Sime SOLIDA?EV 3 User manual

SOLIDA EV
ISTRUZIONI PER L’INSTALLAZIONE E LA MANUTENZIONE
Fonderie SIME S.p.A Cod. 6113718A - 10/2018
IT
PT
ES
ENG
Gentile Cliente,
metta in funzione la sua nuova caldaia entro 30gg dalla data di installazione. Potrà così
beneficiare, oltre alla garanzia legale, anche della garanzia convenzionale Sime riportata
in questo manuale.
RO
RUS
FR
DE
SL

SOLIDA EV - ENGLISH
INDEX
1 MAIN WARNINGS ........................................................................................................................................... 34
2 SUPPLY .......................................................................................................................................................... 34
3 DIMENSIONAL TECHNICAL CHARACTERISTICS .......................................................................................... 35
3.1 DESCRIPTION
3.2 OVERALL DIMENSIONS
3.3 TECHNICAL DATA
3.4 PRESSURE DROP
4 INSTALLATION ............................................................................................................................................... 37
4.1 BOILER ROOM
4.2 CONNECTION TO THE CHIMNEY
4.3 CONNECTION TO THE SYSTEM
4.4 ASSEMBLING THE ACCESSORIES
4.5 ASSEMBLING THE CASING
4.6 DRAUGHT REGULATOR
4.7 SAFETY EXCHANGER
4.8 HYDRAULIC CONNECTION DIAGRAMS
5 USE AND MAINTENANCE .............................................................................................................................. 41
5.1 PRELIMINARY CHECKS BEFORE COMMISSIONING
5.2 BOILER THERMOMETER
5.3 AIR ADJUSTMENT
5.4 CLEANING
5.5 MAINTENANCE
5.6 DISPOSAL OF THE EQUIPMENT

34
1 MAIN WARNINGS
The instruction manual is an integral part
of the product and must be delivered to the
user. Carefully read the warnings contai-
ned in the manual on installation, use and
maintenance of the appliance. Carefully
store the manual for future reference.
Installation must be carried out by qualified
personnel in compliance with the standards
in force and following the instructions pro-
vided by the manufacturer. Improper in-
stallation can damage persons or objects,
which the company is not responsible for.
Ensure that the product is intact. In case of
doubt, do not use the appliance and contact
the supplier. Packaging components must
be disposed of in compliance with the stan-
dards in force.
Before any maintenance operation on the
appliance, disconnect the power supply
using the system switch.
In case of failure or malfunction, deactivate
the appliance avoiding any repair or direct
intervention. Only refer to qualified techni-
cal personnel. Any repair must be carried
out by using original spare parts only.
Failure to comply with that above can com-
promise the integrity of the system and sin-
gle components, being a potential danger
for the user’s safety, which the company is
not responsible for.
Maintenance of the appliance and chimney
is required at least once a year.
2 SUPPLY
As indicated in fig. 1, the boiler is supplied
in two different packaging:
– Cast iron boiler body with flue gas cham-
ber and adjusting dampers, ash collec-
ting tray and draught thermostatic regu-
lator. A bag containing: 2 handles for the
ports, one screw with bakelite knob for
manually adjusting the air gate dumper,
a contact spring for the thermometer
bulb and a M6 lever to be fastened to the
air gate dumper. “Test report” and “De-
claration of conformity” to be stored to-
gether with the documents of the boiler.
– Carton packaging with casing, thermo-
meter and document kit. The document
kit includes: instruction manual, war-
ranty certification, BOILER TECHNICAL
DATA plate and label module to apply on
the declaration of conformity.
ATTENTION: The BOILER TECHNICAL
DATA plate included in the document kit is
adhesive and must be applied on a side of
the casing by the installer.
The serial number of the iron case body is
indicated on the riveted plate on the rear
upper side of the body.
To facilitate transport, the load and drain
of the boiler are placed on the upper side
and are equipped with lifting hooks.
12
Fig. 1

3 TECHNICAL AND DIMENSIONAL CHARACTERISTICS
3.1 DESCRIPTION
Wood is an alternative source of energy and
it is also precious; therefore, use it in the
best way using suitable technologies for
combustion.
Iron cast and traditional combustion wood
boilers SOLIDA EV are designed to en-
sure maximum thermal yield optimising
draught. The boilers are in compliance with
PED Directive 2014/68/UE and Standard EN
303-5/2012.
347
392
211P
ø 147
1001
L
500
176
==
192
15 5
825
1023
M
S
R
3.2 OVERALL DIMENSIONS (fig. 2)
Fig. 2
M C.H. flow 2” (UNI-ISO 7/1)
R C.H. return 2” (UNI-ISO 7/1)
S Boiler drain 1/2” (UNI-ISO 7/1)
35
3.3 TECHNICAL DATA
SOLIDA EV 3 4 5 6 7
Coal-fired thermal output kW 23.0 34.0 45.0 56.0 67.0
Maximum power at wood kW 20.0 30.0 40.0 49.0 58.0
Wood load thermal output kW 14.0 20.5 27.5 34.0 40.0
Performance class EN 303-5/2012 1 1 1 1 1
Duration of a coal-fired h ≥ 4 ≥ 4 ≥ 4 ≥ 4 ≥ 4
Duration of a wood load h ≥ 2 ≥ 2 ≥ 2 ≥ 2 ≥ 2
Load volume dm3 42,7 66,4 90,2 113,9 137,7
Minimum chimney depression mbar 0.08 0.10 0.12 0.13 0.15
Dimensions
P (depth) mm 425 575 725 875 1025
L (combustion chamber depth) mm 260 410 560 710 860
Number of elements n° 3 4 5 6 7
Max. operating temperature °C 95 95 95 95 95
Min. temperature of water returned to the plant °C 50 50 50 50 50
Max working pressure bar 4 4 4 4 4
Test pressure bar 6 6 6 6 6
Boiler capacity l 30 39 48 57 66
Weight kg 226 288 350 412 474

36
Fig. 3
1234
0
5
10
15
20
Portata m3/h
∆p mbar
3
57
5
6
4
25
30
35
3.4 HEAD LOSSES (fig. 3)
Flow rate m3/h
3.3.1 Technical data with kit that can be switched from class 1 to class 3 (to be requested separately)
SOLIDA EV 3 4 5 6 7
Kit that can be switched from class 1 to class 3 8075990 8075991 8075992 8075993 8075994
Heat capacity with wood kW 11,0 17,5 24,0 29,5 35,0
Wood load thermal output kW 8,4 13,7 19.0 23,5 28,0
Performance class EN 303-5/2012 3 3 3 3 3
Duration of a wood load h ≥ 2 ≥ 2 ≥ 2 ≥ 2 ≥ 2
Load volume dm
3
37,5 58,3 79,2 100,0 120,9
Minimum chimney depression mbar 0,20 0,20 0,20 0,20 0,20

37
4.1 BOILER ROOM
Check that the room has the requirements
and features in accordance to the rules in
force. Furthermore, the room should be
aired, in order to have a regular combu-
stion. Therefore it is necessary to practice
some openings in the walls of the room,
which correspond to the following requi-
rements:
– They should have a free section of at
least 6 cm
2
for each 1,163 kW (1000
kcal/h). The minimum opening section
shouldn’t be smaller than 100 cm
2
. The
section can also be calculated, using the
following ratio:
where “S” is expressed in cm
2
.
“Q” is expressed in kcal/h
– The opening should be situated on the
lower part of an outer wall, preferably on
the opposite of the one for the combu-
stion gas discharge.
4.1.1 Positioning in the power station
(fig. 4)
The boiler must be installed on a non-com-
bustion base.
Once the boiler has been installed, it must
be horizontal and stable, in order to reduce
any vibrations and noise.
Always leave free space behind the boiler,
so as to allow opening and maintenance on
the fan.
CAUTION: The minimum distances indi-
cated in the figure are bounding and only
refer to models with power exceeding 35
kW.
4.2 CONNECTION TO THE FLUE
A flue should correspond to the following
requirements:
– It should be of waterproof material and
resistant to temperature of smokes and
related condensations.
– It should be of a sufficient mechanical
resistance and a weak thermal conduc-
tivity.
– It should be perfectly hermetic in order
to avoid cooling of the flue.
– It should have the most possible vertical
process and the terminal part should
have a static aspirator, which assures an
efficient and constant discharge of the
combustion product.
– In order to avoid the wind creating a very
high pressure around the chimneypot, so
that it prevails on the ascensional force
of the combustion gas, it is necessary
that the discharge orifice hangs over at
least 0,4 meters of whatever structure
adjacent the chimney itself (including the
roof ridge) of at least 8 meters.
– The flue shouldn’t have a diameter in-
ferior to the boiler connection; for flues
with square or rectangular sections, the
internal section should be higher than
10% compared to the boiler connection
one.
– The net section of the flue can be obtai-
ned from the following ratio:
S section resulting in cm
2
K reduction coefficient:
– 0,045 for wood
– 0,030 for carbon
P boiler capacity in kcal/h
H height of the chimney in meters me-
asured from the flame axis at the
exhaust of the chimney in the atmo-
sphere. For the dimensioning of the
flue you should consider the effecti-
ve height of the chimney in meters,
measured from the flame axis at the
top, diminished with:
– 0,50 m for each direction chan-
ging of the connection tube
between boiler and flue;
– 1,00 m for each horizontal deve-
lopment meter of the connection
itself.
4.3 CONNECTION OF THE PLANT
The connections should be easily discon-
nected by means of pipelines with revolving
joints. It is always advisable to assemble
suitable interception shutters on the piping
of the heating installation.
CAUTION: It is obligatory to assemble sa-
fety valves on the system not included in
supply.
4.3.1 Filling the system
Before connecting the boiler, it is good
practice to make water circulate inside
the pipes to remove any foreign body that
can compromise the proper operation of
the apparatus.
The filling operation must be carried out
slowly to allow air bubbles to exit from the
specific vents placed on the heating sy-
stem.
In closed circuit heating systems, the cold
loading pressure of the system and the
pre-inflating pressure of the expansion
tank must correspond, or at least not be
lower than the height of the system static
column (e.g., for a 5 m static column, the
pre-load pressure of the tank and the load
pressure of the system must correspond to
the minimum value of 0.5 bars, at least).
4.3.2 Features of the feed water
The heating circuit supply water must be
treated in compliance with Standard UNI-
COI 8065.
Remember that even small deposits of few
millimetres thick cause a considerable
over-heating of the boiler walls, resulting
in serious consequences.
THE TREATMENT OF THE WATER USED
FOR THE HEATING INSTALLATION
IS ABSOLUTELY NECESSARY IN THE
FOLLOWING CASES:
– Very vast plants (with high water con-
4 INSTALLATION
Q
S =
100
P
S = K
√H
600
1300
1000
600
600
1000
Fig. 4

38
tents).
– Frequent replenishment water inlets in
the plant.
– If the partial or total emptying of the
plant should be necessary.
4.4 ASSEMBLING
THE ACCESSORIES
(fig. 5 - fig. 5/a)
The port closing handles and the screw
with knob for the air gate damper regula-
tion is supplied separately, as they can be
damaged during transport.
Both the handles and the screw with knob
are contained in nylon bags inside the ash
collecting tray.
To assemble the handles, proceed in the
following way (fig. 5):
– Take a handle (1), insert it in the load
port slot (2) and insert the roll (3) inside
the handle hole; block the handle by in-
serting the elastic split pin (4).
– Carry out the same operation for the
handle of the ash-pit port.
To assemble the screw with knob, proceed
in the following way (fig. 5/a):
– Remove screw M8 x 60 that fastens the
air gate damper to the ash-pit port and
tighten the screw with Bakelite knob (1)
supplied. Place the blind nut with cap (2)
at the end of screw M 10.
– Fasten lever M6 (3) to the air gate dam-
per placing it in a horizontal direction on
the right. The lever has an opening at its
end, where the chainlet of the thermo-
static regulator will be connected.
4.5 ASSEMBLING
THE CASING
(fig. 6)
From the rear of the boiler, on two upper tie
rods, three nuts are tightened: the second
and the third nut serve to place correctly
the lateral sides of the casing. On the lo-
6
5
1
7
4
2
8
Fig. 6
KEY
1 Handle
2 Load port
3 Roll
4 Elastic split pin
Fig. 5
1
2
3
KEY
1 Screw with knob M10 x 70
2 Blind nut with cap
3 Lever M6 Fig. 5/a

39
wer tie rods, both in the front and rear side
of the boiler, two nuts are tightened, one
of which is used to block the side support
brackets.
The assembly of the casing components
must be carried out in the following way:
– Unscrew with some rotations the second
or third nut of each tie rod.
– Connect the left side (1) on the lower and
upper tie rod of the boiler and adjust the
position of the nut and lock-nut of the
upper tie-rod.
– Block the side by tightening the locknuts.
– In order to assembly the right side (2)
proceed in the same way.
– Connect the rear panel (4) introducing
the two splines in the vents obtained on
each side and lock it with self-threading
screws.
– The protection deflector (5) is fixed to
the control panel (6) with three self-th-
reading screws. Insert the mineral wool
between the two components.
– Fasten the front panel (6) using the pres-
sure pins.
– Unwind the capillary of the thermometer
(7) and and introduce it in the left sheath
of the rear head introducing the contact
spring which must be cut at about 45
mm. The thermometer cable must be
placed above the insulation and must not
contact directly the iron cast body.
– Fasten the cover (8) to the sides of the
boiler using the pressure pins.
- Apply the BOILER TECHNICAL DATA
adhesive plate on the right or left side of
the covering, so as to be legible when the
appliance is installed.
NOTICE: Store the “Test report” and “De-
claration of conformity” placed in the
combustion chamber together with the
documents of the boiler.
4.6 DRAUGHT REGULATOR
WITH THERMOSTATIC
OPERATION
By means of the draught regulator with
thermostatic operation, a continuous va-
riability of the air introduced in the boiler
furnace can be obtained.
By means of a connecting chainlet, this re-
gulator acts on the lower primary air intake
port.
Once the set temperature has been rea-
ched, the regulator decreases the opening
of the air intake port automatically, so to
slow down the combustion and prevent
over-heating.
In order to optimise the combustion on the
upper load port, place a round adjusting
port that distributes the secondary air
countercurrent compared to the path of the
combustion products.
This process further increases the yield
and allows exploiting the combustion more
effectively.
Two types of thermostatic regulators can
be assembled on the boilers.
4.6.1 “THERMOMAT RT-C” Regulator
(fig. 7)
The “Thermomat” regulator is equipped
with a thermosetting resin knob of an
adjustment field from 30 to 100 °C.
Screw the regulator on the 3/4” opening
of the anterior head and orientate the red
index on the upper part.
The lever with the chainlet should be intro-
duced in the regulator holder after having
assembled the instrument holder board
and after having removed the plastic lock.
If the joint is taken out, which fixes the
lever with the chainlet, take care in assem-
bling it again in the same position.
After having placed the knob at 60°C, block
the lever with the chainlet in a slightly
inclined position downwards, so that
the chainlet will be in axis with the air
gate damper. For the adjustment of the
“Thermomat”, which essentially consists
in the determination of the chainlet length,
proceed in the following way:
– Place the knob at 60°C.
– Switch on the boiler with opened air gate
damper.
– When the water temperature of 60° C is
reached in the boiler, fix the chainlet in
such a way on the lever of the air gate
damper, in order to obtain an opening of
about 1 mm.
– Now the regulator is calibrated and it is
possible to choose the desired operating
temperature by rotating the knob.
4.6.2 “REGULUS RT2” Regulator
(fig. 8)
The adjustment field is included betwe-
en 30 and 90°C (fig. 8). Follow the same
instructions of the “Thermomat” regulator
for the assembly and the activation.
4.7 SAFETY EXCHANGER
The safety exchanger is supplied upon re-
quest with a kit:
- code 8105200 for SOLIDA EV 3/4/5
- code 8105201 for SOLIDA EV 6/7.
The kit must be used on closed expansion
tank systems with power lower than 35 kW.
Its function is to cool the boiler in case of
over-temperature, by using a thermal di-
scharge valve connected to the exchanger
inlet hydraulically.
In correspondence to the exchanger outlet,
place one drainpipe with funnel and a
siphon that drive to a suitable discharge.
The discharge must be visible for inspec-
tion.
ATTENTION: Failure to comply with this
precaution, a possible activation of the
thermal discharge valve can damage per-
sons, animals and objects, which the ma-
nufacturer is not responsible for.
Before commissioning the boiler, ensure
that the water flow of the thermal dischar-
ge valve is guaranteed.
Fig. 8
“REGULUS RT2” Regulator
Fig. 7
“THERMOMAT RT-C” Regulator

40
4.8 HYDRAULIC CONNECTION DIAGRAMS
4.8.1 Open expansion tank system (fig. 9)
Fig. 9
4.8.2 Closed expansion tank system and safety exchanger with thermostatic valve (fig. 10)
Fig. 10
KEY
VE Expansion tank
VS System safety valve 3 BAR - 1/2”
VM Mixing valve
VR Check valve
PI System pump
IR Heating system
VT Thermostat valve (97°C opening)
SC Safety exchanger
F Filter
CAUTION: The safety exchanger is supplied in
an optional kit code 8105200/01.
Temperature of the water supplied to the
safety heat exchanger: 10°C.
Pressure of the water supplied to the safety
heat exchanger: 2 bar.
Assembly of the safety heat exchanger (SC)
is mandatory.
Before commissioning the boiler, ensure that
the water flow of the thermostatic valve is
guaranteed (VT).
KEY
VE Open expansion tank
VS System safety valve 3 BAR - 1/2”
VM Mixing valve
VR Check valve
PI System pump
IR Heating system

41
5.1 PRELIMINARY CHECKS
BEFORE COMMISSIONING
Before commissioning the boiler, comply
with the following instructions:
– The system connected to the boiler
should be with open expansion tank sy-
stem (fig. 9).
– The pipe connecting the boiler to the ex-
pansion tank must have a suitable dia-
meter in compliance with the standards
in force.
– The heating pump must always run du-
ring the boiler operation.
– The operation of the pump must never be
interrupted by an environment thermo-
stat.
– If the system is equipped with 3 or 4-way
mixing valve, this must always be opened
towards the system.
– Ensure that the draught regulator runs
regularly and there are no obstructions
that block the automatic operation of the
air gate dumper.
5.2 BOILER THERMOMETER
(fig. 11)
Indicates the temperature of the boiler wa-
ter (pos. 1).
5.3 AIR ADJUSTMENT (fig. 11)
The primary air is adjusted automatically
by means of a thermostatic valve; on the
other hand, the secondary air is adjusted by
means of a round port placed on the upper
side of the load port and must be adjusted
by the user.
At the first start-up, the primary and se-
condary air must be adjusted, considering
that the primary air determines the boiler
power and, therefore, the amount of wood
that is burnt and the secondary air comple-
tes the combustion.
The optimal regulation of the SOLIDA EV
operation is reached when both the boiler
and chimney will be “in temperature”.
Depending on the wood used and its humi-
dity, rotate the round port (anti-clockwise
to open and clockwise to close) so to take
the flame to optimal conditions: orange-
pink-white with a blue centre.
CAUTION:
Secondary air regulator with high tempe-
ratures!
Use gloves or suitable equipment to not
get burned.
5.4 CLEANING (fig. 12)
Cleaning operations must be carried out
frequently, by cleaning, besides the flue
channels, also the ash-pit port, removing
the ash in the collecting tray.
For cleaning the flue channels, use a spe-
cific scraper.
5.5 MAINTENANCE
Do not perform any maintenance work, di-
smantling or removal of parts without pro-
perly emptying the boiler first.
The boiler must not be emptied when the
water is hot.
CAUTION: The safety valve on the system
must be inspected by technically qualified
personnel in accordance with the laws of
the country of distribution and instruc-
tions for use of the safety valve.
If the system is completely emptied and
remains unused for some time, the safety
valve must be inspected before it is used
again.
APRE CHIUDE
1
5 USE AND MAINTENANCE
Fig. 11
OPEN CLOSES

42
If the safety valve should malfunction and
cannot be re-calibrated, replace it with
a new 1/2” valve calibrated to 3 BAR and
conforming with Directive PED 2014/68/
UE.
5.6 DISPOSAL OF THE EQUIPMENT
Once it reaches the end of its operating
life, the equipment MUST BE RECYCLED
in line with current legislation.
IT MUST NOT be disposed of together
with urban waste.
It can be handed over to recycling cen-
tres, if there are any, or to retailers that
offer this service.
Recycling prevents potential damage to
the environment and health. It allows to
recover a number of recyclable mate-
rials, with considerable savings in terms
of money and energy.
Fig. 12