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Sime super mk.ii Installation And Servicing Instructions Download Page 23

19

6.6

D.H.W. MODE - FAULT FINDING

Start from cold - rotary switch set to SUMMER position, D.H.W. thermostat set to maximum, and all D.H.W. taps OFF.

NOTE: 
When commissioning the boiler, please check the polarity in case the pump and the fan are running but the burner does
not fire.

Is there power 
at the external 

socket?

Make 

power 

available

Does 

the pump 

start?

Does 

the fan 

start?

Set right ignition

probe

Is there a spark 

at the ignition elec-

trode?

Is fuse 

at mains 
plug OK?

Replace

fuse in 

mains plug

Is smoke 

pressure switch

connected right?

Check smoke 

pressure 

switch and fan

connection

Is there continuity

between 

ignition probe 

and ground?

Make it 

free to 

rotate

Is there power 

at L and N 
terminals?

Check wire 

connections 

to L and N 

terminals

Is there 

voltage available

at the pump?

Is smoke 

pressure switch

closed?

Replace the smoke

pressure switch

Is the smoke 

pressure switch

contact in open

position?

Check gap

between ignition 

electrode and

hood. Check the

electrode lead 
and fit are not 

damaged. Does it 

now spark?

Is pump 

shaft free 

to rotate?

Open any 

D.H.W. tap 

to give flow 

2.8 l/min. 

Can you 

get the desired 

flow at the 

D.H.W. taps?

Are microswitches 

of divertor valve 

operated?

Is limit 

thermostat 

calling for heat?

Replace the

limit thermostat

Replace the 

pump

Replace the

divertor valve

Is fuse

F1 OK?

Is sensor 

disconnected?

Connect 

the sensor

Check pump 

connection

Clean or replace

filter at inlet of

divertor valve

Set right 

the contacts

Replace 

fuse F1

Is there 

continuity

between 

power terminals

of PCB control

board and PCB

ignition?

Is sensor OK?

Replace 

sensor

Is there 230V AC
available between

11 and 4 

terminals and

between 

11 and 10 

terminals of PCB

ignition?

Replace the
PCB control 

board

Is there 230V AC

available at 

the fan terminal?

Replace 

the fan

Has the PCB 

ignition 

locked-out after 

10 seconds 

without flame 

at the burner?

Has the  PCB 

ignition 

locked-out after 10

seconds 

with flame 

at the burner

before lock?

Can the burner 

pressure be 

reduced by the

D.H.W. ajuster?

Does the burner 
pressure reduce 

as the temperature

rises towards max.?

Check:

1)  Limit 

thermostat

2)  D.H.W. 

thermistor

3) PCB control

board

Is the burner 

pressure set to 

the maximum?

Check the gap

between the

ionisation probe

and hood. 

Check if the 

electrode lead 
and fit are not 

damaged. 

Does it now 

detect the flame? 

Replace the

D.H.W. thermistor

Does 

the boiler 

swich OFF 

before achieving

the temperature?

Is there a 

voltage at the

modulator?

Is the gas 
available?

Open the 
gas cock

Replace the

modulator

Is the limit 

thermostat OK?

Replace the

limit thermostat

Turn 

the plug

Boiler is

satisfactory

Is there 

continuity between 

PCB control 

board and 

the gas valve?

Replace  the

gas valve

No

Yes

Yes

Yes

Yes

Yes

Yes

No

No

No

Yes

No

No

Yes

Yes

No

No

Yes

No

Yes

No

No

Yes

No

Yes

No

No

No

Yes

No

Yes

No

Yes

No

Yes

Yes

No

No

Yes

Yes

No

No

Yes

Yes

Yes

Yes

Yes

No

No

Yes

Yes

No

No

No

Yes

Yes

No

Yes

Yes

Yes

No

No

Yes

Set right 

the connection

No

Summary of Contents for super mk.ii

Page 1: ...Super Mk II Installation and servicing instructions GB ...

Page 2: ...ill be made for a service visit where the fault is not due to a manufacturing defect Has a correct by pass been fitted and adjusted Has the system and boiler 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 Has the pump been rotated manually Is the gas supply working pressure correct Is the boiler wired correctly S...

Page 3: ... 7 3 INSTALLING THE BOILER 3 1 UNPACKING THE BOILER 8 3 2 FIXING THE BOILER MOUNTING FRAME 3 3 WATER CONNECTIONS 9 3 4 HANGING THE BOILER 3 5 FLUE AND TERMINAL PREPARATION 3 6 FLUE AND TERMINAL INSTALLATION 10 3 7 SEPARATE DUCTS 11 3 8 GAS CONNECTIONS 13 3 9 SAFETY VALVE CONNECTION 3 10 WIRING INSTRUCTIONS 3 11 TIME CLOCK INSTRUCTIONS 14 4 COMMISSIONING AND TESTING 4 1 FILLING THE WATER SYSTEM 14 ...

Page 4: ...USTION CHAMBER INSULATION 8 3 FAN ASSEMBLY 8 4 MAIN BURNER 8 5 IGNITION DETECTION ELECTRODES 8 6 GAS VALVE 23 8 7 AIR PRESSURE SWITCH 8 8 LIMIT THERMOSTAT 8 9 OVERHEAT THERMOSTAT 8 10 THERMISTOR 24 8 11 IGNITION CONTROL BOX 8 12 DRIVER PCB 8 13 PUMP 8 14 D H W HEAT EXCHANGER 8 15 DIVERTOR VALVE COMPLETE 8 16 DIVERTOR VALVE MICROSWITCH ASSEMBLY 8 17 C H EXPANSION VESSEL 8 18 PRESSURE GAUGE 25 8 19 ...

Page 5: ...ate flues kit see section 3 for details The boiler is designed for use with sealed primary water sys tems and is supplied fully assembled and equipped with com plete valve packs If the wall thickness is less than 0 5 m 19 in the appliance can be installed from inside the room without access to the external wall although a wall liner is required This is available as an optional extra and full detai...

Page 6: ...NG RANGE 10 5 35 700 13 5 46 200 2 4 1 0 12 5 42 600 15 9 54 200 3 8 1 5 14 5 49 500 18 2 62 200 5 1 2 0 16 5 56 400 20 6 70 200 6 4 2 6 18 5 63 300 22 9 78 200 7 7 3 1 X 20 6 70 200 25 3 86 200 9 0 3 6 22 6 77 100 27 6 94 200 10 3 4 1 24 6 84 000 29 9 102 200 11 6 4 6 26 6 90 900 32 3 110 200 12 6 5 1 DOMESTIC HOT WATER Max 26 6 90 900 32 3 110 200 12 6 5 1 Min 10 5 35 700 13 5 46 200 2 4 1 0 Dif...

Page 7: ...valve with charging 7 NTC sensor 8 100 C safety thermostat 9 Air relief valve 10 Circulation pump 11 Expansion vessel 12 Safety valve 13 Drain plug 14 Manometer 15 Automatic by pass 16 D H W filter 17 C H return cock 18 C H flow cock 19 D H W cock 20 Gas cock 21 Limit thermostat 22 Frost stat 23 Non return valve Fig 2 ...

Page 8: ...he current I E E Wiring Regulations BS 7671 and in Scotland the electrical provisions of the Building Regulations applicable in Scotland A compartment used to enclose the appliance MUST be designed and constructed specifically for this purpose An existing cupboard or compartment may be used provided it is modified accordingly Where installation will be in an unusual location special procedures may...

Page 9: ...PVC insulated cable NOT LESS than 0 75 mm2 24 x 0 2 mm to BS6500 Table 16 Wiring external to the boiler MUST be in accordance with current l E E Wiring Regulations BS 7671 and local regulations The supply connection to the flying lead provided MUST be made to a fused double pole switch having a 3 mm 1 8 in contact separation in both poles serving only the boiler and system controls The fuse rating...

Page 10: ...uld be fitted as shown above Take note of the requirements relative to container capacity height above system inclusion of a non return valve stop cock and automatic air vent in the feed pipe as shown in fig 5 Note also the feed pipe connection is made to the heating return as close to the appliance as possible The Local Water Undertaking MUST approve ALL connections between the system and a water...

Page 11: ...nection The final 600 mm 24 in of the mains supply pipe to the boiler must be copper A maximum D H W flow rate of 10 3 l m 2 3 gpm 13 l m 2 9 gpm for Super 105 Mk II is recommended Higher flow rates will not damage the appliance but may lower the water temperature below an acceptable level If the appliance is installed in an area where the temporary hardness of the water supply is high say over 15...

Page 12: ... section 2 2 and 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 For the rear flue application fix the flue template 14 to the frame with the selftapping screws provided Mark the position of the two upper installation frame fixing holes the two lower frame fixing holes and the flue ai...

Page 13: ...ember locates onto the installation frame Screw the adjusting screws 15 fig 7 until the appliance is secure and vertical Connect the isolation valves to the boiler using the gaskets provided 3 5 FLUE AND TERMINAL PREPARATION If the wall thickness is less than 0 5 m 19 in the flue air duct may be fitted without access to the outside wall providing that the optional wall liner kit is used This consi...

Page 14: ...an 1 m 3 6 1 Installations from inside the room Wall thicknesses up to 0 5 m 19 in only Hole diameter suffi cient to accept wall liner 130 mm 5 1 4 in if optional kit is used A wall liner 127 mm 5 in internal diameter 500 mm 19 in long is available as an optional extra for use when fitting the flue air duct from inside the building or where it is required to seal the hole through a cavity wall Cut...

Page 15: ...re that the silicon seal on the fan outlet correctly engages and forms a seal at its joint with the elbow This must be checked from inside the sealed chamber Secure the elbow onto the top of the appliance using the four screws and washers provided and refit the sealed chamber front panel 3 7 SEPARATE DUCTS Optional alternative twin pipe system When installing the separate ducts comply with the req...

Page 16: ...nction n 5 code 8092700 120 ø 80 160 KEY 1 Sponge rubber gasket ø125 95 2 Fixing screw 3 Air smokes flow splitting unit with take off point 4 Sectors diaphragm ø 38 Fig 14 Fig 15 Fig 16 Example of allowable installation calculation Super 90 Mk II model in that the sum of the head losses of the single fittings is less than 9 00 mm H2O Intake Outlet 7 meter horizontal pipe ø 80 x 0 20 1 40 7 meter v...

Page 17: ...ted in the valve 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 should avoid sharp corners or upward pipe runs where water may be retained 3 10 WIRING INSTRUCTIONS Refer to sections 2 6 2 7 and fig 19 The external wiring is connected to the boiler via a lead cable situated behind the cont...

Page 18: ... Ensure that the rotary switch on the facia panel is set to the SUMMER position D H W Only turn the D H W ther mostat to maximum fully clockwise and turn on the electri cal supply Fully open any D H 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 H W burner pressure is factory set and should not req...

Page 19: ... an acceptable D H W temperature To set the D H W flow procede as follows select Summer position and turn the D H W ther mostat to max fully open the D H W tap furthest from the boiler check that the boiler is firing at maximum burner pressure adjust the D H W flowrate by turning the restrictor lever on the divertor valve until a D H W temperature rise of approx 35 C is achieved This corresponds t...

Page 20: ...old by disconnecting the four screws Inspect and if necessary clean the injectors electrodes and the main burner bars 5 2 FAN ASSEMBLY Disconnect the electrical connections to the fan Note the position of the earth conductor 16 the installer should Give the Users Instructions to the householder and emphasise their responsibilities under the Gas Safety Installation and Use Regulations 1996 as amend...

Page 21: ...iagrams 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 further 6 2 SHORT CIRCUIT CHECK Switches turned FULL ON meter set on Ω ohms x 1 scale Test leads from L to N on appl...

Page 22: ... Replace the pump Check pump connection Set right the contacts Is there continuity between power terminals of PCB control board and PCB ignition Is sensor OK Check gap between the ignition electrode and hood check if the electrode lead and fit are not damaged Does it now spark Is there 230V AC available between 11 and 4 terminals and between 11 and 10 terminals of PCB ignition Replace the PCB cont...

Page 23: ... connection Clean or replace filter at inlet of divertor valve Set right the contacts Replace fuse F1 Is there continuity between power terminals of PCB control board and PCB ignition Is sensor OK Replace sensor Is there 230V AC available between 11 and 4 terminals and between 11 and 10 terminals of PCB ignition Replace the PCB control board Is there 230V AC available at the fan terminal Replace t...

Page 24: ...ectrode ER Detection electrode A SIT 503 control box TS 100 C safety thermostat OP Time clock PF Air pressure switch V Fan P Circulation pump VP Divertor valve TAG Frost thermostat C Rotary switch TA Room thermostat M Modulator SM C H sensor TL Limit thermostat F1 Fuse Note The room thermostat must be connected to the terminals 22 23 20 Fig 25 ...

Page 25: ...Gas valve with control box 4 D H W exchager 6 Combustion chamber 7 Water gas exchager 10 100 C safety thermostat 11 NTC sensor 12 Limit thermostat 13 Air relief valve 14 Circulating pump 15 Fan 16 Smoke pressure switch 17 Frost stat Fig 26 Super 105 Mk II model ...

Page 26: ...ion panels followed by the rear panel re assemble in reverse order refill and recommission the system as described in section 4 8 3 FAN ASSEMBLY Remove the casing front panel and sealed chamber front panel as described in section 5 1 Disconnect the electrical connections to the fan Note the position of the earth conductor Unscrew the four screws securing the fan mounting plate Drop and tilt the fa...

Page 27: ...ectly set by turning on and off the D H W inlet valve several times and ensuring that the pressure returns to that pre viously adjusted Isolate the power supply re connect the modulation lead restore the power and re check the maximum pressure then re fit the plastic cover 1 Reduce the D H W draw off rate to the minimum neces sary to maintain the burner alight by carefully adjusting the D H W Inle...

Page 28: ...he D H W circuit by opening any D H W tap below the level of the boiler Remove the two screws pivot the control box downwards Disconnect all union connections to the D H W heat exchanger and remove the heat exchanger Fit new heat exchanger and re assemble in reverse order using the new gaskets supplied with the heat exchanger Refill and re commission the system as described in section 4 1 8 15 DIV...

Page 29: ...nd re assemble in reverse order Refill and re commission the system as described in section 4 1 8 20 AUTOMATIC AIR VENT Remove the casing front panel as described in section 5 1 Isolate the C H flow and return valves 17 18 fig 2 Drain the appliance through the drain point 13 fig 2 Unscrew the automatic air vent Fit the new automatic air vent using a suitable jointing com pound and re assemble in r...

Page 30: ...t Ø 12x18x2 51 6226403 O ring 2031 52 6017211 Manual air vent 1 4 53 6040201 Pressure relief valve 54 6124803 Myson CP51AS pump 1 90 54 A 6124810 Myson CP61AS pump 1 105 55 6013100 Automatic air vent 3 8 56 2030229 Gasket Ø 22x30x2 Position Code Description Model 57 6264812 C H return pipe 90 57 A 6264822 C H return pipe 105 58 6264712 C H flow pipe 90 58 A 6264721 C H flow pipe 105 59 6146700 Lim...

Page 31: ...ressure nipple 90 33 6229209 Fan mounting plate 90 33 A 6229210 Fan mounting plate 105 34 6225615 Fan 90 34 A 6225613 Fan with venturi 105 Position Code Description Model 35 6139606 Combustion chamber front panel 90 35 A 6139608 Combustion chamber front panel 105 36 6139754 Combustion chamber front insulation 90 36 A 6139756 Combustion chamber front insulation 105 37 6229101 Smoke pressure switch ...

Page 32: ...19571 Lower closing panel 74 6272910 Control panel 75 6044022 Gem 76 6217003 Temperature and pressure gauge 77 6197707 Time programmer 78 6230679 Control board 79 6201501 Trimmer spindle Ø 5 80 6201502 Trimmer spindle Ø 6 Position Code Description Model 81 6260701 Rotary switch 82 2211610 Earth faston 83 6273010 Control panel protecting cover 84 6273110 Room stat connection cover 85 6230921 Knob Ø...

Page 33: ...nd in depth technical training courses FREE LUNCH Certificate on completion of the course Please fill in the form below for more details Combination Boilers Name Address Postcode Tel No Company Please hand this slip to your local merchant or return it to SIME HEATING products UK ltd Jubilee Works Middlecroft Road Staveley Chesterfield Derbyshire S 43 3XN Tel 01246 471950 Fax 01246 281822 ...

Page 34: ... n g p ro d u c t s u k l t d Jubilee Works Middlecroft Road Staveley Chesterfield Derbyshire S 43 3XN Tel 01246 471950 Fax 01246 281822 For service enquiries and boiler faults contact our service company on Tel 01246 470777 Fax 01246 470094 ...

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