Sime rondo User manual

Rondò
Estelle

Remove the “Testing Certificate” from inside the combustion chamber
(“RONDÒ” version) and keep together with the instructions manual
CONTENTS
1 BOILER DESCRIPTION
. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
.2 DIMENSIONAL DETAILS
.3 TECHNICAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
.4 FUNCTIONAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
.5 COMBUSTION CHAMBER
.6 COMPATIBLE BURNERS
2 INSTALLATION
2. BOILER ROOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 BOILER ROOM DIMENSIONS
2.3 CONNECTING UP SYSTEM
2.4 CONNECTING UP FLUE
2.5 FITTING THE CASING “RONDÒ”
2.6 ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 USE AND MAINTENANCE
3. COMMISSIONING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.2 LIGHTING AND OPERATION
3.3 REGULAR CLEANING
3.4 FROST POTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 USER WARNINGS
EN LISH

24
1.1 INTRODUCTION
The new “RONDÒ - ESTELLE” series of
cast iron boilers has been designed in
compliance with the Efficiencies
Directive CEE 92/42.
They use light oil and have a perfectly
balanced combustion with a very high
thermal efficiency for economical per-
formance. This manual provides the
instructions for the following boiler
models:
– “RONDÒ” for central heating only,
matchable with a separate boiler
unit “BA100 - BA150 - BA200”
– “ESTELLE” for central heating only,
with combustion hinged door, mat-
chable with a separate boiler unit
“BA100 - BA150 - BA200”.
The components for “RONDÒ” installa-
tion are supplied in three separate
packages: boiler body, casing with
enclosed documents and control panel.
1 BOILER DESCRIPTION
460
850
280
P
55
95
505
625
= =
ø 30
S
M
R
1.2 DIMENSIONAL DETAILS
Fig.
Rondò - Estelle
34567
P Dep th 4 5 5 5 6 5 7 5 8 5
M C.H. flow /4”
/4” /4” /4” /4”
R C.H. return /4”
/4” /4” /4” /4”
S Boiler drain /2” /2” /2” /2” /2”
850
460 P
95
505
625
280
ø 30
=
55
=
S
M
R
“RONDÒ”
“ESTELLE”

25
1.3 TECHNICAL FEATURES
* With ∆t 0°C ** With the sanitary water at inlet temperature 5°C - Boiler temperature 80°C
UE
40 40
L
S4
R3
M2
H50
A
B
==
C
40
C
1.2.1 D.H.W. storage tank BA
Fig. /a
RONDÒ - ESTELLE BA tank
3 4 5 6 7 100 150 200
Output
Minimum kW (kcal/h) 8,9 ( 6.300) 24,5 (2 .000) 32,5 (28.000) 4 ,7 (35.900) 49,9 (42.900) – – –
Maximum kW (kcal/h) 23,5 (20.200) 3 ,3 (26.900) 40,0 (34.400) 48, (4 .400) 57,5 (49.500) – – –
Input
Minimum kW (kcal/h) 2 , ( 8. 00) 27,2 (23.400) 36,0 (3 .000) 46, (39.600) 55,0 (47.300) – – –
Maximum kW (kcal/h) 26,2 (22.500) 34,8 (29.900) 44,3 (38. 00) 53, (45.700) 63,3 (54.400) – – –
Sections n° 3 4 5 6 7 –––
Maximum water head bar 4 4 4 4 4 – – –
Water content l 2,8 6,8 20,8 24,8 28,8 – – –
Smokes loss of head
Minimum/Maximum mbar 0,05/0, 0, 2/0, 6 0, 5/0,2 0,30/0,35 0,32/0,43 – – –
Water loss of head* mbar 5 0 5 20 25 – – –
Combustion chamber pressure mbar –0,02 –0,02 –0,02 –0,02 –0,02 – – –
Suggested chimney depression mbar 0,07/0, 3 0, 4/0, 8 0, 7/0,23 0,32/0,37 0,34/0,45 – – –
Smokes temperature
Minimum/Maximum °C 60/ 85 60/ 85 60/ 85 60/ 70 60/ 70 – – –
Smokes flow
Minimum/Maximum m3n/h 24,0/3 ,6 32,4/4 ,4 42,9/52,8 54,8/63,3 65,5/73,8 – – –
Smokes volume dm39 2 5 8 2 –––
CO2% 2,5 2,5 2,5 2,5 2,5 – – –
C.H. adjustment range °C 30÷85 30÷85 30÷85 30÷85 30÷85 – – –
D.H.W. adjustment range °C – – – – – 30÷65 30÷65 30÷65
D.H.W. flow rate ∆t 30°C** l/h – – – – – 9 8 990 308
D.H.W. tank capacity l – – – – – 00 50 200
D.H.W. maximum water head bar – – – – – 6 6 6
Weight kg 09 35 6 86 2 2 82 02 22
BA 100 BA 150 BA 200
U D.H.W. outlet 3/4” 3/4” 3/4”
C Re-circulation 3/4” 3/4” 3/4”
E D.H.W. inlet 3/4” 3/4” 3/4”
M2 D.H.W. tank flow ” ” ”
R3 D.H.W. tank return ” ” ”
S4 Drain cock /2” /2” /2”
BA 100 BA 150 BA 200
L ø mm 505 505 555
H mm 845 75 265
A mm 225 225 235
B mm 645 685 825

26
1.5 COMBUSTION CHAMBER
The combustion chamber is of the
straight flow type and complies with
standard pr EN 303-3 appendix E.
The dimensions are shown in fig. 3.
1.6 COMPATIBLE
BURNERS
In general, the oil burner that is com-
patible with the boiler should use spray
of the semi solid type.
Section .6. shows the matching table
of the burners together with the boi-
lers have been tested with.
1.6.2 Burners assembly
The boiler door details is shown in fig-
ure 4 for burner mounting.
The burners must be regulated such
that the CO2value is that indicated in
point .3, with a tolerance of ± 5%.
R
M
4
5
6
6
7
0120
20 100
40 80
60
2
3
04
13
2
3
C
E
8
9
2
0
U
1.4 FUNCTIONAL DIA RAM
L
270
280
Fig. 3
Fig. 2
L Volume
mm dm3
Rondò/Estelle 3 305 7,5
Rondò/Estelle 4 405 24,0
Rondò/Estelle 5 505 30,5
Rondò/Estelle 6 605 37,0
Rondò/Estelle 7 705 43,5
R 75
ø 0
M8
Fig. 4
KEY
Burner
2 Boiler
3 Boiler thermometer
4 Boiler drain
5 Non-return valve
6 Automatic air vent
7 D.H.W. pump
8 Magnesium anode
9 D.H.W. tank drain
0 D.H.W. storage tank
D.H.W. tank expansion vessel
2 D.H.W. tank safety valve
3 Hydrometer
1.6.1 “RIELLO” burners
Model Nozzle Atomising Pump pressure
Tipo P min P max angle P min P max
ø ø P min P max bar bar
Rondò/Estelle 3 RG0. R DELAVAN 0,50 0,60 60°W 60°W ,5 2,0
Rondò/Estelle 4 RG R DELAVAN 0,65 0,75 80°W 60°W 2,5 3,0
Rondò/Estelle 5 RG R DELAVAN 0,85 ,00 60°W 60°W ,5 ,5
Rondò/Estelle 6 RG2 DELAVAN ,00 , 0 60°W 60°W 0,0 0,0
Rondò/Estelle 7 RG2 DELAVAN , 0 ,25 60°W 60°W ,0 ,0

2.1 BOILER ROOM
The boiler room should feature all the
characteristics required by standards
governing liquid fuel heating systems.
2.2 BOILER ROOM DIMENSIONS
Position the boiler body on the founda-
tion bed, which should be at least 0
cm high. The body should rest on a sur-
face allowing shifting, possibly by
means of sheet metal.
Leave a clearance between the boiler
and the wall of at least 0.60 m, and
between the top of the casing and the
ceiling of m (0.50 m in the case of
boilers with incorporated D.H.W. tank).
The ceiling height of the boiler room
should not be less than 2.5 m.
2.3 CONNECTIN UP SYSTEM
When connecting up the water supply
to the boiler, make sure that the speci-
fications given in fig. are observed.
All connecting unions should be easy to
disconnect by means of tightening
rings. A closed expansion tank system
must be used.
2.3.1 Filling the water system
Before connecting the boiler, thor-
oughly flush the system to eliminate
scale which could damage the appli-
ance.
Filling must be done slowly to allow any
air bubbles to be bled off through the
air valves.
In closed-circuit heating systems, the
cold water filling pressure and the pre-
charging pressure of the expansion
vessel should be no less than or equal
to the height of the water head of the
installation (e.g. for water head of 5
meters, the vessel pre-charging pres-
sure and installation filling pressure
should be at least 0.5 bar).
2.3.2 Characteristics of feedwater
The water used for the central heating
system should be treated in the follow-
ing cases:
– For extensive systems (with high
contents of water).
– Frequent addition of water into the
system.
– Should it be necessary to empty the
system either partially or totally.
2.3.3 D.H.W. storage tank
The “RONDÒ -ESTELLE ” boilers may
be matched with the separate boiler
units “BA100 -BA150 -BA200 ”.
The glass enamelled D.H.W. storage
tank comes with a magnesium anode
to protect the boiler and an inspection
flange for checking and cleaning.
The magnesium anode must be
checked annually and replaced if it
is worn.
Fit a safety valve calibrated to 6 bar
on the tubing of the cold water supply
to the boiler unit ( 2 fig. 2).
In case the system pressure is exces-
sive fit an appropriate pressure
reducer. If the safety valve calibrated
to 6 bar frequently intercepts, fit an
expansion vessel with a capacity of 8
litres and a maximum pressure of 8
bar ( fig. 2). The tank should be of
the membrane type, made of natural
rubber “caoutchouc”, which is suitable
for foods.
2.4 CONNECTIN UP FLUE
The flue is of fundamental importance
for the proper operation of the boiler; if
not installed in compliance with the
standards, starting the boiler will be
difficult and there will be a consequent
formation of soot, condensate and
encrustation.
The flue used to expel combustion
products into the atmosphere must
meet the following requirements:
– be constructed with waterproof
materials, and resistant to smoke
temperature and condensate;
–
be of adequate mechanical resilience
and of low heat conductivity;
– be perfectly sealed to prevent cool-
ing of the flue itself;
– be as vertical as possible; the termi-
nal section of the flue must be fitted
with a static exhaust device that
ensures constant and efficient
extraction of products generated by
combustion;
–
to prevent the wind from creating
pressure zones around the chimney
top greater than the uplift force of
combustion gases, the exhaust outlet
should be at least 0.4 m higher than
structures adjacent to the stack
(including the roof top) within 8 m;
– have a diameter that is not inferior
to that of the boiler union: square or
rectangular-section flues should
have an internal section 0%
greater than that of the boiler union;
– the useful section of the flue must
conform to the following formula:
S resulting section in cm2
K reduction coefficient for liquid
fuels:
– 0.045 for firewood
– 0.030 for coal
– 0.024 for light oil
– 0.0 6 for gas
P boiler input in kcal/h
H height of flue in meters, mea-
sured from the flame axis to the
top of the flue reduced by:
– 0.50 m for each change of
direction of the connection
union between boiler and flue;
– .00 m for each metre of
union itself.
2.5 FITTIN THE
CASIN “RONDÒ”
The casing and the control panel are
supplied in separate cardboard pack-
ages. The housing package also con-
tains the boiler documents and the
glass wool for insulating the cast iron
body. To fit the casing, proceed as fol-
lows (fig. 5):
– fit the lower front ( ) and back (2)
brackets to the heads with the four
TE screws supplied;
– insert the upper brackets (5) on the
tie-rods, fixing them with nuts;
– insulate the cast iron body with
glass wool, fixing it with the two
springs supplied;
– fit the left side (3) and the right side
(4) by inserting them in the tangs on
the brackets ( -2);
– fix the sides to the upper brackets
(5) with the four self-tapping screws
supplied;
– fit the two back panels (6) and (7) of
the sides with the ten self-tapping
screws supplied;
– fit the front panel (8) fixing it to the
sides with pin clutches
– fit the control panel (9) inserting the
two lower tangs of the panel on the
drains on the sides, and fix it with
the two self-tapping screws sup-
plied. Before carrying out this opera-
tion unwind the capillaries of the two
thermostats and the thermometer
and place the respective feelers in
the sheath ( 0), fixing all with a capil-
lary pin. Insert the burner cable into
the hole on the right or left side;
– screw the hydrometer feeler on the
connection ( );
27
P
S=K√H
2 INSTALLATION

– complete the assembly by fixing the
lid ( 2) to the sides with pin clutches.
NOTE: Remove the “Testing
Certificate” from inside the combus-
tion chamber and keep together with
the instructions manual.
2.6 ELECTRICAL CONNECTION
The boiler is fitted with an electricity
cable, and requires a ph - 230V -
50Hz power supply through the main
switch protected by fuses. The room
thermostat (required for enhanced
room temperature control) should be
installed as shown in fig. 6.
Connect the burner with the cable
supplied.
NOTE: SIME declines all responsibility
for injury caused to persons due to
failure to earth the boiler.
2.6.1 Electrical connection
to the BA boiler unit
To connect the boiler to the boiler unit
proceed with the following operations:
28
KEY
TS Safety stat
TA Room stat
TC Boiler stat
IG Main switch
PI C.H. pump
B Burner
SB Burner lock-out lamp
Fig. 6
0
2
4
9
8
5
7
6
3
2
Fig. 5

– remove the casing lid of the boiler
and the back protection of the con-
trol panel in order to have access to
the terminal board of the boiler;
– remove the protection of the boiler
unit to have access to the terminal
board of the boiler unit (fig. 7);
– connect the cables as shown in the
diagram (fig. 6/a).
29
LN 23456 LN 23456
B
TS
TC
2
C
I
2
C
TB
PB
PI
C
NA
NC
C
NA
NC
R
KEY
B Burner
IG Main switch
TS Safety stat
TC Boiler stat
R Relais
PI C.H. pump
PB D.H.W. pump
TB D.H.W. stat
NOTE: When a room stat is to
be fitted remove the link
between terminal 1 and 5 on
the connector plug.
Fig. 6/a
RONDÒ - ESTELLE BA100 - BA150 - BA200 storage tank

30
3.1 COMMISSIONIN
THE BOILER
When commissioning the boiler always
make sure that:
– the system has been filled with
water and adequately vented;
– the flow and return valves are fully
open;
– the flue and chimney are free from
obstructions;
– the electrical connections to the
mains and the earthing are correct;
– no flammable liquids or materials
are near the boiler;
– check that the circulating pump is
not locked.
3.2 LI HTIN AND OPERATION
3.2.1 Lighting the boiler (fig. 7)
To light the boiler proceed as follows:
– check that the “Testing Certificate”
has been removed from inside the
combustion chamber;
– switch on the main switch ( ); the
burner will start;
– turn the boiler stat knob (5) to a
temperature no lower than 60°C.
The set temperature value can be
checked on the thermometer (4).
– set the temperature of the hot-
water service by pressing the ther-
mostat of the boiler unit (6). The set
temperature value can be checked
on the thermometer (7).
3.2.2 Safety stat (fig. 7)
The manually reset safety stat (2) trips
to switch-off the burners immediately
when the boiler temperature exceeds
00°C. To restart the boiler, unscrew
the black cover and press the button
underneath. If the problem occurs fre-
quently, call an authorised technical
assistance centre for the necessary
checks to be carried out.
3.2.3 System filling (fig. 7)
Periodically check the pressure values
of the hydrometer (3) which, when the
system is cold, should range between
and .2 bar. If the pressure is less
than bar, reset the system.
3.2.4 Turnig OFF boiler (fig. 7)
To temporarily turn off the boiler turn
off the electricity supply by pressing
the main switch ( ).
The following operations must be car-
ried out if the plant will not be in use for
a lengthy period of time:
– position the main switch of the plant
on off;
– turn the fuel and water taps of the
central heating plant off;
– empty the central heating plant if
there is danger of frost:
3.3 RE ULAR CLEANIN
Maintenance of the boiler should be
carried out annually by an authorised
service engineer.
Disconnect the boiler from the elec-
trical supply before servicing or main-
tenance is carried out.
3.3.1 Smoke side boiler (fig. 8)
To carry out cleaning of the smoke
passages remove the screws that fix
the door to the body of the boiler and
with the special cleaning brush clean
the internal surfaces and the smoke
evacuation tube well, removing any
deposits.
Once the maintenance is compled, the
baffles have to be fitted onto the origi-
nal positions (ref. “RONDÒ/ESTELLE
3-4-5-6” models).
In the “ESTELLE” versions the mainte-
nance operations can be carried out
without removing the burner.
3.3.2 Tank unit protection anode
The tank unit comes with a protection
magnesium anode (fig. 9).
This non-rust anode in normal oper-
3 USE AND MAINTENANCE
5
23
4
RONDÒ - ESTELLE
BA100 - BA150 - BA200 storage tank
Fig. 7
KEY
Main switch
2 Safety stat
3 Hydrometer
4 Boiler thermometer
5 Boiler stat
6 D.H.W. stat
7 D.H.W. tank thermometer
8 Bulb holder thermostat/
D.H.W. tank thermometer
9 Relais
0 Connector plug
0
68
7
9

ating conditions has life span of 5
years. It is, however, advisable to
check the erosion annually and
replace it if worn. To disassemble the
tank unit flange ( ), remove the cover
(5) and unscrew the two nuts that fix
the upper cover (4). Then lift the
upper cover (4) which is simply insert-
ed with pressure.
3.3.3 Disassembly of the casing
“ESTELLE”
To disassemble the casing of the boi-
ler, proceed as follows (fig. 0):
– remove the cover ( ) fixed with pin
clutches;
– remove the control panel (2) whose
sides are fixed by two self-tapping
screws;
– remove the right back panel (3)
which is fixed to the side by two
screws;
– remove the left back panel (4) which
is fixed to the sides by three screws;
– remove the back panels (5) and (6)
which are fixed to the sides by ten
self-tapping screws;
– disassemble the left side (7)
unscrewing the screws fixing it to
the upper bracket (8), and remove
the screws that fix it to the lower
bracket (9);
3
Fig. 8
2
34
5
Fig. 9
KEY
Tank unit flange
2 Gasket
3 Magnesium anode ø 33x 85
4Cover
5 Protection
RONDO' 3/4
ESTELLE 3/4
RONDO' 5/6
ESTELLE 5/6

32
– disassemble the right side ( 0) fol-
lowing the same operations.
3.3.4 Fault finding
Herefater we outline a number of
potential problems that may occur on
the appliance and the relevant list of
actions required. A working fault, in
most cases, provocates the “lock out”
signal onto the control panel of the
control box. When this light turns on,
the burner can operate again only
after the reset button has been
pressed; if this has been done and a
regular ignition occurs, it means the
failure can be defined momentary and
not dangerous. On the contrary, if the
“lock out” stays, the cause of the fault,
as well as the relevant action must be
made according to the following chart:
The burner does not ignite
– Check the electric connections.
– Check the regular fuel flow, the
cleanness of the filters, of the nozzle
and air vent from the tube.
– Check the regular spark ignition and
the proper function of the burner.
The burner ignites regularly but the
flame goes out immediately
– Check the flame detection, the air
calibration and the function of the
appliance.
Difficulty in regulating the burner
and/or lack of yield
– Check: the regular flow of fuel, the
cleanness of the boiler, the non
obstruction of the smoke duct, the
real input supplied by the burner
and its cleanness (dust).
The boiler gets dirty easily
– Check the burner regulator (smoke
analysis), the fuel quantity, the flue
obstruction and the cleanness of
the air duct of the burner (dust).
The boiler does not heat up
– Control the cleanness of the shell,
the matching, the adjustment, the
burner performances, the pre-
adjusted temperature, the correct
function and position of the regula-
tion stat.
– Make sure that the boiler is suffi-
ciently powerful for the appliance.
Smell of unburnt products
– Control the cleanness of the boiler
shell and the flue, the airtightness of
the boiler and of the flue ducts (door,
combustion chamber, smoke ducts,
flue, washers).
– Control the quality of the fuel.
Frequent intervention of the boiler
shutoff valve
– Control the presence of air in the
system, the function of the circula-
tion pumps.
– Check the load pressure of the appli-
ance, the efficiency of the expansion
tanks and the valve calibration.
3.4 FROST PROTECTION
In the event of frost, ensure that the
central heating plant is functional and
effective frost protection interlocks
are in place to protect against frost
damage
3.5 USER WARNIN S
When faults occur and/or the equip-
ment does not operate correctly, turn
the boiler off and
contact the autho-
rised service engineer.
0
2
3
8
6
5
7
4
9
Fig. 0