Sime FORMAT DGT HE Installation And Servicing Instructions
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Sime FORMAT DGT HE Installation And Servicing Instructions

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ENSURE THAT THESE INSTRUCTIONS ARE LEFT
UK
FOR THE USER AFTER COMPLETION OF THE
BENCHMARK SECTION
FORMAT
DGT HE
199838
Installation and

servicing instructions

Please read the Important Notice within
this guide regarding your boiler warranty

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Summary of Contents for Sime FORMAT DGT HE

  • Page 1: Servicing Instructions

    ENSURE THAT THESE INSTRUCTIONS ARE LEFT FOR THE USER AFTER COMPLETION OF THE BENCHMARK SECTION FORMAT DGT HE 199838 Installation and servicing instructions Please read the Important Notice within this guide regarding your boiler warranty...

  • Page 2: Safe Handling

    For the first year all of our appliances are protected by our manufacturer’s guarantee which covers both parts and labour. As you would expect from Sime Ltd, it is our aim to provide our valued customers with the best in after sales and service.

  • Page 4: The Benchmark Scheme

    The Benchmark Scheme Sime Ltd is a licensed member of the Benchmark Scheme which aims to improve the standards of installation and commissioning of domestic heating and hot water systems in the UK and to encourage regular servicing to optimi- se safety, efficiency and performance.

  • Page 5: Table Of Contents

    IPX5D Format DGT HE 20 System: Gas Council number 41-283-18 Format DGT HE 25: Gas Council number 47-283-24 Format DGT HE 30: Gas Council number 47-283-25 Format DGT HE 35: Gas Council number 47-283-26 These appliances comply with the S.E.D.B.U.K. scheme, band “A”...

  • Page 6: Description Of The Boiler

    1. 1 INTRODUCTION manage all the functions. All modules are this manual. compliant wit h Eur opean Dir ectives FORMAT DGT HE - FORMAT DGT HE 2009/142/CE, 2004/108/CE, The products manufactured and sold by SYSTEM are premixed gas condensation 2006/95/CE and 92/42/CE.
  • Page 7 TECHNICAL FEATURES Models 20 System Heat output Nominal (80-60°C) 19.5 24.6 29.4 19.5 Nominal (50-30°C) 20.7 26.3 31.2 20.7 Reduced G20 (80-60°C) Reduced G20 (50-30°C) Reduced G31 (80-60°C) Reduced G31 (50-30°C) Heat input nominal C.H./D.H.W. 20/24 25/30 30/35 Heat input reduced G20/G31 6.0/7.0 8.2/9.0 6.0/7.0...
  • Page 8 9 Safety thermostat 10 Pump with air release vent 11 D.H.W. flow meter 12 Water inlet filter 13 ----- FORMAT DGT HE 20 SYSTEM 14 2.5 BAR safety valve 15 Water pressure valve 16 Automatic bypass 17 Pressure release valve...
  • Page 9 MAIN COMPONENTS (fig. 3) NOTE: Analogue pressure gauge see fig. 22/a. 1 Control panel 2 Fan 3 Mixer 4 Ignition electrode 5 C.H. sensor (SM) 6 Primary exchanger 7 Smoke chamber 8 Fumes sensor 9 Safety thermostat 10 Condensate collection tray 11 Diverter valve 12 Automatic air vent 13 Pump...

  • Page 10: Installation

    INSTALLATION Wall mounting bracket Plastic wall plug (2 Off) Woodscrew (2 Off) Washer (2 Off) Fig. 4 It is important that the boiler is initially FIXING THE WALL seamless steel or copper pipe. filled and started for the first time using MOUNTING BRACKET (fig.
  • Page 11 The system design should incorporate the connections appropriate to one of 2.3.4 Requirements for sealed water these methods. systems FORMAT DGT HE SYSTEM 2.3.2 Dealing with e) It is most important that the boiler is condensate not allowed to ignite until it and the The heating system design should be based heating system is filled.
  • Page 12 Sime Ltd recommend only the use of modification and at every service in The diagrams of fig. 6 illustrate some FERNOX products for the flushing and accordance with the manufacturer’s...
  • Page 13 Divider with vent Air intake Exhaust CA Inlet CS Outlet Fig. 7 Example of allowable installation “25” calculation in that the sum of the head losses of INSTALLATION OF SEPARATE the single fittings is less than 15.0 mm H DUCTS ø 80 (fig. 7 - fig. 7/a) Inlet Outlet 9 m horiz.
  • Page 14 TABLE 4 Terminal position Minimum spacing – If the terminal discharges into a pathway or passageway check Directly below an openable window, air vent that combustion products will not cause nuisance and that the or any other ventilation opening 300 mm 12 in terminal will not obstruct the passageway.
  • Page 15 The boiler is supplied with an electric cable. NOTE: SIME declines all responsibility for injury Including connection of the RF clock kit Sime Should this require replacement, it must be or damage to persons, animals or property, part number 7102604 (BCG part 38493).
  • Page 16 Hydraulic separator also be required. P 1-2 Zone pump Floor system 2.9.2 Connection of RF Clock Expansion card kit Sime part number 7102604 2.9.4 Use with different (code 8092240) (BCG part 138493) (fig. 10/a) electronic systems Three-way mixer valve Safety thermostat...
  • Page 17 BASIC SYSTEM MULTI-ZONE SYSTEM WITH VALVE, ROOM THERMOSTAT AND EXTERNAL SENSOR (Code 8094101) BASIC SYSTEM MULTI-ZONE SYSTEM WITH PUMP, ROOM THERMOSTATS AND EXTERNAL SENSOR (Code 8094101) BASIC SYSTEM MULTI-ZONE SYSTEM WITH VALVE, ROOM THERMOSTATS, REMOTE CONTROL (Code 8092219), KIT EXPANSION REMOTE CONTROL (Code 8092240) AND EXTERNAL SENSOR (Code 8094101) PARAMETERS SETTINGS Set the opening time of the VZ zone valve:...
  • Page 18 BASIC SYSTEM MULTI-ZONE SYSTEM WITH PUMPS, ROOM THERMOSTATS, REMOTE CONTROL (Code 8092219), KIT EXPANSION REMOTE CONTROL (Code 8092240) AND EXTERNAL SENSOR (Code 8094101) NOTE: The heating is set from the remote control for the first zone and from the boiler panel for the other zones. If there is a request for heat at the same time, the boiler is acti- vated at the highest temperature setting.
  • Page 19 2. 1 0 BOILER ELECTRICAL “FORMAT DGT HE 20 SYSTEM” (fig. 11) (24 VDC) code 6301460 (24 VDC) code 6301422C TA (24 VDC) SE (3,3 VDC) SF (3,3 VDC) TS (3,3 VDC) SL (24 VDC) SM (3,3 VDC) NOTE (See section 2.8. 1 ): Fuse (1.6 AT)
  • Page 20 2. 1 1 BOILER ELECTRICAL “FORMAT DGT HE 25-30-35” (fig. 11/a) code 6301460 (24 VDC) (24 VDC) code 6301422C TA (24 VDC) SE (3,3 VDC) S.AUX FLM (12 VDC) (3,3 VDC) SF (3,3 VDC) TS (3,3 VDC) SM (3,3 VDC)

  • Page 21: Characteristics

    CHARACTERISTICS 3. 1 CONTROL PANEL (fig. 12) 1 - DESCRIPTION OF DISPLAY ICONS 2 - DESCRIPTION OF CONTROLS SUMMER MODE ICON OPERATING MODE/RESET By pressing the key in succession, pass to the sum- mer and winter function (stand-by function if perma- WINTER MODE ICON ne on the key more than two second).
  • Page 22 ACCESS TO INSTALLER'S PARAMETERS INSTALLER PARAMETERS FAST CONFIGURATION PAR DESCRIPTION RANGE UNIT OF INC/DEC DEFAULT For access to the installer's parameters, MEASUREMENT UNIT SETTING press simultaneously the ( ) keys 01 Combustion configuration -- = ND “--” for 5 seconds. 1 ...
  • Page 23 EXTERNAL SENSOR (fig. 13) If there is an external sensor, the heating settings SET can be taken from the climatic curves according to the external tempera- ture and, in any case, limited to with the range values described in point 3.2 (para- meters PAR 13 and PAR 14).
  • Page 24 con by-pass By-pass on senza by-pass By-pass off 25 - 30 1000 1200 PORTATA (l/h) FLOW RATE (l/h) con by-pass By-pass on senza by-pass By-pass off 20 T - 25/15 12 T 1000 1200 PORTATA (l/h) FLOW RATE (l/h) Fig. 14 LEGENDA By-pass on By-pass off...

  • Page 25: Use, Maintenance (Including Benchmark) And Commissioning

    (Lo). This operation must be performed by 5) Determine the CO values at min power authorised personnel using original Sime MODELS PAR 1 stated below, if required adjust using the components. METHANE 20 System - 25 OFF-SET adjustment screw (6 fig.
  • Page 26 Codice/Code 8108110 MAINTENANCE (fig. 20) Modello/Model FORMAT DGT HE 25 Matricola/Serial n. 9999999999 To guarantee the operation and efficiency of PAR 1 = 02 (METANO)/ 06 (GPL)
  • Page 27 same time the installer's key ( ) for a few seconds. The chimney sweep function will switch on and will continue for 15 minu- tes. During the 15 minutes functioning of chimney sweep function, pressing the keys ) take the boiler respective at maximum (Hi) and at minimum (Lo) power.
  • Page 28 up the boiler again. rotated. in 4.2.2 and 4.3 (fig. 23). Open the gas cock, press the “ mode key” (fig. 12). Check the operational (working) gas inlet pressure. Set up the boiler to operate at maximum r at e as descr ibed in 4.5.1 (Chimney sweep]).
  • Page 29 Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
  • Page 30 Service R ecord It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. This is also a condition of any extended warranty offered. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.

  • Page 31: Fault Finding

    FAULT FINDING If an electrical fault occurs on the appliance SHORT CIRCUIT approx.: 240 V ac. the preliminary electrical system checks CHECK – Test leads from L to E “ ” meter reads must be carried out first. approx. 240 V ac. Switches turned FULL ON - meter set on Ω...
  • Page 32 – Refit in reverse order ensuring seals are replaced as required fit in reverse order ensuring seals are replaced as required – Setting the gas valve procedure for FORMAT DGT HE: 1. Remove the heating sensor from the flow pipe. 2. Open the downstream test point (4 fig.
  • Page 33 6. 1 3 SAFETY VALVE – Remove cover – Remove cable from flow sensor and pull – Isolate from mains forward – Remove cover – Lift flow sensor blue clip pull forward – Isolate flow and return valves – Refit in reverse order –...

  • Page 34: Exploded Views

    EXPLODED VIEWS 8108118 FORMAT DGT HE 20 SYST. Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 006A...
  • Page 35 6226410 O-Ring Ø 63 x 3 6028703 Gasket for duct flange 6028646 Air diaphragm 6083055 Duct flange 60 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246505 C.H. flow pipe 6226412 O-ring 3068 6231360 Temperature sensor 1010215 Rubber pipe dia.
  • Page 36 8108110 FORMAT DGT HE 25 Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 6319201 Main exchanger body...
  • Page 37 6226410 O-Ring Ø 63 x 3 6028703 Gasket for duct flange 6028646 Air diaphragm 6083055 Duct flange 60 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246504 C.H. flow pipe 6226412 O-ring 3068 6231360 Temperature sensor 1010215 Rubber pipe dia.
  • Page 38 8108112 FORMAT DGT HE 30 Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 006A 6319202 Main exchanger body...
  • Page 39 6028703 Gasket for duct flange 6083055 Duct flange 60 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246504 C.H. flow pipe 6226412 O-ring 3068 6231360 Temperature sensor 1010215 Rubber pipe dia. 15x2,5 6227431 C.H. return pipe 6226457 O-ring 12bis diam.
  • Page 40 8108114 FORMAT DGT HE 35 Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 006A 6319202 Main exchanger body...
  • Page 41 6028703 Gasket for duct flange 6083055 Duct flange 60 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246504 C.H. flow pipe 6226412 O-ring 3068 6231360 Temperature sensor 1010215 Rubber pipe dia. 15x2,5 6227431 C.H. return pipe 6226457 O-ring 12bis diam.
  • Page 42 8108130 FORMAT DGT HE 25 Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 6319201 Main exchanger body...
  • Page 43 6010844 Trap fixing bracket 6034160 Condensate drainage rubber pipe 6226410 O-Ring Ø 63 x 3 6028703 Gasket for duct flange 6028646 Air diaphragm 6083055 Duct flange 60 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246504 C.H.
  • Page 44 8108132 FORMAT DGT HE 30 Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 006A 6319202 Main exchanger body...
  • Page 45 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246504 C.H. flow pipe 6226412 O-ring 3068 6231360 Temperature sensor 1010215 Rubber pipe dia. 15x2,5 6227431 C.H. return pipe 6226457 O-ring 12bis diam. 16x1,90 6026410 Exchanger elbow flange return 6226619 Spring for heat exchanger conne 6280590...
  • Page 46 8108134 FORMAT DGT HE 35 Posiz. Codice Descrizione 6318350 Left hand side frame part 6318300 Right hand side frame part 6140006 Bracket for expansion vessel 5139121 Expansion vessel l.6 - 3/8" M 6010840 Exchanger fixing bracket 006A 6319202 Main exchanger body...
  • Page 47 6028703 Gasket for duct flange 6083055 Duct flange 60 6001150 Air intake pipe 60 6243823 Gas valve type 6277416 Pipe connecting gas valve-mixer 6246504 C.H. flow pipe 6226412 O-ring 3068 6231360 Temperature sensor 1010215 Rubber pipe dia. 15x2,5 6227431 C.H. return pipe 6226457 O-ring 12bis diam.

  • Page 48: Appendix 1

    APPENDIX 1 INDUSTRY GUIDANCE FOR INSTALLERS ON CONDENSATE DRAINAGE PIPE INSTALLATION This guidance is endorsed by HHIC members. 1. BACKGROUND During recent winters the UK has experienced prolonged spells of extremely cold weather - down to minus 20 C and below in many areas. This resulted in a significant increase in the number of calls to boiler manufacturers and heating engineers from householders with condensing (high efficiency) boilers where the condensate drainage pipe had frozen and become blocked with ice, causing the boiler to shut down.
  • Page 49 2.1 INTERNAL TERMINATION: Wherever possible, the condensate drainage pipe should be terminated at a suitable internal foul water discharge point such as (a) an internal soil and vent stack or (b) an internal kitchen or bathroom waste pipe, washing machine waste pipe etc. A suitable permanent connection to the foul waste pipe should be used.
  • Page 50 The use of fittings, elbows etc should be kept to a minimum and any internal “burrs” on cut pipework should be removed so that the internal pipe section is as smooth as possible. The customer/householder should be advised that even with the above measures this type of installation could freeze, and that if this were to occur then boiler shutdown could result, requiring remedial action - possibly involving a chargeable engineer call-out.
  • Page 51 NOTES The Benchmark Commissioning Checklist (located at the back of the boiler installation manual) should be completed as required to record details of the condensate drainage pipe installation. Where an external condensate drainage pipe is installed, the customer should be made aware of the risks and consequences of its freezing and offered the option to fit trace heating (or other measures approved by the boiler manufacturer or service organisation).
  • Page 52 Figure 1 – Connection of condensate drainage pipe to internal soil and vent stack Boiler Visible air break 75 mm trap Visible air break and trap not required if there is a trap with a minimum condensate seal of 75 mm incorporated into the boiler Soil and vent stack Invert 450 mm minimum up to three storeys...
  • Page 53 Figure 2(a) – Connection of a condensate drainage pipe downstream of a sink, basin, bath or shower waste trap Boiler Visible air break 75 mm trap Visible air break and trap not required if there is a trap with a minimum condensate seal of 75 mm incorporated into the boiler.
  • Page 54 Figure 2(b) – Connection of a condensate drainage pipe upstream of a sink, basin, bath or shower waste trap Boiler Visible air break at plug-hole 75 mm sink, basin, bath or shower waste trap Sink, basin, bath or shower with integral overflow Open end of condensate drainage pipe direct into gully 25 mm min below grating but above water level;...
  • Page 55 Figure 3 – Connection of a condensate pump - typical method (NB manufacturer’s detailed instructions should be followed).
  • Page 56 Figure 4 – Connection of condensate drainage pipe to external soil and vent stack Boiler 450 mm minimum up to three storeys Visible air break Minimum internal diameter 19 mm 75 mm trap Pipe size transition point Visible air break and trap not required if Minimum internal diameter 30 mm there is a trap with a minimum condensate seal of 75 mm incorporated into the boiler.
  • Page 57 Figure 5 – External termination to rainwater downpipe (NB only combined foul/rainwater drain) Condensate discharge pipe from boiler Air gap Pipe size transition point 68 mm PVCu strap-on fitting Water/weather proof insulation Minimum internal diameter 19 mm 43 mm 90° male/female bend Minimum internal diameter 30 mm External rain water pipe into foul water End cut at 45 °...
  • Page 58 Figure 6 – External drain, gully or rainwater hopper Boiler Visible air break 38 mm minimum trap Visible air break and trap not required if there is a trap with a minimum condensate seal of 38 mm incorporated into the boiler External length of pipe 3 m maximum Open end of condensate drainage pipe direct into gully 25 mm min below grating but above water level;...
  • Page 59 Figure 7 – Example of a purpose-made soakaway Condensate discharge pipe from boiler Ground (this section of the condensate drainage pipe may be run either above or below ground level); End cut at 45 ° Diameter 100 mm minimum plastic tube Bottom of tube sealed Limestone chippings Two rows of three 12 mm holes at 25 mm centres, 50 mm from bottom of tube and...
  • Page 60 Sime Ltd 1a Blue Ridge Park Thunderhead Ridge Glasshoughton, Castleford, WF10 4UA Phone: 0845 9011114 Fax: 0845 9011115 www.sime.ltd.uk Email: enquiries@sime.ltd.uk...

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