Libretto Iven B 60 Inglese.pmd

Transcript

IVEN B60 TFS 24 IVEN B60 TN 24 00334052 - 1st edition - 03/2011 INSTALLATION USE AND MAINTENANCE General info IMPORTANT This INSTRUCTION MANUAL, which is an integral and indispensable part of the product, must be handed over to the user by the plumbers and must be kept in a safe place for future reference. The manual must be handed over with the boiler should it be sold or transferred. This boiler must be used for the purposes for which it has been designed. Any other use shall be considered incorrect and therefore dangerous. The boiler must be installed in compliance with applicable laws and standards and according to the manufacturer’s instructions given in this manual. Incorrect installation may cause injury to persons and/or animals and damage to property. The manufacturer shall not be held liable for any such injury and/or damage. Damage and/or injury caused by incorrect installation or use and/or damage and/or injury due to non-observance of the manufacturer’s instructions shall relieve UNICAL from any and all contractual and extracontractual liability. Before installing the boiler, check that the technical data corresponds to requirements for its correct use in the system. Check that the boiler is intact and that it has not been damaged during transport and handling. Do not install equipment which is patently damaged and/or faulty. Do not obstruct the air suction and/or heat dissipation grates. Only original accessories must be used for all boilers supplied with optionals or kits (including electrical ones). Dispose of the packaging with care as all the materials can be recycled. The packaging must therefore be sent to specific waste management sites. Keep the packaging out of the reach of children as it may represent a choking and suffocation hazard. In the event of failure and/or faulty functioning, switch off the boiler. Do not attempt to make repairs: contact qualified technicians. Original parts must be used for all repairs to the boiler. Non-observance of the above requirement may jeopardize the safety of the boilers and expose people, animals and property to danger. To guarantee efficiency and correct functioning of the equipment it is legally binding to service the boilers once a year according to the schedule indicated in the relative section of this manual. In the event of long periods of inactivity of the boiler, disconnect it from the power mains and close the gas tap (Warning! In this case the boiler’s electronic anti-freeze function will not be operative). Should there be a risk of freezing, add anti-freeze: it is not advisable to empty the system as this may result in damage; use specific anti-freeze products suitable for multi-metal heating systems. N.B. For boilers which use gaseous fuel, if you smell gas: - do not turn on or off electrical switches and do not turn on electrical appliances; - do not ignite flames and do not smoke; - close the main gas tap; - open doors and windows; - contact a Service Centre, qualified installer or the gas supply company. Never use flames to detect gas leaks. WARNING This boiler has been built for installation in the country indicated on the technical data plate: installation in any other country may be a source of danger for people, animals and property. Read the warranty conditions and clauses on the warranty certificate attached to the boiler with care. ‘’WATER TREATMENT IN C.H. SYSTEM FOR CIVIL USE’’ NOTE FOR INSTALLER AND USER 1) The frequency of the cleaning of the D.H.W. heat exchanger is related to the hardness of the feeding water. 2) With a water hardness higher than 28°f (16°d) the use of antiscaling devices, whose choice will be made on the base of water characteristics, is suggested. 3) To increase the resistance to the scaling, a D.H.W. temperature adjustment very close to that one of the actual use, is suggested. 4) The adoption of a modulating room thermostat reduces the scaling danger. 5) We advise you to verify the state of cleaness of the D.H.W. heat exchanger at the end of the first year and subsequently every two years. 2 General info 1 2 TECHNICAL FEATURES AND DIMENSIONS ........................................................... pag. 4 1.1 1.2 1.3 1.4 1.5 pag. pag. pag. pag. pag. 4 4 5 6 6 DIRECTIONS FOR INSTALLERS ......................................................................... pag. 7 2.1 2.2 pag. pag. pag. pag. pag. pag. pag. pag. pag. 7 7 7 8 8 9 9 11 12 pag. 13 pag. pag. pag. pag. pag. pag. pag. pag. pag. pag. pag. 14 16 16 17 17 18 20 21 21 22 23 USERS' INSTRUCTION ............................................... pag. 24 3.1 3.2 3.3 24 25 25 2.3 2.4 2.5 2.6 2.7 2.8 3 Technical features .................................................................... Dimensions .............................................................................. Hydraulic circuits ..................................................................... Operating data ......................................................................... General features ...................................................................... Installations rules .................................................................... Installation ............................................................................... 2.2.1 Packing ....................................................................... 2.2.2 Positioning the boiler .................................................. 2.2.3 Assembling the boiler ................................................. 2.2.4 Ventilation ................................................................... 2.2.5 Flue gas discharge system ........................................ 2.2.6 Position of terminals for Type C boilers ...................... 2.2.7 Discharge and suction pipe configuration .................. 2.2.8 Discharge of flue gas into coaxial pipes with a diameter of 100/60 mm (Type A accessories) ............ 2.2.9 Flue gas discharge and air suction with separate pipes with 80 mm diameter ........................................ 2.2.10 Measurements of combustion efficiency .................... 2.2.11 Connection to the gas mains ...................................... 2.2.12 Hydraulic connection .................................................. 2.2.13 Connection to the power mains .................................. Wiring diagram ........................................................................ Filling the system .................................................................... Starting the boiler .................................................................... Adjusting the burner ................................................................ Modification of other gases ..................................................... Adapting thermal power to the heating system ...................... Control panel ........................................................................... pag. Switchting ................................................................................ pag. Maintenance ............................................................................ pag. 3 General info 1 TECHNICAL FEATURES AND SIZES 1.1 - TECHNICAL FEATURES IVEN B60 is a gas boiler with atmospheric gas burner; and 60-litre storage tank; it is available in the following versions: TN TFS with natural draught open chamber; with forced draught Sealed combustion chamber; All versions have electronic ignition. Models in the IVEN series: IVEN B60 TN 24: open boiler with electronic ignition; IVEN B60 TFS 24: forced draught sealed boiler with electronic ignition; The IVEN B60 boilers comply with the fundamental requirements of the following EEC directives: Directive Gas 90/396/EEC dated 29 June 1990; Yield Directive 92/42 EEC dated 21 May 1992; EMC Directive 89/336/EEC dated 3 May 1989 amended by Directive 92/31/EEC dated 28 April 1992; European Community’s Low Voltage Directive 73/23/EEC dated 19 February 1973 amended by Directive 93/68/EEC dated 22 July 1993; and is supplied with all safety features pursuant to relative applicable laws. The main technical features of the IVEN B boilers are summarised below. • High-performance copper heat exhanger • 60-litre enamelled upright storage tank with a helical steel heat exchanger • Magnesium anode • Electronic ignition; • Electronic flame modulation; • Minimum thermal power control; • Electronic control of ignition ramp; • Anti-freeze function; • D.H.W. precedence thermostat • Pump anti-blocking function; • • • • • • • • • • • • • • • • Pump over run function; Safety limit thermostat (85°C); Three-way motorised valve; Three-speed circulation pump with automatic air vent Manual air vent for system filling 7,5 litre expansion vessel; System water inlet tap; Safety pressure switch for low water level; Control panel with IP44 class protection; Temperature and pressure gauge; Warning light for: presence of power, request for heating, burner in function, cut off; D.H.W. temperature selector (45/65°C); Heating temperature selector (35/85°C). Reset button; Summer / Off / Winter / Anti-freeze selecto Assembly template for connection layout. 855 1.2 - DIMENSIONS 600 476 493 fig. 1 4 General info 1.3 - HYDRAULIC CIRCUIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 IVEN B60 TN 24 14 13 12 11 11 15 10 16 9 17 8 7 18 6 5 5 19 4 M C G F R 20 3 21 1 2 - 3 bar safety valve 3-way valve Water pressure switch Pump with automatic air vent Ignition card Gas valve Ignition electrode Burner Ionisation electrode Overheating safety device Heat exchanger Temperature probe Flue gas thermostat Manual air vent Heating expansion vessel Storage tank D.H.W. expansion vessel (optional) Storage tank thermostat Magnesium anode Boiler drain tap Filling system 7 bar safety valve Heating system flow D.H.W. outlet Gas inlet D.C.W. inlet Return from system - 22 1 G R M C F fig. 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 IVEN B60 TFS 24 13 23 14 12 11 11 15 10 16 9 17 8 7 6 18 5 19 M C G F R 4 20 3 21 2 - 3 bar safety valve 3-way valve Water pressure switch Pump with automatic air vent Ignition card Gas valve Ignition electrode Burner Ionisation electrode Overheating safety device Heat exchanger Temperature probe Flue gas circuit safety pressure switch Manual air vent Heating expansion vessel Storage tank D.H.W. expansion vessel (optional) Storage tank thermostat Magnesium anode Boiler drain tap Filling system 7 bar safety valve Flue gas fan Heating system flow D.H.W. outlet Gas inlet D.C.W. inlet Return from system 22 1 G R M C F fig. 3 5 General info 1.4 - OPERATING DATA The pressures at the burner indicated in the following table must be checked after the boiler has been operating for 3 minutes. FUNCTION IVEN B60 TN 24 IVEN B60 TFS 24 OUTPUT POWER (kW) 23.8 24.0 INPUT CAPACITY (kW) 12.5 - 26.5 12.5 - 26.5 Natural gas 2.9 - 12.3 3.2 - 13.2 BURNER PRESSURE (mbar) Butane gas Propane gas 5.3 - 23.5 7.1 - 30.3 5.8 - 25.1 7.6 - 32.2 Production of D.H.W. with 45°C delta T delta T di 45K = 7.2 l/min. Production of D.H.W. with 45°C delta T delta T di 40K = 8.1 l/min. Production of D.H.W. with 45°C delta T delta T di 35K = 9.3 l/min. Production of D.H.W. with 45°C delta T delta T di 30K = 10.8 l/min. Quantity of D.H.W. available at 45°C in the first ten minutes of use with storage tank water at 60°C and cold water at 10°C = 121.7 litres. 1.5 - GENERAL FEATURES Equipment category Burner nozzles Minimum rate of the heating circuit Minimum pressure of the heating circuit Maximum pressure of the heating circuit Minimum pressure of the D.H.W. circuit Maximum pressure of the D.H.W. circuit Storage tank capacity Power supply Voltage/Frequency Fuse on the supply mains Maximum absorbed power TN 24 Maximum absorbed power TFS 24 Net weight TN 24 Net weight TFS 24 n° l/min bar bar bar bar l V-Hz A (F) W W kg kg II2H3+ 13 7,5 0,5 3 0,5 7 60 230/50 4 110 165 72,5 78 Consumption of natural gas TN 24\TFS 24 (*) Consumption of butane gas TN 24\TFS 24 Consumption of propane gas TN 24\TFS 24 m³/h kg/h kg/h min. 1,32 - max. 2,80 min. 0,98 - max. 2,09 min. 0,97 - max. 2,05 Maximum operating temperature of the heating circuit Maximum operating temperature of D.H.W. circuit Total capacity of the expansion vessel Max water content (**) °C °C l l 90 65 7,5 138 (*) Value refers to 15°C - 1013 mbar (**) Calculated for a maximum temperature of 90°C IVEN B60 TN 24 6 Jacket heat dispersion Chimney loss with burner functioning Mass rate of flue gas T flue – T air CO2 value Useful thermal efficiency % % g/s °C % % Pmax. 3.0 7.2 19.8 86.9 4.9 89.81 Pmin. 4.54 9.5 18.1 IVEN B60 TFS 24 Jacket heat dispersion Chimney loss with burner functioning Mass rate of flue gas T flue – T air CO2 value Useful thermal efficiency % % g/s °C % % 1.85 7.7 16.5 108.8 5.9 90.45 1.09 11.1 17.7 30% red. load 88.78 88.36 Installation info 2 DIRECTIONS FOR INSTALLERS 2.1 - INSTALLATION REGULATION IVEN B60 is an II2H3+ class boiler which must be installed pursuant to applicable standards and laws. 2.2 - INSTALLATION 2.2.1 - PACKING IVEN B60 is packed and delivered in a strong cardboard box. Once the boiler has been unpacked check that it is intact. The packaging material can be recycled and it must be disposed of accordingly. Keep the packaging out of the reach of children as it represents a choking and suffocation hazard. The packaging contains: - the copper pipe kit for hydraulic connection of the boiler to the heating and water system and to the gas mains; - a bag with: a) installation, use and maintenance handbook, b) template for fixing the boiler to the wall, c) 4 screws with dowels to fix the boiler to the wall, d) for models TFS, a diaphragm for flue gas exhaust. 650 UNICAL waives all liability for injury to persons and animals or damage to property resulting from non-observance of the above. 96 0 65 0 fig. 4 7 Installation info 2.2.2 - POSITIONING THE BOILER - When choosing the position of the boiler: - refer to the indications given in the section “Flue gas exhaust system “. - remember that it is advisable to leave a space of 50 mm on each side of the boiler to facilitate maintenance operations. - check that the walls are suitable. - avoid fixing the boiler to thin partitions. avoid installing the boiler above appliances which might affect operation when in use (cookers which produce greasy steam, washing machines etc.) avoid installing natural draught boilers in corrosive or very dusty atmospheres such as hairdressers’, laundrettes etc. as the life of the boiler components could be signifi- - cantly shortened. 350 mm free space must be left between the top of the boiler and the ceiling to allow replacement of the magnesium anode. This condition is met when there is a space of 436 mm between the axis of the holes in the boiler bracket and the ceiling. 165 MOUNTING JIGS FOR BOILER CONNECTIONS (code 00211067) 135 65 160 Ø 100 (only for version IVEN B60 TFS 24) 50 780 880 290 600 68 140,5 68 117 59 147,5 23,5 35 90 C F G M R = = = = = D.H.W. outlet D.C.W. inlet Gas inlet Heating system flow Return from system R 1/2" 1/2" 3/4" 3/4" 3/4" 2.2.3 - ASSEMBLING THE BOILER Before connecting the boiler to the D.H.W. and heating system pipes, carefully clean the pipes to remove all traces of metal resulting from processing and welding operations as well as any oil and grease which could damage the boiler or jeopardize its operation. NB: Do not use solvents which could damage the components. 8 175 G M C S 199 F S S 190 fig. 5 Unical declines all liability for injury to persons and animals or damage to property resulting from non-observance of the above. To install the boiler: - fix the template to the wall; - make four, Ø 10 holes in the wall for the dowels and insert the hooks; Warning! Rispect the minimum distance between hook and ceiling (436 mm). - - position the junction points for the connection of the gas supply pipe, cold water supply pipe, D.H.W. outlet, CH flow and return by using the mounting jigs (lower part); fit the boiler onto the support hooks; join the boiler and supply pipes using the pipe kit supplied; connect the boiler to the intake and outlet system; connect to the power mains. Installation info 2.2.4 - VENTILATION Boiler model IVEN B60 TN 24 have an open combustion chamber and have been designed for connection to a chimney: the combustion air is taken directly from the room in which the boiler is installed. The boiler must be installed in a suitable room pursuant to applicable standards and laws which shall be considered as having been transcribed in full in this manual. Boiler model IVEN B60 TFS 24 have a sealed combustion chamber with reference to the environment in which it is installed, so no special measures need be taken as regards ventilation for the combustion air. This is valid also for the room the boiler will be installed in. The boiler must be installed in a suitable room pursuant to applicable standards and laws which shall be considered as having been incorporated in full in this manual. 2.2.5 - FLUE GAS DISCHARGE SYSTEM NATURAL DRAUGHT BOILER Connection to the chimney Direct emission into the atmosphere The chimney is indispensable for the correct functioning of the boiler; it must therefore conform with the following requirements: - it must be made from waterproof material and be resistant at the temperature of the flue gas and relative condensate; - it must have sufficient mechanical strength and low thermal conductivity; - it must be perfectly sealed to prevent cooling due to parasite air inlets; - it must be as vertical as possible and the end section must have a chimney cap which guarantees efficient and constant removal of the combustion products; - the chimney must have a larger diameter than that of the boiler’s draught stop; for chimneys with a square or rectangular section, the internal section must be 10% larger than the section of the connection duct to the draught stop; - starting from the draught stop, the duct fitting must have a vertical section of more than twice the diameter before joining the chimney. Natural draught boilers can discharge combustion products directly into the atmosphere using a duct which goes through the outside walls of the building connected to a flue exhaust terminal. The exhaust duct must also comply with the following requirements: - the sub-horizontal part inside the building must be as short as possible (no more than 1.000 mm); - for boiler with vertical discharge, such as boiler IVEN B60 TN 24, there must be no more than 2 direction changes; - it must receive the discharge from a single boiler; - the part going through the wall must be protected by a sheath duct; the part of the sheath duct facing the inside of the building must be closed and the part facing outwards must be open; - the final section, on which the draught outlet will be fixed, must protrude from the wall of the building for a length of a least twice the diameter of the duct; - the draught outlet must overlap the connection to the boiler exhaust duct connection by at least 1.5 metres (see fig. 6) 9 Installation info 1 m max. Inclination min. 3% 1 m max. >3Ø Ø 2Ø 2Ø 1,5 m min. 1,5 m min. Ø Inclination min. 3% >3Ø 2 Ø min. 2 Ø min. fig. 6 WARNING: The boiler is fitted with an automatic safety reset device as protection against leakage of combustion products inside the building (fig.8). After 15 minutes the boiler will automatically reset. DIMENSIONAL HEIGHTS FOR CONNECTING THE FLUE GAS EXHAUST DUCTS 246 135 Ø 130 It is absolutely forbidden to tamper with and/or exclude the safety device. If the boiler cuts off regularly, check the flue gas exhaust duct. This duct may be obstructed or may be unsuitable for the discharge of flue gas into the atmosphere. 855 UNICAL waives all liability for damage caused as a result of incorrect installation, use, modification of the boilers or for non-observance of the instructions provided by the manufacturer or applicable installation standards for the product in question. 600 476 fig. 7 fig. 8 10 Installation info 2.2.6 - POSITIONING OF TERMI NALS FOR TYPE ‘’C’’ BOILERS either take place through the roof or directly outwards the room they are installed in. The following distances shall be considered for terminals proper positioning: FORCED DRAUGHT BOILER The distances specified in appliance standards and laws must be complied with when positioning the boiler vent terminals on walls. Pursuant to the directives of regulations in force, discharge of forced draught boilers can POSITIONING OF TERMINALS FOR "FORCED DRAUGHT" BOILERS Min. distances in mm. POSITIONING OF THE TERMINAL Under a window Under a ventilation opening Under a gutter Under a balcony (1) From an adjancent window From an adjacent ventilation opening From vertical or horizontal air pipes or drains (2) From an external corner of the building From an internal corner of the building From the ground or from another floor Between two vertical terminals Between two horizontal terminals From a facing front surface without opening or teminals within a radius of 3 mt. from smoke outlet point As above, but with openings or terminals within a radius of 3 mt. from smoke outlet point A B C D E F G H I L M N 600 600 300 300 400 600 300 300 300 2500 1500 1000 O 2000 P 3000 NOTES (1) Terminals below a practicable balcony shall be arranged in such a way as to assure that the total run of smokes, from their outlet from terminal up to outlet from balcony external perimeter, including the height of protection baluster, if any, is not less than 2 m. (2) Distances of not less than 500 mm shall be adopted in placing the terminals, due to the proximity to materials subject to the action of products of combustion such as plastic gutters or waterspouts, wooden jetties, etc.) unless adequate screeening measures are taken for the said materials. FLUE TERMINAL POSITIONING fig. 9 11 Installation info 2.2.7 - SMOKE DISCARGE AND AIR SUCTION DUCT CONFIGURATION C12, C32, C42, C52, C62, C82 - B22 C12 C32 C42 Boiler designed for connection to horizontal exhaust and suction terminals directly into the atmosphere using coaxial or dual ducts. The distance between the air intake duct and the flue gas outlet duct must be at least 250 mm and both end sections must be located within a 500 mm square. Boiler designed for connection to vertical discharge and suction outlets directly into the atmosphere using coaxial or dual ducts. The distance between the air intake duct and the flue gas outlet duct must be at least 250 mm and both end sections must be located within a 500 mm square. Boiler designed for connection to collective chimneys including two ducts, one for the suction of combustion air and the other for the exhaust of the combustion products, through coaxial or dual ducts. type C12 type C32 type C42 The chimney must comply with relevant applicable law provisions. C52 Boiler with separate combustion air suction and combustion product exhaust ducts. These ducts can discharge into areas with different pressure. The dual ducts must not be located on two opposite walls. C62 Boiler that has to be connected to a system of air supply and smoke of approved type and sold apart. C82 Boiler designed for connection to an air supply terminal and fitted to an individual or shared chimney. type C52 type C62 The chimney must comply with relevant applicable law provisions. type C82 Note: type B22 is not approved by Turkish market. 12 Installation info 2.2.8 Discharge of flue gas into coaxial ducts with a diameter of 100/60 mm (Type A accessories) EXAMPLE WITH COAXIAL PIPES To 1,5 m Type C12 The minimum lenght of horizontal coaxial ducts is 0.5 metres. The maximum allowable length of horizontal coaxial ducts is 3 metres; for each additional bend the maximum allowable length must be reduced by 1 metre. Moreover, the duct must have a downward dip of 1% towards the outlet point to prevent rain water from getting into the duct. Type C32 The minimum lenght of vertical coaxial ducts is 0.5 metres. The maximum allowable length of vertical coaxial ducts is 4 metres including the stack; for each additional bend the maximum allowable length must be reduced by 1 metre. Diaphragm Diaphragm Neoprene seal The diaphragm supplied with the boiler must be inserted in the flue gas exhaust pipe as shown in figure 10 for installations with a coaxial pipe of 0.5 m to 1,5 m. fig. 10 DIMENSIONAL HEIGHTS FOR CONNECTION OF THE FLUE GAS DISCHARGE TO COAXIAL DUCTS 880 95 Ø 100 182 165 600 476 fig. 11 13 Installation info 2.2.9 Flue gas exhaust and air suction with dual ducts with 80 mm diameter (type B accessories) N.B. The maximum allowable load loss must be the same as the values shown in the following examples, depending on the type of installation. For all installations with a load loss of less than or equal to 40 Pa, it is necessary the fit the diaphragm provided inside the flue gas discharge duct (see fig. 12). EXAMPLE WITH DUAL DUCT Up to Δ P = 40 Pa Diaphragm Important If the flue gas discharge duct has to run through walls and/or infrastructures or if it is easily accessible, it must be properly insulated as it can reach very high temperatures – over 120°C. Neoprene seal Diaphragm fig. 12 DIMENSIONAL HEIGHTS FOR CONNECTION OF FLUE GAS DISCHARGE WITH DUAL DUCTS 165 182 120 880 Ø 80 600 476 fig. 13 14 Installation info Example No. 1 Primary air suction from perimeter wall and flue gas discharge on roof. _ 500 > Maximum allowable load loss: 65 Pa fig. 15 15 Installation info Example No. 2 135 Primary air suction from perimeter wall and flue gas discharge from the same outside perimeter wall. Maximum allowable load loss: 80 Pa CALCULATION OF PRESSURE LOSSES FOR DISCHARGE AND SUCTION DUCTS Bear in mind the following parameters when calculating pressure losses: - for each metre of duct with Ø 80 (both suction and discharge) the pressure loss is 2 Pa; - for each 90° Ø 80 (R=D) bend with long radius, the pressure loss is 2 Pa; - for each 90° Ø 80 (R=½ D) bend with short radius, the pressure loss is 6 Pa in suction and 8 Pa in discharge; - for the Ø 80 L = 0.5 m horizontal air inlet terminal, the pressure loss is 3 Pa; - for the Ø 80 L = 0.6 m horizontal discharge end section, the pressure loss is 5 Pa; - 2 short radius 90° Ø 80 curves + 1 adapter Ø 80, the pressure loss is 14 Pa. NB: These values refer to discharges through original UNICAL non-flexible and smooth ducts. 2.2.10 - MEASUREMENTS OF COMBUSTION EFFICIENCY Min 200 mm Hmin. = 165 mm 45 fig. 16 Example of check using wide radius bends: - 2 Ø 80 long radius 90° bends + 1 adapter Ø 80 = (14 Pa) - 29 mt duct Ø 80 x 2 = (58 Pa) - horizontal Ø 80 air inlet terminal = 3 Pa - horizontal Ø 80 terminal = 5 Pa Tot. pressure loss = 80 Pa A Analyser probe (Type A accessories) Coaxial ducts To determine combustion efficiency the following measurements must be made: - the combustion air measured in hole 2 (see fig. 17). - the flue gas temperature and CO2 measured in hole 1 (see fig. 17). 1 B 2 Analyser probe (Type B accessories) Dual ducts To determine the combustion efficiency the following measurements must be made: - the combustion air measured in 2 (see fig. 17). - the flue gas temperature and CO2 measured in hole 1 (see fig. 17). Air Smoke 1 Make these measurements with the boiler running. 2 Analyser probe fig. 17 2.2.11 - CONNECTION TO THE GAS MAINS The supply pipe must have a section which is the same as or greater than the one used in the boiler. Comply with the applicable installation standards which shall be considered as 16 having been incorporated in full in this manual. Before opening the internal gas distribution system; i.e. before connecting the gas meter, all seals must be checked. If any part of the system is concealed the seals must be checked before the pipes are covered. The seal test must be conducted using fuel gas: use air or nitrogen. When gas is flowing in the pipes, remember never to look for gas leaks using a naked flame. Use specific products found on the market for the purpose. Installation info 2.2.12 – HYDRAULIC CONNECTION DIAGRAM OF FLOW RATE/PRESSURE AVAILABLE FOR THE INSTALLATION Pressure available m.c.a. Before installing the boiler we recommend that the system be cleaned to remove any impurities which could originate from components and which could risk damaging the circulating pump and exchanger. HEATING The heating flow and return must be connected to the relative ¾” connections of the boiler M and R (see fig. 5). When determining the size of the heating circuit pipes it is essential to bear in mind the load losses induced by radiators, any thermostatic valves, radiator cut-off valves and the configuration of the system. We recommend that the discharge of the safety valve mounted in the boiler be conveyed into the sewer. Flow rate (Q) l/h If this precaution is not taken, activation of the safety valve may result in flooding of the room where the boiler is installed. fig. 18 PRODUCTION OF D.H.W. UNICAL shall not be held responsible for damage caused by non-observance of this technical precaution. D.H.W. Outlet and inlet of D.H.W. must be connected to the relative ½” connections of the boiler C and F (see fig. 5). Drawing temperature °C UNICAL shall not be held responsible for damage caused by non-observance of this technical precaution. The mains supply pressure must not exceed 7 bar. A pressure reducer and the sanitary expension vessel kit must be installed if the pressure is higher. It is advisable to limit the pressure in the D.H.W. system to 3 bar. WARNING Depending on the hardness of the supply water, it is important to assess the convenience of installing a domestic device to dose products of food purity which can be used to treat the drinking water. It is always advisable to treat the water if the supply water has a hardness value of more than 20°F. 2.2.13 - CONNECTION TO THE POWER MAINS The IVEN B60 boiler is supplied with a triplepole lead, already connected at one end to the electronic board and protected against tearing by a special cable clip. The boiler must be connected to the power mains at 230V-50Hz. Make sure the poles correspond, correctly connecting phase and neutral. Δt mean = 41,9°C Quantity drawn at 10 litres/min fig. 19 WARNING Due to its pH value, water supplied from normal water softeners may not be compatible with some components of the heating system. should be connected to the drainage system, otherwise the room may get flooded if the safety valves come into operation. IMPORTANT The outlet of the safety valves in the boiler UNICAL shall not be held responsible for danaged caused by non-observance of this technical precaution. When installing the boiler comply with applicable standards which shall be considered as having been incorporated in full in this manual. A bipolar switch must be installed upstream of the boiler to enable all maintenance operations to be carried out safely. The boiler mains supply must be protected by a differential magnetothermal switch with appropriate breaking power. The mains power supply must be earthed. This fundamental requirement for safety purposes must be checked; in case of doubt, ask for a professionally qualified technician to check the electrical system. UNICAL disclaims all liability for damage on injury caused by failure to earth the system properly. Gas, domestic water and central heating pipes are not suitable for earthing purposes. 17 Installation info 2.3 - WIRING DIAGRAM SR DK MD VERSION TFS GREEN GREEN WHITE BROWN WHITE WHITE C.H. D.H.W. MVD IVEN B60 TN/TFS 24 WHITE A6 VERSION TN WHITE BROWN A4 WHITE RED A5 (5) (2) GREY BLUE A6 P3 HTL A4 PT E/I AG LL BLACK ORANGE TA BLACK SS FR A5 ALIMENTATION 230 V - 50 Hz BROWN BLUE Y1 GND1 LINE 2 1 BROWN BLUE ROOM STAT 1 2 GREEN GREEN BLUE BLUE WHITE WHITE IG Y2 A1 BROWN BLACK MODULATIN BOARD A2 BLUE BROWN SR DK TF MD P GND2 ALIMENTATION 230 V - 50 Hz GND3 A3 GREEN RED BLUE BROWN (5) (4) SEEPER CONTACT (PT) (2) HLT TMOD (1) NEUTRAL GND3 LINE Y2 GND2 A1 LL MD MVD P P1 = = = = = MAIN SWITCH GND GND1 ROOM STAT A2 (3) TA OMODULATING TA ON/OFF P1 CH-POWER P2 TMOD (1) BURNER IGNITION ON BURNER IGNITION OFF SOFTL Y1 NIGHT TA 18 Low water level = Summer/Winter switch = Main switch CONTINUES PUMP PUMP POST CIRCULATION SOFTL E/I IG GPL NATURAL GAS TA PC 160 (3) BURNER LEVEL ‘’HIGH’’ BURNER LEVEL ‘’LOW’’ A1...A6 = Utilities connectors AG = Antifrost DK = Safety pressure switch against HIGH (4) HIGH A3 Power light Coil modulating Motore 3-way valve Circulating pump Temperature regulator (factor y setting) SR SS TA TF = = = = Heating detector D.H.W. detector Ambient thermostat (optional) Flue gas anti-overflow sensor fig. 20 Installation info WIRING DIAGRAM - IGNITION CARD IVEN B60 TN/TFS 24 CONNECTION BLEU BLEU BLACK BLEU ORANGE BROWN BLACK BLACK BLACK BLACK BLEU ORANGE BROWN GREEN WHITE RED BROWN BLU BROWN BLEU YELLOW/GREEN BROWN BLEU YELLOW/GREEN ALIMENTAT. 230 V - 50 Hz MODULATING BOARD BLEU BLEU ALIMENTAT. 230 V - 50 Hz MODULATING BOARD IVEN B60 TFS 24 ELECTRODE OUTLET CONNECTION IVEN B60 TN 24 YELLOW/GREEN TEFLON RED (E. ACC. 1) TEFLON WHITE (E. RIV) fig. 21 19 Installation info TABLE OF RESISTANCE VALUES AS A FUNCTION OF THE TEMPERATURE OF THE HEATING SENSOR (SR) AND D.H.W. SENSOR (SS) T°C 0 1 2 3 4 5 6 7 8 9 0 10 20 30 40 50 60 70 80 90 32755 20003 12571 8112 5363 3627 2504 1762 1263 920 31137 19072 12019 7775 5152 3491 2415 1703 1222 892 29607 18189 11493 7454 4951 3362 2330 1646 1183 865 28161 17351 10994 7147 4758 3238 2249 1592 1146 839 26795 16557 10519 6855 4574 3119 2171 1539 1110 814 25502 15803 10067 6577 4398 3006 2096 1488 1075 790 24278 15088 9636 6311 4230 2897 2023 1440 1042 766 23121 14410 9227 6057 4069 2792 1954 1393 1010 744 22025 13765 8837 5815 3915 2692 1888 1348 979 722 20987 13153 8466 5584 3768 2596 1824 1304 949 701 Relation between the temperature (°C) and nominal resistance (Ohm) of the heating sensor SR and D.H.W. sensor SS Example: At 25°C, the nominal resistance is 10067 Ohm At 90°C, the nominal resistance is 920 Ohm 2.4 - FILLING THE SYSTEM After completing all the connections of the system the heating circuit can be filled. This filling operation must be performed with care as follows: - open the air vents of the radiators and check that the automatic air vent in the boiler is functioning; - gradually open the special water inlet tap and check operation of any automatic air vents installed in the system; - close the air vents on the radiators as soon as water comes out; - use the pressure gauge on the boiler to check that the pressure has reached the value of 0.8/1bar; - close the water inlet tap and then release the air again through the radiator air vents; - after switching on the boiler and after the system has reached the correct temperature, stop the pump and repeat the air relief operations; - let the system cool down and then adjust the water pressure to 0.8/1 bar. WARNING To optimise the efficiency and safety of heating systems used for domestic purposes, to keep them in good working order over time, to ensure long-lasting efficient functioning also of ancillary equipment and to minimise energy consumption, thus complying with relative standards and laws, it is essential to treat the water using specific products compatible with multimetal systems. WARNING The low water level safety pressure switch does not give electrical impulse to the burner to ignite when the pressure is lower than 0.4/ 0.6 bar. The pressure of the water in the heating system must not be lower than 0.8/1bar; if this value is lower use the water inlet tap on the boiler to adjust the pressure. This must be performed when the system is cold. Use the temperature and pressure gau20 Rubinetto di carico impianto fig. 22 ge on the boiler to read the pressure value of the circuit. NB: After a given period of inactivity the pump could be blocked. Before switching on the boiler it is important to restart the pump as follows: loosen the protection screw in the centre of the pump engine, in sert a screwdriver in the hole and then manually rotate the pump shaft clockwise. Once the pump has been restarted tighten the protection screw and check that there are no water leaks. WARNING Once the protection screw has been removed a little water may leak out. Before replacing the cover of the boiler dry any wet surfaces. fig. 23 Regulation info 2.5 - STARTING THE BOILER - 2.5.1. - PRELIMINARY CHECKS Before starting the boiler check that: - the flue gas exhaust duct and the outlet section are installed correctly: when the boiler is switched on there must be no leakage of any combustion products from any seals; - the supply voltage of the boiler is 230 V50 Hz; - the system is correctly filled with water 2.6 - ADJUSTING THE BURNER All the instructions below are for the exclusive use of qualified technicians. All the burners leave the factory calibrated and tested. If it is necessary to change the calibration following changes in the type of gas or adaptation to the supply network conditions, it is necessary to recalibrate the gas valve. To correctly regulate the gas valve, follow the steps below: A) Setting maximum power - Check the feed pressure value (see NOZZLES – PRESSURES table). - Remove the plastic cap C (fig. 24) protecting the pressure regulator screws on the top of the modulator coil. - Set the heating system water to the maximum temperature. - Connect a U gauge according to the instructions given in fig. 25. - Set the thermal power regulator P to MAXIMUM, turning CLOCKWISE. - Switch the Summer / Off / Winter / Antifreeze selector to the Winter position. - Check that the contact of the ambient thermostat TA is closed. - Turn the (outer) nut A CLOCKWISE to increase the pressure at the nozzles or ANTICLOCKWISE to decrease it. B) Setting minimum power - Disconnect the modulator coil electrically. - Ignite the burner and check whether the MINIMUM pressure corresponds to the value shown in the NOZZLES-PRESSURES table. - Set the required pressure. Hold the nut A firmly using a 10 mm spanner and turn the screw B CLOCKWISE to increase the pressure or ANTICLOCKWISE to decrease it. - Reconnect the coil. C) Final operations - Recheck the maximum and minimum gas valve pressures and adjust if necessary. - Remount the plastic cap C. - Close the gas intakes. - Check for any gas leaks. - (pressure at the hydrometer 0.8/1 bar); any cut-off taps of the system are open; the mains gas corresponds to that with which the boiler has been calibrated: otherwise, convert the boiler to use the gas available (see section: “MODIFICATION FOR OTHER GASES “): this operation must be performed by qualified technicians; the gas supply tap is open; there are no gas leaks; the external mains switch is on; the boiler’s safety valve is not locked; there are no water leaks. 3.4.2 - SWITCHING ON/OFF To switch on and off the boiler follow the indications in the “Users’ Instructions”. MODULATION BOARD C A B A B fig. 24 PRESSURE MEASURING POINTS RMP MP Connect the pressure gauge on MP (version TN) Connect the pressure gauge on MP and RMP (version TFS) MP = Pressure tube RMP = Differential pressure point fig. 25 21 Regulation Info 2.7 - MODIFICATION FOR OTHER GASES The IVEN B60 boilers are manufactured for the type of gas specifically required upon order. Any subsequent conversion must be performed by qualified technicians who will use the kits supplied by Unical and perform the conversion and required adjustments for correct preparation of the boiler for use. To convert the boiler from one type of gas to another: - remove the main burner; - Remove the 13 nozzles 1 (fig. 26) from the main burner and replace them with ones of a diameter suitable for the new gas (see NOZZLES – FLOW RATES – PRESSURES table). - Fit (for gas GPL only version 24 kW) or remove (for natural gas) the diaphragm 2 at the gas valve outlet. - Fit the main burner back in position. - position the jumper ''160'' (4) on the modulation card in the electrical panel in the correct position - Check the pressure upstream of the gas 2 fig. 26 - fig. 27 valve (see NOZZLES – PRESSURES table) and regulate the burner pressure as instructed in the section entitled HOW TO ADJUST THE BURNER. Check that the burner works correctly. Make sure there are no gas leaks. Lastly, fill in the gas change label provided with the conversion kit and affix it to the boiler next to the specification sticker. TABLE NOZZLES - PRESSION - DIAPHRAGME - CONSUMPTION The pressures at the burner indicated in the following table must be checked after the boiler has been operating for 3 minutes. fig. 28 NOZZLES - PRESSURES IVEN B60 TN 24 Type of gas Natural Gas Butan Gas Propan Gas Pressure supply (mbar) 20 28 37 Ø Nozzles (mm) Ø Diaphragm (mm) 1.20 0.77 0.77 4.9 4.9 Pressure supply (mbar) 20 28 37 Ø Nozzles (mm) Ø Diaphragm (mm) 1.20 0.77 0.77 5,1 5,1 Burner Pressure (mbar) Minimum Maximum 2.9 12.3 5.3 23.5 7.1 30.3 IVEN B60 TFS 24 Type of gas Natural Gas Butan Gas Propan Gas 22 Burner Pressure (mbar) Minimum Maximum 3.2 13.2 5.8 25.1 7.6 32.2 Regulation info 2.8 - ADAPTING THERMAL POWER TO THE HEATING SYSTEM With the heating system cold. Connect the pressure gauge to the burner as shown in fig. 28, switch on the boiler in heating mode and proceed as follows. - Wait about two minutes to allow the pressure to reach the operating value. - Read the pressure measured and check that the thermal power generated by the boiler suits the installation requirements. - If necessary – but this is not compulsory – you can regulate the potentiometer P1 on the modulation board to adjust the thermal power to the heating system. Turn the potentiometer clockwise (seen from the front) to increase the pressure or anticlockwise to decrease it. fig. 28 GAS PRESSURE BURNER DIAGRAM CORRESPONDING TO THE SYSTEMS OUTPUT Note Since the boiler is the modulating type, it automatically adapts the thermal power to the features of the heating system. By operating potentiometer P1 you effectively limit the maximum power of the boiler and hence its pickup capacity. Example 1 If the boiler runs on methane gas, adjust the potentiometer P1 to set the pressure to 8 mbar for version 24 TN and to 8.2 mbar for version 24 TFS. Example 2 If the boiler runs on butane gas, adjust the potentiometer P1 to set the pressure to 14.8 mbar for version 24 TN and to 15.2 mbar for version 28 TFS. Example 3 If the boiler runs on propane gas, adjust the potentiometer P1 to set the pressure to 19 mbar for version 24 TN and to 20 mbar for version 28 TFS. 25 IVEN B 60 TN 20 IVEN B60 TFS 15 Output kW Using the pressure/thermal power graph (fig. 29) Assuming that the heating system has a total absorption of 18 kW, using the graph in figure 29 you can determine the maximum pressure at which the burner can be set. 30 10 5 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Natural Gas (mbar) Butan Gas (mbar) Propan Gas (mbar) fig. 29 23 Service info 3 USERS' INSTRUCTION 3.1 - CONTROL PANEL D A F C E H G B fig. 30 A = Summer / Off / Winter / Anti-freeze selector Power light Heating water temperature control B C = = - Summer – Off – Winter – Boiler antifreeze selector (A) D E F G - This selector is used to select the required operating mode for the boiler. With the selector in the Summer position, the boiler only produces D.H.W. Heating water temperature control (C) This knob is used to set the required temperature of the heating circuit. The tempe- rature range is 35-85°C. D.H.W. temperature control (D) This knob is used to set the required storage temperature for the D.H.W. in the boiler. The temperature range is 35-60°C. Pressure gauge (G) This device displays the pressure of the water in the heating system, which must be at least 0.8-1 bar (cold). - Thermometer (H) The thermometer displays the temperature of the water in the heating system that has been set on the regulator - Release button (F) This button is used to restart the boiler after intervention of the burner cut-off device. With the selector in the Winter position, the boiler provides for heating and D.H.W. - Hot water temperature control Cut-off light Release button Pressure gauge - With the selector in the Off position, the boiler is switched off. With the switch in the Anti-freeze position, the boiler is off but the anti-freeze safety function is active. This protects the heating circuit of the boiler and the storage tank when the water temperatur to the hydraulic circuits is lower than 15°C. = = = = H = Thermometer - Cut-off light (E) This light indicates that the burner cut-off safety device has come into operation. - Power light (B) This light indicates that the boiler is powered on. Service info 3.2 - SWITCHING - - - open the gas tap; set the switch on the system upstream the boiler to ON (power light B on); Select the operating mode by turning the selector A to the required position (summer / winter / anti-freeze): the power light B will come on. In the summer position the boiler will only produce D.H.W. In the winter position it will also produce hot water for the heating system. In the anti-freeze position no hot water is produced and the boiler is protected against freezing. set the temperature value required for the heating system using the heating water control knob C; Turn the D.H.W. temperature control knob D to the required temperature setting. If the temperature of the water in the boiler is less than the set value, the boiler will start up and heat it to that temperature. has precedence over the heating function. The temperature setting range is 40-60°C. When the knob is in a central position, the water is about 50°C. Warning: when starting the boiler after a long period of inactivity, especially boilers powered by LPG, air bubbles may have formed in the supply pipe. Before switching on the boiler switch on another gas powered device (e.g. cooker gas ring). Even so the boiler may block once or twice. Reset the boiler using the reset button F (see below) If the boiler does not function correctly it automatically cuts off: the cut off light E on the control panel comes on. In this case: - check that the gas tap is open and that there is a gas supply, for example by lighting a gas ring; - if there is a gas supply wait for a minute before restarting the boiler using reset button F; if the boiler does not restart, try to reset the boiler three times and then call an authorised Service Centre or qualified maintenance personnel. If the boiler cuts off frequently, this indicates that there is a recurring anomaly. In this case contact qualified personnel or an authorised Service Centre for maintenance. Boiler cut off The D.H.W. heating will function always 3.3 - MAINTENANCE The boiler must be serviced once a year. Correct maintenance allows the boiler to work optimally, respecting the environment and without endangering people, animals and property. The boiler must be serviced by qualified personnel. The user may only clean the exterior cover of the boiler, using furniture cleaning products. Do not use water! Information for the user The user can access only the parts of the boiler which can be reached without the need for tools and/or implements: it is therefore forbidden to disassemble the exterior cover of the boiler and tamper with the interior parts. No-one, including qualified personnel, may make modifications to the boiler. UNICAL declines all responsibility for injury to persons and animals and damage to property resulting from tampering or improper operations on the boiler. If the boiler remains inactive and disconnected from the power supply for long periods it may be necessary to reset the pump. This operation, which entails disassembling the outside cover and working on internal parts of the boiler, must be performed by qualified personnel. It is possible to prevent the pump from blocking by adding special filming products suitable for multi-metal systems to the water. If the boiler is not disconnected from the mains power supply the pump will not block becau- se the boiler’s electronic system has an antiblock programme. In this case the pump goes into operation for a few seconds every day. The boiler is fitted with an anti-freeze system setting by selector A. This device switches on automatically: - for the heating system - when the temperature of the water in the boiler drops below 7°C the circulating pump starts up. If the temperature drops below 5°C, the burner ignites and stays on for up to 15 minutes or until the water temperature reaches 15°C. - for the D.H.W. system - when the temperature in the boiler is less than 6°C, the burner ignites and stays on for up to 15 minutes or until the water temperature reaches 15°C. WARNING This system is not activated if the boiler is not connected to the mains supply and the gas tap is closed. IMPORTANT When the boiler anti-frost protection function is active, both the central heating and D.H.W. functions are deactivated, which means the anti-frost protection of the ambient thermostat is also deactivated. The boiler protects the central heating system indirectly. If the boiler is installed in a separate boiler room, the central heating system may be at a lower temperature than the boiler and there is the risk of frost, the boiler must be switched to Winter mode as a safety measure. This protects both the boiler and the system from frost, but the boiler keeps the storage tank at the set temperature. This system protects the heating system against freezing, not the D.H.W. circuit. The heating system can also be effectively protected against freezing using specific antifreeze products suitable for multi-metal systems. Do not use car engine anti-freeze products and check the effectiveness of the product over time. The boiler has a temperature and pressure gauge which allows you to check the temperature and pressure of the water in the heating system. When the boiler is switched off the pressure of the water must be around 1 bar. If this value drops then use the pressure control tap to adjust to the correct value. WARNING After adjusting the pressure, close the tap without over-tightening it. If the tap is not closed properly the pressure could rise, resulting in the safety valve opening and the water leaking. DATA BADGE CE Marking - The CE marking documents that the boilers satisfy: - The essential requirements of the Directive regarding gas appliances (Directive 2009/142/CEE) ) - The essential requirements of the Directive regarding electromagnetic compatibility (Directive2004/108/CEE) - The essential requirements of the Efficiency Directive (Directive 92/42/CEE) - The essential requirements of the low voltage Directive (Directive 2006/95/CEE) ® 1 2 3 4 5 6 7 8 A 9 10 11 12 13 14 B 15 16 17 18 19 C 20 D 22 21 25 24 26 23 E 27 28 LEGEND: 1 2 3 4 5 6 7 8 = = = = = = = = CE Surveillance notify body Boiler type Boiler model Number of stars (Directive 92/42/CEE) (S.N°) Serial number P.I.N. code Approved fluing configurations (N0x) N0x class A 9 10 11 12 13 14 = = = = = = = Central Heating circuit features (Pn) Nominal output (Pcond) Condensing nominal output (Qmax) Nominal heat input (Adjusted Qn) Adjusted for nominal Heat input (PMS) Max. pressure C.H. system (T max) Max. C.H. temperature B 15 = 16 = 26 = Domestic Hot Water circuit features (Qnw) Nominal heat input in D.H.W. mode (if different from Qn) (D) Specific D.H.W. flow rate according to EN 625 - EN 13203-1 17 = 19 = 20 = (R factor) N° taps based on the quantity of water declared EN 13203-1 (F factor) N°stars based on the quality of water declared EN 13203-1 (PMW) Max. pressure D.H.W. system (T max) Max. temperature D.H.W system C 21 22 23 = = = = Electrical features Electrical power supply Consumption Protection grade D 24 25 26 = = = = Countries of destination Direct and indirect country of destination Gas family Supply pressure 18 = E = 27 = 28 = Factory setting Adjusted for gas type X Space for national brands 27 AG S.P.A. 46033 casteldario - mantova - italia - tel. 0376/57001 (r.a.) - telefax 0376/660556 La Unical declina ogni responsabilità per le possibili inesattezze se dovute ad errori di trascrizione o di stampa. Si riserva altresì il diritto di apportare ai propri prodotti quelle modifiche che riterrà necessarie o utili, senza pregiudicarne le caratteristiche essenziali.