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6.5

C.H. MODE - FAULT FINDING (“FRIENDLY FORMAT 80” model)

Start from cold

Rotary switch set to WINTER position.
Room thermostat (if fitted) calling for heat and all D.H.W. taps off.
C.H. thermostat set to maximum position.
Clock in the on position (if fitted).

NOTE:
After completing fault finding reset the room thermostat (if fitted) to the required setting. If the appliance will not function
check the wiring to the clock and if necessary, replace the clock.

Is there power
at the external

socket?

Make

power

available

Does

the pump

start?

Does

the fan

start?

Is there a spark

at the ignition

electrode?

Is fuse

at mains
plug OK?

Is there power

at L and N
terminals?

Is smoke

pressure switch

connected right?

Check smoke

pressure switch

and fan

connection

Set properly

ignition probe

Is there continuity

between

ignition probe

and ground?

Make it free

to rotate

Replace fuse in

mains plug

Check wire

connections

to L and N

terminals

Is there voltage

available to the

pump?

Is smoke

pressure switch

closed?

Replace the

smoke pressure

switch

Is the smoke

pressure switch

contact in open

position?

Is pump

shaft free

to rotate?

Check pump

connection

Is limit

thermostat

calling for heat?

Replace the

limit thermostat

Replace

the pump

Is the room
thermostat

contact closed?

Is fuse F1 OK?

Is sensor

disconnected?

Connect

the sensor

Replace

sensor

Replace the fan

Replace

fuse F1

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

control board

Is there 230V AC

available at the

fan terminals?

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?

Check the gap

between

ionisation probe

and hood;

check if the

electrode lead
and fit are not

damaged. Does it

now detect the

flame?

Can the burner

pressure be

reduced by the

C.H. ajuster?

Does the burner

pressure reduce as

the temperature

rises towards max.?

Check:

1) Limit

thermostat

2) C.H.

thermistor

3) PCB control

board

Is the burner

pressure set to

the maximum?

Replace the

C.H. thermistor

Does the

boiler switch

OFF before

achieving the
temperature

attainment?

Is there a

voltage at the

modulator?

Is the gas
available?

Open the
gas cock

Turn the plug

Replace the

modulator

Is the safety

thermostat OK?

Replace the

safety

thermostat

Boiler is

satisfactory

Is there

continuity

between the

PCB control

board and

the gas valve?

Replace the

gas valve

Set properly

the connection

Yes

Close the room

thermostat

contact

Yes

Содержание benchmark FRIENDLY FORMAT

Страница 1: ...Friendly Format Installation and servicing instructions GB ...

Страница 2: ... 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 See installation manual Has the D H W flow rate been set to the customer requirements Has the customer been fully advised on the cor...

Страница 3: ... 7 3 INSTALLING THE BOILER 3 1 UNPACKING THE BOILER 8 3 2 FIXING THE WALL MOUNTING BRACKET 3 3 HANGING THE BOILER 3 4 FLUE AND TERMINAL PREPARATION 9 3 5 FLUE AND TERMINAL INSTALLATION 10 3 6 SEPARATE DUCTS 11 3 7 WATER CONNECTIONS 13 3 8 GAS CONNECTIONS 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 ...

Страница 4: ...IONAL FLOW WIRING DIAGRAM 21 7 2 INTERNAL VIEW 22 8 REPLACEMENT OF PARTS 8 1 HEAT EXCHANGER 23 8 2 COMBUSTION CHAMBER INSULATION 8 3 FAN ASSEMBLY 8 4 MAIN BURNER 8 5 IGNITION DETECTION ELECTRODES 8 6 GAS VALVE 24 8 7 AIR PRESSURE SWITCH 8 8 LIMIT THERMOSTAT 8 9 OVERHEAT THERMOSTAT 8 10 THERMISTOR 25 8 11 IGNITION CONTROL BOX 8 12 DRIVER PCB 8 13 PUMP 8 14 D H W HEAT EXCHANGER 8 15 DIVERTOR VALVE C...

Страница 5: ...h 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 details are given in section 3 The boiler can be used with a 240V room thermostat class II according to EN 60730 1 This booklet provides instructions for the f...

Страница 6: ...inimum bar psi 0 5 7 3 0 5 7 3 Maximum bar psi 3 0 43 5 3 0 43 5 D H W pressure Minimum bar psi 0 5 7 3 0 5 7 3 Maximum bar psi 7 0 102 7 0 102 Weight Empty kg lb 43 95 49 108 Total full kg lb 46 5 102 52 5 116 Electrical supply 230 V 50 Hz Fused at 3 A Internal fuse Line F 1 6 A Maximum power consumption Watt 150 160 Maximum gas consumpt G20 m3 h ft3 h 2 72 96 3 34 118 Max working temperature C F...

Страница 7: ...anger 6 Divertor 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 Fig 2 ...

Страница 8: ...e current I E E Wiring Regula tions 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 provid ed it is modified accordingly Where installation will be in an unusual location special procedures ma...

Страница 9: ...ed 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 should be ...

Страница 10: ...ould 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 wate...

Страница 11: ... 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 FRIENDLY FORMAT 100 E is recom mended Higher flow rates will not damage the appliance but may lower the water temperature below an accept able level If the appliance is installed in an area where the tempo rary hardness of the water supply is high say over ...

Страница 12: ... position of the two wall mounting bracket fixing holes the two lower frame fixing holes and the flue air duct hole on the appropriate wall s Remove the template s and drill the top two fixing holes using a 10 mm masonry drill and the bottom two fixing holes using a 6 mm masonry drill Fit the plastic plugs pro vided Cut the hole in the wall for the flue air duct The diameter should not be less tha...

Страница 13: ...using the following procedure fig 9 For the flue ducts in turn push the plain end of the stan dard and if using two or three extensions extension duct into the swaged end of the extension duct s Push an air duct in to the clamp Join the air ducts larger ducts and tighten the screws an the clamp to connect them 3 4 2 Cutting the flue air duct to the correct length Rear flue outlet Only fig 10 Selec...

Страница 14: ...e ring is pulled up to the wall surface Procede to section 3 5 3 3 5 2 Installations from outside the building only Hole diameter 100 mm 4 in Push the flue duct assembly into the air duct until the external swaged ring on the flue terminal stops against the internal swage on the air duct fig 12 From inside or outside the building slide the duct assem bly into the wall until the sealing ring forms ...

Страница 15: ...r to Table 8 3 6 1 Separate flue accessories Part No 8093000 is supplied for this purpose fig 14 The sectored diaphragm is to be used according to the max imum head loss allowed in both pipes as given in fig 15 The complete range of accessories necessary for satisfying all installation requirements is shown in fig 16 11 Example of allowable installation calculation FRIENDLY FORMAT 80 80 E models i...

Страница 16: ...MF code 8077404 2b Isolated 90 elbow MF code 8077408 3a Extension L 1000 code 8077303 3b Isolated extension L 1000 code 8077306 4 Outlet terminal code 8089501 5 Int est ring kit code 8091500 6 Intake terminal code 8089500 7 45 elbow MF code 8077406 8 Condensation outlet L 135 code 8092800 9 Locking junction n 5 code 8092700 KEY 1 Tile with articulated joint 2 Lead panel 3 Collar 4 Locking screw 5 ...

Страница 17: ...e 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 control box at the L H S If a room...

Страница 18: ...pen 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 require adjusting If the burner pressure is low check that the appliance has not begun to modulate this will occur if the D H W flow rate is low If modulation is suspected open all D H W tap...

Страница 19: ...s of use of hot water given in Table 4 have been obtained by positioning the selector of the circulation pump on the max imum value Should there be any reduction in the D H W flow rate the filter installed on the inlet to the pressure switch valve will need cleaning To gain access to the filter first close the cold water isolation valve 19 figure 2 drain the D H W circuit via the lowest tap make p...

Страница 20: ...nd then lift the burner clear Remove the burner manifold 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 Remove the four screws securing the fan mounting plate Tilt the fan assembly forwards and remove in a down wards direction...

Страница 21: ...eter set on Ω ohms x 1 scale Test leads from L to N on appliance terminal block if meter reads 0 then there is a short circuit Meter set on Ω ohm x 100 scale Repeat it with leads from L to E If meter reads less than infinity there is a fault NOTE Should it be found that the fuse has failed but no fault is indicated a detailed continuity check i e by discon necting and checking each component is re...

Страница 22: ...ere 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 control board Is there 230V AC available at the fan terminals Has the PC...

Страница 23: ... Replace the fan 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 Repl...

Страница 24: ... 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...

Страница 25: ...e ER Detection electrode A SIT 503 control box TS 100 C safety thermostat OP Time clock 80 E 100 E models 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 Fig 25 ...

Страница 26: ...rol 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 Time clock 80 E 100 E models 18 Frosto stat FRIENDLY FORMAT 100 E model Fig 26 ...

Страница 27: ...s 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 fan assembl...

Страница 28: ...djusting the mini mum pressure Check that the minimum pressure is cor rectly set by turning on and off the D H W inlet valve sev eral times and ensuring that the pressure returns to that previously 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 nec ess...

Страница 29: ...the system as described in section 4 1 8 14 D H W HEAT EXCHANGER Remove the casing front panel as described in section 5 1 Remove the gas valve to improve access as described in section 8 6 Isolate the C H flow and return valves and the D H W iso lation valve 17 18 19 fig 2 Drain the appliance through the drain plug 13 fig 2 Drain the D H W circuit by opening any D H W tap below the level of the b...

Страница 30: ...he gauge forwards Reassemble in reverse order Refill and re commission the system as described in sec tion 4 1 8 19 SAFETY VALVE Remove the casing front panel as described in section 5 1 Remove the two screws and pivot the control box down wards Isolate the C H flow and return valves 17 18 fig 2 Drain the appliance through the drain point 13 fig 2 Unscrew the union supporting the outlet pipe from ...

Страница 31: ...25707 8 Air pressure switch 100 E 1 6225708 9 Overheat thermostat 1 6146701 10 397 590 Limit thermostat 1 6146700 11 D H W heat exchanger 80 80 E 1 6265602 11 D H W heat exchanger 100 E 1 6265600 12 Heat exchanger 80 80 E 1 6174221 12 Heat exchanger 100 E 1 6174223 13 Thermistor 1 6231352 14 397 585 Fan assembly 80 80 E 1 6225612 14 Fan assembly 100 E 1 6225613 15 Rotary switch 1 6260701 16 Circul...

Страница 32: ...Cod 6272206B Documentation Dpt Sime Ltd Unit D2 Enterprise Way Bradford Road Idle Bradford BD10 8EW Tel 0870 9911114 Fax 0870 9911115 www sime ltd uk e mail enquiries sime ltd uk ...

Страница 33: ...Friendly Format User instructions GB ...

Страница 34: ......

Страница 35: ... YOUR LOG BOOK ENCLOSED IS FILLED IN CORRECTLY ALL CORGI REGISTERED INSTALLERS CARRY A CORGI ID CARD BOTH SHOULD BE RECORDED IN YOUR CENTRAL HEATING LOG BOOK YOU CAN CHECK YOUR INSTALLER IS CORGI REGISTERED BY CALLING ON 01256 372300 2 YEAR GUARANTEE IN ORDER TO OBTAIN THE SECOND YEAR S COVER PLEASE REGISTER YOUR BOILER BY SENDING IN THE ENCLOSED GUARANTEE CARD OR PHONING OUR SERVICE DEPARTMENT WI...

Страница 36: ...t water will be sensed by the appliance detecting water flow providing that the flow rate is above 2 l m 0 5 gal min The fan will start and the burner will light at full output If the draw off rate is near the maximum design flow rate the appliance will run continuously at full output until a tap is either turned off or the flow rate is reduced in which case the heat output will reduce accordingly...

Страница 37: ...tem pressure If the normal running pressure is seen to decrease over a period of time there is a water leak and you should consult your installer or service engineer 1 6 3 Electrical supply The mains plug used must be a 3 pin type to BS1363 and fused at 3 A THIS APPLIANCE MUST BE EARTHED NOTE an interruption in the electricity supply whilst the burner is alight may cause the overheat thermostat to...

Страница 38: ...that a fault exists on the appli ance it MUST NOT be used until the fault has been rectified by a competent person WARNING IF A GAS LEAK IS SUSPECTED OR EXISTS TURN OFF THE GAS SUPPLY TO THE APPLIANCE AT THE GAS SERVICE COCK DO NOT OPERATE ANY ELECTRICAL SWITCHES DO NOT OPERATE ANY ELECTRICAL APPLIANCE OPEN ALL WINDOWS AND DOORS DO NOT SMOKE EXTINGUISH ALL NAKED LIGHTS CONTACT THE GAS SUPPLIER IMM...

Страница 39: ......

Страница 40: ...Cod 6272205B Documentation Dpt Sime Ltd Unit D2 Enterprise Way Bradford Road Idle Bradford BD10 8EW Tel 0870 9911114 Fax 0870 9911115 www sime ltd uk e mail enquiries sime ltd uk ...

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