Sime Format 34i User manual

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e cod. 6272262A

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
2
GENERAL DATA
– Heating Data
Heat Output Input
(Adjustable) (Adjustable)
Format 34i 11.2 – 34KW 45 – 145MJ/hr
Format 34e 11.2 – 34KW 45 – 145MJ/hr
– General Specifications
FORMAT 34i – 34e
Main burner injectors No off 15
Dia for Natural gas mm 1.45
Dia for LPG mm 0.85
Water Capacity l(gal) 4.7 (1.00)
Burner pressure Natural gas Maximum kPa 0.71kPa
Minimum kPa 0.09kPa
Burner pressure LPG (Propane) Maximum kPa 2.41 kPa
Minimum kPa 0.50 kPa
Static head Maximum bar (psi) 3.0 (43.5)
Minimum bar (psi) 0.5 (7.3)
Weight Empty kg (lb) 40 (88)
Total (full) kg (lb) 44.7 (98)
Electrical supply 230V – 50Hz, Fused at 3A
Internal fuse Line: F 1.6A
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)
TABLE 4
Gas Supply Min. Pressure Max. Pressure
Natural Gas 0.09kPa 0.71kPa
Propane Gas 0.50kPa 2.41kPa
Nominal Gas Consumption 145 mj/h

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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Fig. 1
Connections Minimum clearances
For ventilation For servicing
R C.H. return ¾ Above the appliance casing 450mm 300mm
M C.H. flow ¾ At the R.H.S. 15mm 15mm
G Gas connection ¾ At the L.H.S. 15mm 15mm
C Filling Connection ½ Below the appliance casing 200mm 200mm
In front of the appliance 100mm 500mm

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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SIME FORMAT WALL HUNG BOILERS
MODEL 34i, MODEL 34e
CENTRAL HEATING BOILERS
INSTALLATION INSTRUCTIONS
INTRODUCTION
These instructions cover the installation of the SIME FORMAT 34i, an internally
mounted boiler using a co-axial flue system, and the SIME FORMAT 34e, an
externally mounted boiler. They are fully automatic in operation, being fitted with
direct fired ignition, modulating temperature control and safety control by means of
electronic and electro-mechanical devices, integrated with a custom-designed
P.C.B..
The central heating output range is adjustable between 11.2 KW and 34 KW.
NOTE: THE BOILER IS NOT TO BE USED FOR POOL OR SPA
HEATING.
THE BOILER MUST BE INSTALLED ONLY BY AN
AUTHORISED PERSON
1.0 GENERAL INFORMATION
1.0.1 Related Documents
The boilers must be installed strictly in accordance with these
Instructions, the Australian Gas Association “Gas Installation Code”
AG601, Local Water and Electricity Authority Requirements and all
State and Local Government Regulations which may be applicable.
1.0.2 Delivery Check
The Installer shall, upon delivery, immediately remove all
packaging materials, and inspect the appliance for any
damage, and ensure that the boiler is equipped for the gas to
which it is to be connected. Report to the supplier any
discrepancies and / or damage, quoting the model number
and serial number, which can be found on the appliance Data
Plate.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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Fig. 2
KEY
1. Control panel
2. Ignition transformer
3. Combustion chamber
4. Fan
5. Combustion analysis intakes
6. Smoke pressure switch
7. Limit thermostat
8. C.H. sensor (SM)
9. Main exchanger
10. Gas valve
11. Flow water switch
12. 102°C resettable safety stat

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
6
Fig 3.
Key
1. Fan 11. Circulation Pump
2. Water-gas exchanger 12. Expansion Vessel
3. Combustion chamber 13.Safety Valve
4. Gas Valve 14. Drain Plug
5. Limit thermostat 85o C 15. Automatic By-pass
6. 102o C safety Thermostat C. Filling Connection
7. NTC sensor G. Gas Connection
8. Hydrometer M. C.H.Flow
9. Water Flow Switch S. Discharge Safety Valve
10.Air Relief Valve R. C.H.Return

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
7
2.0 INSTALLATION
2.1 Location
2.1.1 Model 34i
a) The boiler must be installed within the building.
b) The boiler must be installed on a flat vertical surface which
is capable of supporting the weight of the filled boiler.
c) The location must take account of the flueing method to be
used and the position of the external flue terminal with
regard to the requirements of AG601. Flue terminals must
terminate outside.
2.1.2 Model 34e
a) The boiler must be installed on the outside of the building.
b) The location must take account of the position of the flue
with regard to the requirements of AG601.
2.2 Clearances
2.2.1 Model 34i
a) There must be a minimum clearance of 450mm between
the top edge of the boiler and any horizontal surface above
the boiler. Any regulations with regard to combustible
surfaces and suitable fire protection must be observed.
b) A minimum clearance of 15mm must be provided between
the side of the boiler and any adjacent wall.
c) A clear space of at least 600mm must be provided in front
of the boiler, for user access to the controls, and for service
purposes.
d) The location must take account of the requirements of
AG601
2.2.2 Wall Fixing
Mounting Bracket.
a) The Boiler is located on the wall using the bracket (see
Fig.4). This bracket should be located horizontally,
between 1.70 – 1.85 meters above the ground.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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Model 34i & 34e Mounting Bracket
b). The position of the boiler will depend on the flue
method used and with respect to Gas Regulation Code
AG 601.
Fig 4
KEY
1. Wall Mounting Bracket
2. Plastic wall plug ( 2off)
3. Woodscrew (2 off)
4. Washer (2 off)
5. Adjustment Screw (2 off)

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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2.3 Flueing
2.3.1 The flue system for the Model 34i is by 60/100 mm dia co-axial
flue components. It can be applied horizontally to the rear of the
boiler, to either side, and vertically by means of a custom-designed
flue terminal.
2.3.2 The maximum length for both horizontal and vertical systems is
3 metres. Fig. 5
2.3.3 Horizontal Flue
Rear Wall Outlets (see Fig. 5)
a) The centre line of the hole through the wall must be 115mm
above the top of the boiler.
b) The hole should be large enough to accommodate a
130mm dia PVC tube, which has a length equal to the wall
thickness. The tube must be sealed both inside and outside
faces of the wall.
c) The standard flue kit (P/N 8084808) is used. The flue
assembly will need to be cut to the correct length.
d) Measure the thickness of the wall. This will be dimension
“X”.
e) Remove the inner flue duct from the assembly. From the
swaged end of the outer duct measure Z = X + 130mm.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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Cut square at this dimension and remove all burrs and
sharp edges.
f) Refit the inner duct (see Fig. 6) and cut square this duct
20mm longer than the outer duct. Remove all burrs and
sharp edges. Fig 6
g) Fit outer seal in the swage next to the terminal, and slide
the assembly through the wall to clear the outer seal. Fit the inner seal and junction
collar to the outer duct.
h) Ensure that the sealing ring is in place in the elbow and fit
inner duct and outer duct to the elbow.
i) Locate the joining clamp and tighten, using screws
provided.
j) Locate the gasket in the boiler flue outlet and pull back
assembly to locate the elbow. Fit four (4) screws provided
and tighten.
2.3.4) Side Wall Outlets
a) Extension ducts are available for this application. The flue
elbow should be fitted to the boiler.
b) In this case, the cut length of the outer duct Z = X + Y + 20.
Where X = wall thickness
Y = distance from inner face of the wall to the
front edge of the elbow.
c) It is recommended that, to drain any condensate, a fall of
5mm/meter length be provided.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
11
2.4 Vertical Installation (see Fig. 7.)
Fig 7
2.4.1 Vertical installation
a) requires a 200mm long adaptor (P/N 8086903A) be fitted to the outlet flange
of the boiler. Vertical roof terminal (P/N 8091200) is used. Extension ducts
are available when required. The same principles with regard to duct length,
and the removal of burrs and sharp edges are applicable. Extensions P/N
8084804.
2.5 Gas Connection
2.5.1 The gas connection is made to a G¾” male thread on the
centre line of the boiler (see Fig.1). It is recommended that a
manual shut-off valve is installed adjacent to the inlet
connection in accordance with the provisions of AG 601.
2.5.2 Gas fitting lines must be designed and installed in accordance
with the requirements of AG601, to which reference should be
made for pipe sizing information.
2.5.3 Piping MUST be sized so that a minimum pressure of 1.13kPa
for Natural Gas and 2.75kPa for Propane is measured at the
gas control inlet test point WHEN THE BOILER IS
OPERATING AT ITS MAXIMUM INPUT RATE.
2.5.4 For Propane, the second stage regulator should have a
minimum capacity in accordance with the provisions of AG 601.
Important! Each
additional 90˚elbow
reduces the available
length by 0.9 meters.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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2.6 Central Heating Connection
a) Before any connection of the central heating system is made to
the boiler, the system should be thoroughly flushed through to
remove any dirt and foreign matter which could damage the
pump and other devices in the boiler.
b) The connection to the boiler are by G¾” male threads.
c) When an auto-fill valve is used, it must be installed to the cold
fill inlet. It is recommended that after filling the boiler and
adjusting the pressure setting, the manual shut-off valve be
closed. It is also recommended that a manual shut off valve be
installed before the AFV for maintenance purposes.
d) The system should be filled to a cold static pressure of 1.5 bar,
filling to be carried out slowly and all air bled from the system.
Should the system pressure drop below 0.8 bar, the boiler will
not operate until the pressure is restored to 1.5 bar.
e) The drain pipe from the 3 Bar pressure relief valve in the boiler
must terminate in such a position that any discharge is visible
to the user. (See Fig 3)
f) The boiler is provided with an automatic by-pass, which
operates on systems fitted with thermostatic radiator valve.
g) The condition of the water in the system is of great importance.
Treatment, such as Fernox, is recommended, to reduce the
effect of sludge and scale on the efficiency of the heating
system.
h) For installations where the heater is connected to larger
systems, the additional volume will need to taken into account.
A temperature pressure relief valve may be needed for such
installations.
2.7 Electrical Connection
a) The electrical connection is made to a standard 10amp 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 ELECTRICIAN
b) The room thermostat is connected to terminals 2 & 4 in the
control box (see note on Fig. 9.) The thermostat must be
capable of operating 240V AC, and the relative wiring should
also be the same.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
13
3.0 OPERATION
a) The boiler is controlled by a PCB located in the control
box. A potentiometer on the PCB, together with a thermistor located
on the heat exchanger outlet, controls the temperature of the
circulating water, by modulating the gas pressure.
. The control box also contains the operation selector switch (B),
which has OFF, ON and RESET positions.
a) OFF will turn the boiler OFF.
b) ON will start and run the boiler.
c) RESET is a momentary-on operation, which will reset the ignition
sequence, should the boiler shut down with lockout.
d) Central Heating Temperature adjusting knob (A)
Two indicator lights are positioned to the right of the Selector Switch.
These indicate fault and reset functions (see Fig. 8).
Fig 8

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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Fig. 9
Fig9a
Terminal Strip
Disconnect power from main supply before removing cover.
Remove link between 2 & 4 and connect thermostat wires to terminals
2 & 4
Fig10

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
15
3.2 PCB Features
a) POT.ACC. Bridge.( see Fig 9) This modifies the ignition pressure programme of
the gas valve. With the bridge disconnecting, the ignition pressure varies in a linear
manner from low to the maximum set heating pressure. With the bridge connected,
the pressure varies in a linear manner from 50% to the maximum set heating
pressure.
When the boiler is operating on Propane, it is recommended that
the bridge be connected to improve the ignition function (quicker
cross-lighting) ( see Fig 9a).
b) Natural Gas/ LPG Selector Bridge. With the bridge disconnected, the
boiler will operate correctly for Natural Gas. With the bridge connected, the
boiler will operate correctly for LPG gas. Failure to use in the correct
position for either gas will mean that the required maximum and minimum
gas pressure cannot be obtained.
3.3 Temperature Control
Temperature control is provided by modulation of the gas burner
pressure, and thus the input of the boiler. The water temperature is
sensed by N.T.G. thermistor located on the outlet of the heat
exchanger. The varying voltages thus produced by the PCB will
operate the modulating coil on the gas valve, and move the servo
regulator accordingly.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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3.4 Limit Switches
The boiler is fitted with two limit switches.
(a) Switch located on the heat exchanger, 85º, will turn the boiler OFF,
without lockout. It will reset when the temperature drops by 2ºC.
(b) Switch located on the C.H. flow pipe, behind the control box,
100ºC, will turn the boiler OFF with lockout. A complete manual
restart is necessary.
Fig 11
To reset the overheat thermostat
The appliance is fitted with a safety cut-out
thermostat in the event of overheating this will
interrupt the power supply and prevent the
appliance from functioning.
If this occurs, allow the appliance to cool, reinstate
the thermostat button as shown in figure 11, turn
the rotary switch to “ “ position until both
leds on the facia panel flash; then turn it back to
the previous position. If the cut-out condition is
repeated, turn off the electrical supply and consult
your installer or service engineer.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
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4.0 COMMISSIONING
Preliminary Checks
a) Ensure that the central heating system is full of water and that the
pressure gauge indicates a cold static pressure of 1 – 1.5 bar.
b) Ensure that all air has been bled from the system and all air vents
are closed.
c) Ensure that all heat emitter valves are open, and that all
thermostatically operated radiator valves are fully open.
d) Ensure that the boiler is connected to the gas supply for which it
has been assembled, and that the gas line has been purged of air
up to the gas control inlet.
e) Ensure that the electricity supply is correctly connected, and that a
positive earth connection is provided.
f) Ensure that no flammable liquids or materials are in contact with or
are in the immediate vicinity of the boiler.
OPERATION
a) Ensure that the gas supply is turned ON and that electrical supply is
turned ON.
b)Turn the temperature control knob to maximum.
c)Turn the room thermostat on.
d) Turn the Selector Knob to the ON position, indicated by a star. A
green light will then appear on the front panel.
e) The pump will start and run for approximately 60 seconds.
f) The boiler will then commence the ignition start-up sequence, and
will modulate to the maximum set input.
g) Turn the temperature control knob to the desired position. The
boiler will now heat the system water to the set temperature and
continuously modulate to maintain that temperature.
ADJUSTMENTS
a) The PCB operates two colour LED’s one is bi-colour, green and
orange, the other is red. The green indicates power ON,

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
18
Fig12
steady orange indicates a faulty CH sensor, and flashing orange indicates low
water pressure. The red indicates lockout. Other features available of the PCB
are:-
b) POT ACC trimmer, (Fig.12),used to set the ignition power
from min. to max.
c) MET-GLP Bridge (Fig.12),used to set the PCB for either
NG or LPG usage.
4.1 Gas Valve
a) The SIT 845 SIGMA is fitted with a continuously modulating
Zero regulator, having two definite pressure settings. These
pressures, shown in Table 4 for both Natural Gas and Propane
usage, are factory set for the gas supply to which the boiler is
to be connected. There should not be any need other than the
field conversion from one gas to another or the exchange of a
gas valve, for these to be adjusted. In the case of the above
exceptions, or if it is obvious that adjustment is necessary, the
following procedures are to be followed. It is important to
note that, the maximum pressure is to be set first, followed
by the minimum, to the pressure indicated in Table 4 for the
gas used. All adjustments are made with the CH adjusted set
fully clockwise, and the temperature knob at maximum.

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
19
Pressure Adjustment
SIT 845 Sigma (see Fig.13)
Setting the Maximum Pressure
(a) Connect the pressure gauge as shown in Fig. 13.
(b) Remove the plastic cap.
(c) Turn the rotary switch to ON, and ensure that the room
thermostat is calling for heat. Turn the C.H. thermostat to
maximum and the boiler will light.
(d) Using a 10mm spanner, turn nut 3 clockwise to increase
counter clockwise to decrease to arrive at the pressure shown
in Table 4.
Setting the Minimum Pressure
(a) Turn Boiler off and disconnect one lead to the modulating
coil.
(b) Turn Boiler on and using a Phillips head screwdriver
turn clockwise to increase, counter clockwise to decrease to
the pressure as shown in Table 4.
(c) Operate the main switch a number of times and check
that the pressure corresponds to the pressures in Table 4
(d) Replace the lead to the modulating coil and the plastic
cap.
Fig. 13
KEY
1. Plastic Cap
2. Minimum Pressure adjusting screw
3. Maximum Pressure adjusting Nut
4. Sime pressure manometer
5. Burner test point

SIME FORMAT WALL HUNG BOILERS
MODEL 34i AND MODEL 34e
REF: INSTALLATION INSTRUCTIONS 19/02/04
20
TABLE 4
Gas Supply Min. Pressure Max. Pressure
Natural Gas 0.09kPa 0.71kPa
Propane Gas 0.50kPa 2.41kPa
Nominal Gas Consumption 145 mj/h
4.3 Adjusting the Heat Output
The boiler is supplied with the C.H. output set to maximum.
The Tables, Fig.14a & Fig. 14b, show the output (pressure
requirements of both Natural Gas and Propane. To adjust the
CH output/pressure, the following procedure is used:-
(a) Consult the appropriate table for the relative gas, and
establish the required pressure.
(b) Connect the manometer to position 5 as shown in
Fig.13.
(c) Heat the boiler by turning the Selector Knob to the ON
position.
(d) Turn the temperature control knob to maximum, and
remove the knob as shown in Fig.12.
(e) Using a small screwdriver, access the trimmer inside the
hole marked “B”. Turn carefully clockwise to increase,
counter clockwise to decrease the pressure.
(f) Turn the selector knob off and on several times to
ensure that the set pressure is stable.
(g) Replace knob, and set to required temperature.
FIG 14