FonteCal MINITECH Series Manual de referencia

Ottobre 2003

10.1

technical manual for

installation, use and maintenance

WALL HUNG GAS BOILER

MINITECH

MINIPLUS

MODELS

WITH CONTINUOUS MICROPROCESS MODULATION

FOR HEATING AND SANITARY HOT WATER PRODUCTION

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

Index

Introduction .................................................................................................. 3

Models .......................................................................................................... 3

1. General Information ................................................................................. 4

2. Warnings.................................................................................................. 4

3. Installation ............................................................................................... 4

3.1 Boiler location ...............................................................................................4

3.2 Water installations and combustible system....................................................6

3.3 Air inlet and flue discharge ............................................................................7

3.4 Electrical system...........................................................................................10

3.5 Precautions before and during the boiler mounting on the wall....................10

3.6 Electronic board settings..............................................................................11

3.7 Modification of the boiler preset gas............................................................12

4. Use, operations and maintenance........................................................... 16

4.1 System filling...............................................................................................16

4.2 Boiler use ....................................................................................................16

4.3 Boiler operation...........................................................................................18

4.4RoomThermostat ........................................................................................18

4.5 Antifreezing function...................................................................................18

4.6Maintenance............................................................................................................19

Technical data............................................................................................... 20

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

CAN BE INSTALLED

EVERYWHERE !!!

ALWAYS SAFE !!!

Introduction

DearCustomer,

Congratulation on your choice and thank you for the trust reposed in our

products.

Buyingthisproductyouhavechosentechnologyandthebestsynthesisenergy

efficiencyandfunctionalityinfull respect of the strictest European norms on

safety

Your boiler is:

versatile

:the combustion circuit is completely sealed so that the

boilercanbeinstalled every where without specific requirements

and in accordance with the rules in force;

safe

: the boiler is equipped with advanced safety features which

itfrom abnormaloperating devicesofsuperiorclass ascompared

to the ones usually prescribed, this will guarantee the highest

safetyfortheuser.

Thefollowingparagraphshall brieflydescribe brieflydescribesthefunctioning

principle which characterizes the boiler itself.

Please carefully follow the both use and maintenance instructions in order

tocommence the warranty period.

Models

The boiler is available into the following versions::

W Models S E / S ER :heating only; opened / sealed chamber.

W Models X E / X ER :heating and hot water production opened /sealed

chamber.

“S” model is designed for heating only or for the connection to an external

watertank.Theboilerelectronicscontrolsthechangeover valve which could

be used to manage the water tank.

“X” model is equipped with a rapid exchange system for hot water

instantaneous production, the system can supply 13 l/min with a 25°C heat

differenceascomparedto the inlet water. Hotwaterdemandis detected by

a differential pressure switch which is activated with a minimum water flow

of 1.6 l/min

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

1 GENERAL INFORMATION

Please read and retain this manual in order to achieve full

satisfaction from the boiler use.

The equipment name, series, model, serial number and

technical data are shown on the label located inside the

boiler.

Thelettersfollowingthe commercialname definethe main

features of Your wall-hung boiler according tothe scheme

below:

Model:

S E:

heating only, natural draught, open

combustion chamber (B11BS - EN297);

X E:

heating and hot water instantaneous

production,naturaldraught,opencombustion

chamber (B11BS - EN297);

S ER:

heating only, forced draught, sealed

combustion chamber (C2x, C62 - EN483);

X ER:

heating and hot water instantaneous

production, forced draught, sealed

combustion chamber (C62x, C62 - EN483).

All the models have the same following features:

- electricignition;

- continuousflame modulation with microprocessor;

- nominal heat input 25 kW (21.500 kcal/h).

2 WARNINGS

This manual is delivered with the boiler and should always

be stored in the vicinity of the equipment for proper use

and maintenance.

PRELIMINARYOPERATIONS

Unpack the boiler by removing its cardboard and do not

turn it upside down. Always keep the boiler vertical on its

lower polystyrene base. Never place the boiler direcly on

the floor. After unpacking the boiler, make sure that the

equipmentis intact. When indoubt, contact your supplier.

Forsafety reasons and correct operation, installationmust

be carried out by professionally qualified technicians, in

compliance with current regulations and Manufacturer’s

instructions.

Manufacturer abdicates any responsibility in case of

damage caused by tempering, incorrect use and wrong

equipment installation, use and maintenance.

Shouldfailuresormalfunctioning occur,turn theequipment

off, refrain from making any repairs and call the Service

Centre.

NOTE!

The boiler

COMMISSIONING

must be carried out

by the

Service Centre technicians within 8 days from the

installation of the equipment. After commissiong, the

Service Centre shall fill in the guarantee certificate and

release part of it, which must be stored, thus starting the

guarantee period. Carefully read the conditions specified

inthe guaranteeform. Serviceduring theguarantee period

shall be provided if the guarantee slip has been validatd

duringcommissiong.

NOTE!

Maintenance is compulsory and must be executed

at least once a year (DPR 412/93, 551/99). Contact the

authorised Service Centre. In any case, only technicians

who are qualified according to the laws in force can carry

out the maintenance activities.

3 INSTALLATION

NOTE!

ONLY authorised and professionally-qualified

technicians who know the equipment, have read this

manual and comply with the (national and local) laws in

forcein the placeof installation, caninstall the equipment.

3.1 BOILER LOCATION

Open chamber boilers can only be installed in place which

comply with current regulations and, in any case, in

permanentlyventilatedplaces. Usethetwo screwsanchors,

suppliedwiththeequipment,toinstallthe boiler onastrong

masonrywall. Leave at least 35cm from the front panel of

the front panel of the equipment to facilitate use and

maintenance activities; leave at least 40 cm between the

top of the equipment and the ceiling and between the

bottomof theequipment andthe floorand from any other

no-removal impediment.When defining the installation

heightof the boiler, make surethat this its top partcannot

be easily reached with one’s hands.

NOTE

! Do not install the boiler in a dusty or very humid

environment. If the boiler is installed outdoor, it must be

protected against RAIN, ICE, HUMIDITY and DUST; make

sure that unauthorised people, children, animals, or

anything else which may damage or be damaged by the

boiler, cannot easily access the boiler.

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

FIGURE 1

: Dimensions, free distance to be maintained, hydraulic connections, air inlet and flue

exhaustconnection.

Mod. E

MIN 50 cm

MIN 35 cm

6 878

Fori per tassello Ø14

1534

301

120

178

236

700

300

Mod. ER

MIN 40 cm

355

400

215

137

700

200

185 mod.E

159 mod.ER

Uscite e

scarico fumi

127

236

N° Description Dimens. Model N° Description Dimens. Model

1 System inlet G ¾” M E/ER 6 Double pipe system air inlet ∅60 mm ER

2 System flow G ¾” M E/ER 7 Double pipe system flue exhaust ∅60 mm ER

3 Water network G ¾” M E/ER 8 Double pipe system flue inlet/exhaust∅100/ ∅60 mm ER

4 Hot Water G ¾” M E/ER 9 flue exhaust ∅130 mm E

5 Gas G ¾” M E/ER 10 Space for electric cables 20x40 E/ER

air inlet and

flue discharge

holes for screw anchors Ø14

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

wall

boiler

3.2 WATER AND COMBUSTIBLE SYSTEM

The equipment has been designed for the type of

combustible gas specified on the plate located inside the

shell. Make sure that the available gas type and the gas

specified on the equipment match.

Thecombustiblesupply pipingand thecontrol system must

be perfectly sealed and their sections must be suitable for

the equipment capacity.

If L.P.G. is supplied, make sure that the second-stage

pressurereducer located on the tank-boiler line has a min.

capacity of 4 kg/h and 37 mbar (column of water 370)

outletpressure adjustment.

The original gas preset of the boiler can be changed by

replacing the gas nozzles and re-calibrating the gas valve

minimumpressure.

This operation must be carried out by

qualified

technicians

: contact the authorised Service Centre.

The Service Centre must verify the correct operation of

the equipment and officially validate the guarantee

certificate within 8 days from installation.

Fornewly-designed water systems, Fig. 1 shows the piping

layout when looking at the wall.

Fig. 2 shows how to connect pipes to the wall.

Place the wall mounting jig (delivered with the boiler) on

the wall to define the correct location of screw anchors

and pipes.

The pressure of the water coming from the water system

must be kept under control and below the limit specified

on the equipment plate, on the inlet point.

Hence the need for a pressure reducing valve on the

equipment cold water pipe.

The circulation device, at speed III, is suitable for the

majorityofthe systems.In single-pipeor very largesystems,

when the load loss is remarkable or when all radiators are

not equally supplied, the circulation of water can be

increasedby installing anadditional pump orreplacing the

pumpsuppliedwith theboilerwith anexpandedcirculation

device.

Seefig. 3for available head/flowrate curvesof the heating

system.

The boiler is equipped with a 7 litres storage tank which is

suitablefor standard heatingsystem. Specific solutionsare

needed for larger or vertical systems.

The standard equipment does not include an automatic

by-pass valve between the supply and return system.

A special automatic by-pass valve is needed when

thermostatic valves are installed on all radiators or when

local flow stopping valves are mounted.

FIGURE 2

: Pipes connection to the wall

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

Normal pump

Expanded pump

Beforemaking thehydraulic connections(heating, sanitary

water, relief valve and combustible gas discharge) remove

any test water plugs and check the system sealing.

Inareas where the temperature mayreach very lowvalues,

add some antifreeze to the heating system water.

Discharge the sanitary system when the boiler is not used

forvery long periods.

Topreventfreezing,operate the equipment by means of a

roomchrono-thermostat.

FIGURE 3:

heating system available head/flow rate

chart.

3.3 AIR INLET AND FLUE DISCHARGE

E Models

(SE, XE).

Theboilertakes thecarburantair necessaryforits operation

from the installation area, where air intakes must be

installed, in compliance with current regulation.

NOTE

! The equipment must be installed in a constantly

ventilated environment. Flue discharge Ø 130mm, must

comply with national and local technical regulation

concerning boilers which are not equipped with a fan on

thecombustion circuit (natural draught).

ER (SER, XER) model

The boiler has a forced draught and a sealed combustion

chamber; hence the need for two separate circuits: one

forcarburant air,taken fromexternal environmentand one

for combustion flue discharge. These circuits can follow

any path within the boiler; they can be very close to each

other,or evencoaxial. Theycan beconnected tojoint ducts

forsealed-chamber boilers or go directly to the roof or the

wall in compliance with laws in force (fig. 5).

The best (Directive 92/42/CEE) of the sealed chamber

boilercan be achieved inall installation conditions (air-flue

system, pipe diameter and length) thanks to the presence

of an air-intake calibrating diaphragm and an adjustable

shutter.

The shutter is located on the front part of the hood (Fig. 4

and 5) and it is placed on the “-” (upper) position by the

Manufacturer;to remove it to the “+”(lower) position, lift

the lever and turn it clockwise, down to the “+” position.

Bigger-diameter pipes canbe used tocollect anddischarge

condensate.

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

FIGURE 5

FIGURE 4

Seal chamber devices are manufactured for air intake and

flue discharge(Ø100-Ø60) coaxial systems; however it is

possibleto realizesome double pipesystems with separate

airintake (Ø60) and flue discharge pipes (Ø60); in order to

do so it is necessary to replace the cap and the collar

describedon picture 4 with those of picture 5, these latter

are supplied with the boiler itself.

NOTE

:inside the lower sealed part of the boiler, inside the

metal casing, there is a 3mm hole which helps keeping

the pressure inside the boiler lower than the room one. In

this way, gas escapes are in-taken inside the combustion

chamber and they are not released into the room.

PIPES SELECTION FOR X ER MODELS

Follow the procedures below in order to realize a proper

pipe selection:

1) Select one of the four air-flue systems, in compliance

with current regulation, as per Fig.6 (C12, C32, C42,

C52).

2) Measure the total path length of air and flue pipes.

3) Select the air-flue pipe diameter/s and refer to Fig.6 to

define the aerodynamic resistance

for each pipe

section

4) Calculate the total aerodynamic resistance

Rtot

adding up the aerodynamic resistance R of air and flue

pipes.

5) Compare the calculated Rtot value with the max. value

specified in fig.5 for the selected air-flue system. The

calculated value should be equal to or lower than the

value specified in fig.5. Should this not be then case,

increase the pipe diameter and repeat the test starting

from point 3 above.

6) After passing the above mentioned test, establish how

to set the shutter. The cross reference table below

specifies the shutter setting depending on the type of

air-flue system(coaxial or double pipe),boiler type,total

aerodynamic resistence

Rtot

of the air-flue path.

Sealed chamber with forced draught:

;(5

5WRW

systems C12-C32 till 2,0 From 2,0 a 3,0 From 3,0 a 5,0

5WRW

systems C42-C52 till 1,0 From 1,0 a 2,0 From 2,0 a 4,0

Shutter setting

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

carburant air route R = aerodynamic resistance of a plain pipe route

flue route Rtot = total aerodynamic resistance of the pipes inside the air-flue route

EXAMPLE. Boiler X ER.

1) Selected air-fume system: double pipe C52.

2) Total path length: air (a) wind-proof head + (b) 0.8m

straight + (c) 90° bend; fumes (e) 90° bend + (f) 1.5m

straight,(g) wind-proof-head.

3)If ø60mm forair andø80mm forfumes, Rfor thevarious

sectionsis: Ra=0.2, Rb=0.8x0.8=0.64,Rc=0.8, Re=0.2,

Rf=1.5x0.3=4.5, Rg=0,1; for ø80 fume pipe, the (d)

60-80 reducer section is needed, resistance: Rd=0,2.

4)Rtot=0.2+0.64+0.8+0.2+0.2+0.45+0.1=2.59

5) Rtot=2.59 is good for C52 because it is lower than 4.0.

6) According to the table, the diaphragm is not needed

because Rtot is higher than 2.0, but the shutter must be

moved to the position

C12 = horizontal air

and flue pipes

system. Intake and

discharge areas are

very close and

under the same

wind conditions.

C32 = vertical air-

flue pipes. Intake

and discharge

areas are very

close and under the

same wind

conditions.

C42 = the air-flue

intake and

discharge system

are made through

the connection to

two collective and

separate pipes; one

for the air and the

other for the flues .

C52 = double pipe

air-flue system: one

for the air and the

other for the flues

which flowinto

different pressure

FIGURE 6:

“ER” MODELS : Rtot TOTAL MAXIMUM ALLOWED AERODYNAMIC RESISTANCE OF THE PIPES

INSIDEW THE DIFFERENT AIR INTAKE AND FLUE DISCHARGE SYSTEMS

FIGURE 7:

“ER” MODELS: TOTAL AERODYNAMIC RESICETENCE OF SOME PIPES SECTIONS

TECHNICAL MANUAL FOR INSTALLATION, USE AND MAINTENANCE

Terminal strip

NOTE

.Duringinstallation,make surethatthe fumes cannot

go back into the equipment near terminal pieces or

jointsbetween various pipe sections. When no seals

areprovided, apply some silicon between two pipes.

3.4.ELECTRICAL SYSTEM.

Makesure thatthe available AC power matchesthe power

specifiedonthe equipmentrating plate (230VACFN 50Hz).

Check the grounding line and connect it to the boiler. The

manufacturer shall not shoulder any responsibilities for

damage caused by lack of compliance with this

requirement.

De-energisethe equipment and connectit to the electrical

system.For the electrical connection, use the terminal strip

located in the control panel and pay attention to the

indicated electrical connections. Remove the shell and the

control panel cover to access the terminal strip.

NOTE : the boiler needs to be powered with a

magneto-thermal differential switch (Idn=30mA).

NOTE. Pay attention to the phase and neutral polarity

and to the ground connection. Mistakes made

during this stage may permanently block the

burner.

Access to the terminal strip located in the boiler control

panel is needed in order to connect the room thermostat

TA (or chrono-thermostat). Remove the jumper between

terminals11-12ontheterminal strip,andconnecttheroom

thermostat(or chrono-thermostat).

Flow water temperature is adjusted in accordance to the

outdoor one (

climatic function

). In order to do so, it is

necessary to mount an outdoor probe (SE), available as

optionalan option. Use connector 9-10 on theconnecting

strip to connect the probe. Place it on the outside, north

wallof thebuilding, do notabsolutely place it on thesouth

one or towards the sun.

NOTE:

separate electric cablesfrom powerand signalones

(TA, SE) and install them inside separates pipes.

3.5.INFORMATION TO BE RESPECTED BEFORE AND

DURING THE INSTALLATION OF THE EQUIPMENT ON

THE WALL.

- The heating system, and radiators in particular, and the

sanitary water system must be thoroughly washed with

water and a detergent-degreaser;

- Make sure the external systems are connected to the

correct boiler pipes. Ensure that all pipe connections are

correct.

- The relief valve inside the boiler must be connected to a

dedicated discharge pipe.

The Manufacturer shall not

shoulder any responsibilities for damage caused by

the relief valve water, when not connected to a

discharge system.

-Whenthe equipmentisinstalled undertheheating system

units,on-offvalvesshouldbeinstalledbetweenthesystem

and the boiler, thus facilitating maintenance activities.

- The sanitary water flow rate must be adjusted (on the

flow meter, no.19 Fig.7): when the flow rate decreases,

the water temperature increases; when the flow rate

increases,the temperature decreases. The flow regulator

is not a pressure reducer; therefore, if the water system

pressure is too high, external pressure reducers must be

installed.

- Make sure that the free space and distances

recommended in this manual are respected, to facilitate

maintenance activities.

- Make sure that the fume discharge pipe, the chimney

and carburant air supply system are clean and efficient.

-With referenceto forced-flowequipment, makesure that

no other fume discharge pipes are connected to the

chimney, with the only exception of chimneys for sealed-

chamberboilers.

- Make sure that condensation and rain water in the fume

and air pipes are collected and discharged and do not

reach the boiler.

- Connect the air intake and fume discharge pipes; make

sure that they are stable, but removable; they must not

beloose and theirsealing over timemust be guaranteed.

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