– 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. . knob protecting the
potentiometer;
– set the burner pressure as required using a small
screwdriver on potentiometer (1 fig. 14). Rotate the
screw anti-clockwise to reduce the burner pressure;
– operate the rotary switch between SUMMER and WIN-
TER position a few times and check that the correct
burner pressure is maintained.
– Replace the C. . knob over potentiometer.
– To set the time clock see the user instructions.
4.4 SETTIN THE D.H.W. FLOWRATE
A restrictor nut is fitted into the diverting valve to reduce the
D. .W. flow to that which will give an acceptable D. .W. tem-
perature. To set the D. .W. flow, procede as follows:
– select Summer position “ ” and turn the D. .W. thermo-
stat to max.;
– fully open the D. .W. tap furthest from the boiler;
–
check that the boiler is firing at maximum burner pressure;
– adjust the D. .W. flowrate by turning the restrictor lever
on the divertor valve until a D. .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 posi-
tioning 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 may need
cleaning.
To gain access to the filter, first close the cold water, drain the
D.H.W. circuit via the lowest tap, make provision to collect a
small discharge of water, then loosen the brass swivel connec-
tion to access the filter.
12
4 COMMISSIONIN AND TESTIN
BURNER PRESSURE
TEST POINT
Fig. 13
16
KEY
1 “ eating output” trimmer
6 “Ignition pressure” trimmer
NOTE: To gain access to trimmers (1) and (6),
take off the central heating potentiometer knob.
Fig. 14

13
4.5 FINAL CHECKS
– Re-light and test for gas soundness.
– Re-fit the casing front panel and securing brackets.
– Set the C. . and D. .W. potentiometers to the required
settings.
– Ensure that the time clock is set at the desired time peri-
ods. Set the room thermostat (if fitted) to the required
setting.
4.6 USER’S INSTRUCTIONS
Upon completion of commissioning and testing the system,
the installer should:
– Give the “Users Instructions” to the householder.
– Explain and demonstrate the lighting and shutdown proce-
dures.
– Advise the householder on the efficient use of the system,
including the use and adjustment of all system controls
for both D. .W. and C. .
– 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 boil-
er should be turned off and the installer or service engi-
neer consulted.
– Stress the importance of an annual service by a regis-
tered heating engineer.

14
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.
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.
5.1 MAIN BURNER ASSEMBLY
5.1.1 Model “FORMAT 34I BF” (fig. 15)
– Remove the casing.
– Remove the 8 fixing screws securing the sealed chamber
front panel then remove the panel.
– Unscrew the 7 screws securing the combustion chamber
front panel and remove the panel, taking care not to dam-
age the insulation.
– Remove the electrode by unscrewing it from the burner
manifold.
– Unscrew the burner manifold union and locking nut. Lift
the front of the burner to disengage manifold thread and
then lift the burner clear.
– Remove the burner manifold by disconnecting the four
screws.
– Inspect and if necessary, clean the injectors, electrodes,
and the main burner bars.
5.1.2 Model “FORMAT 34E BF” (fig. 15)
– Remove the rubber ring around the flue terminal.
– Remove two screws each side at the underside of the
casing.
– Pull the bottom of the case forward, to disengange the
lower location studs, and then lift straight up, to disen-
gange the upper location studs, and withdraw the casing
over the boiler
NOTE: Use the reverse of the above procedure to replace the
casing, taking care not to trap the wiring on the R.H. side.
5.2 FAN ASSEMBLY
– Disconnect the electrical connections to the fan. Note the
position of the earth conductor.
5 ROUTINE SERVICIN INSTRUCTIONS
1
2
Fig. 15
SCREWS
1
2
3
4
“FORMAT 34I BF” model “FORMAT 34E BF” model

– Remove the three screws securing the fan.
– Tilt the fan forwards and remove in a downwards direction.
– Inspect the fan assembly and clean if necessary.
5.3 HEAT EXCHAN ER
Inspect the heat exchanger, and clean if necessary as
showed in fig. 16.
5.4 WATER FLOW SWITCH
– Revome the cover from the micro assembly to gain
access to the flow switch spindle.
– Ensure the spindle is free to move (see fig. 17).
– Re-assemble the cover.
5.5 CHIMNEY SWEEP FUNCTION
(combustion analysis)
To carry out the verification of combustion in the boiler turn
the selector and stop on the position ( ) until the
green/orange led starts to flash intermittently. From that
moment the boiler will start functioning in heating mode at
the maximum power, with switching off at 80°C and restar-
ting at 70°C.
Before activating the chimney sweep function make sure
that the radiator valves or eventual zone valves are open.
The test may be carried out also during D. .W. mode. To do
so it is enough, after having activated the chimney sweep
function, to take some hot water from one or more outlets.
Even in this condition the boiler functions at the maximum
temperature always with the primary controlled between
80°C and 70°C.
During the entire duration of the testing the
hot water taps must remain open. After verifying the combu-
stion the boiler should be switched off by placing the selector
on the OFF position; then return the selector to the desired
function.
ATTENTION:
After about 15 minutes, or once the hot
water request has been fulfilled, the chimney sweep func-
tion automatically deactivates.
5.6 RE-ASSEMBLY
– 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 pres-
sure sensing line is correctly fitted.
Check that the fan earth connection is correctly re-fitted.
Note that the fan polarity (Line and Neutral) is immaterial.
– Check for gas soundness before fitting the casing.
5.7 RE-COMMISSIONIN
– Turn on the gas supply, and check for gas soundness
whilst the appliance is running.
– Check the operation of the appliance in both C. . and
D. .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 4 . Adjust if necessary as
15
8 SEALED C AMBER SCREWS
BURNER MANIFOLD
UNION
3 FAN FIXING SCREWS
7 COMBUSTION C AMBER
FRONT PANEL SCREWS
MAIN EXC ANGER
Fig. 16
Fig. 17

described in section 8.
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.
5.8 CLEANIN THE C.H. WATER FILTER (fig. 18)
To clean the filter, close the delivery/return on/off taps, turn
off the power to the control panel, remove the casing and
empty the boiler using the drain provided (14 fig. 2) until the
hydrometer shows “zero”. Place a container for collection
underneath the filter, unscrew the cap and proceed to clean
the filter, removing impurities and limestone deposits. Check
the seal o-ring before reassembling the cap with the filter.
16
Fig. 18

17
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 futher.
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 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
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.
6.5 FAULT FINDIN LEDS
The indicator leds signalling irregular and/or incorrect oper-
ation of the equipment are indicated in fig. 19.
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.
6 FAULT FINDIN
Fig. 19
Bi-colour green led off if power is cut-off
Bi-colour orange led: C. . sensor fault
Bi-colour orange led flashing: insufficient system pressure
Green led flashing: fan/smoke pressure switch failure
Red led on, ignition lock-out/safety and smokes stats
tripped: turn the selector switch briefly to the position
marked ( ) to restore functioning

18
6.6 C.H. MODE - FAULT FINDIN
Start from cold Rotary switch set to WINTER position.
Room thermostat (if fitted) calling for heat and all D. .W. taps off.
C. . thermostat set to maximum position.
Clock in the on position.
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.
Is there power
at the external
socket?
Make
power
available
Does
the pump
start?
After 20 seconds
from start of the
pump is the green
led flashing?
Is flow water
switch closed?
Does
the fan
start?
Is there a spark
at the ignition
electrode?
Is fuse
at mains
plug OK?
Is there power
at L and N
terminals?
Is the green
led on?
Check flow
water switch
and the C. .
water filter
Flue fault.
Check air pressure
switch and
connections
After 20 seconds
from start of the
fan, is the green
led flashing?
Replace fuse
on the PCB
Replace fuse in
mains plug
Check wire
connections
to L and N
terminals
Is the clock in
the correct
band time?
Check the
time clock.
Do the contact
open and close
when the clock
turns?
Is there 230V AC
available at the
fan terminals?
Replace the PCB Check: gap
between the
electrode and
burner, conditions
of the electrode
and ignition
transformer.
Does it spark
now?
Turn the clock
to the right
position
Close room
thermostat
contact
Replace
the fan
Is there voltage
available
to the pump?
Replace
the clock
Check pump
connection
Is pump shaft
free to rotate?
Replace
the pump
Make it free to
rotate
as the PCB
ignition
locked-out after
10 seconds
without flame
at the burner?
as the PCB
ignition
locked-out after
10 seconds
with flame
at the burner
before lock?
Check: gap
between the
electrode and
burner, conditions
of the electrode
and ignition
transformer.
Does it now
detect the flame?
Can the burner
pressure be
reduced by the
C. . adjuster?
Does the burner
pressure reduce
as the temperature
rises towards max.?
Check:
1) C. .
thermistor
2) PCB control
board
After two minutes
(safety time +
C. . delay time),
is the burner
pressure set to
the maximum? Is there
voltage at the
modulator?
Does the boiler
switch off before
achieving the tem-
perature?
Is the gas
available?
Open the
gas cock
Is L and N
polarity correct?
Replace the
modulator
Replace the PCB
Is the safety
thermostat OK?
Replace the
safety
thermostat
Correct Replace the
C. . thermistor
Is there
voltage available
to the gas valve?
Replace the
gas valve
Check the
connection
Boiler is
satisfactory
Yes
No
Is the room
thermostat
contact closed?
Yes
No
Yes
No
Yes
No
No
Yes
No
Yes
No
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes No Yes
No
No
No
No
No
No Yes Yes Yes Yes No
Yes
Yes
No
No
No
No
Yes
Yes
Yes
No
Yes
No
No Yes
No
No
No
No