Edition 2008-03

STEEL BOILERS series

Technox3 1101900BT

INSTALLATION USE AND MAINTENANCE (to be kept safely)

ATTENTION
In case of boiler fonctioning with gas fired pressure jet burner, the appliance being not covered by any category among those considered by the Annex II of Directive 97/23/CE (Pressure Equipment Directive - PED), and furthermore being covered by the Directive 90/396/CEE (Gas Appliances Directive - GAD) to which the 1st article, paragraph 3 (6.5) makes reference, is excluded by the application area of the directive itself.

GENERAL INFORMATIONS Introduction This manual is an essential part of the product and must be consigned to the user. The instructions must be read carefully as they provide important information about the safety rules for installation, use and maintenance. The manual should be kept safely for further references. It provides a summary of all that needs to the done during installation, use and servicing of Technox3 BT Baltur boilers. Choosing a boiler To choose and utilise Technox3 BT boilers correctly it is essential to follow the instructions laid out. Installation Installation of the boilers and accessories relating to the heating system must comply with all the latest legally required safety regulations. Installation and starting up of the boilers and their heating systems must be carried by a registered installer. A registered installer is someone with specific technical skills in the domestic heating system components and hot water production sector and in particular Servicing Centres authorised by the manufacturer. Starting up for the first time The main aim when starting up for the first time is to check that all safety any control devices are working properly. Before leaving the system, the installer should check a complete working cycle of the boiler. Regulations The installation must be in accordance with the latest regulations regarding boiler rooms, safety devices, flue, fuel supply lines, wiring and any relevant local requirements. Approvals Technox3 BT range of Baltur boilers is CE approved in accordance with the following directives: - Gas directives for gas appliances (90/396 EEC). - Efficiency directive (92/42 EEC). - Low tension directive (73/23 EEC). Technical data plate and serial number The technical data plate provided in an envelope with the other documents refers to a serial number printed on a small aluminium plate nailed on to the front tube plate in the lower right hand corner. Use These boilers are for heating water to a temperature that does not exceed boiling point during operation. Guarantee The guarantee is valid only if the regulations and suggestions for use contained in this manual are followed. Any modification or failure to comply with these will nullify the guarantee. Any damage caused by corrosion from acid condensation of combustion products or by scale from hard or aggressive water is not included in the guarantee since it is caused by the way the system is run.

TECHNICAL CONSTRUCTION AND DIMENSIONS ......................................................... page

1.1 1.2 1.3 Construction of Technox3 BT boilers .................................... page Working principle ................................................................... page Dimensions and water connections ...................................... page

4 4 4 5 9 9 9 9 10 10 10 10 10 10 10 11 11 11 11 11 12 12 13 14 22 22 22 23 24 24 24 25 25 25 25 26 26 26 26 27 27 27 28 28 28

INSTALLATION ................................................................. page

2.1 2.2 2.3 2.4 2.5 Packaging .............................................................................. page Handling ................................................................................. page Positioning in boiler house .................................................... page Connection to the chimney ................................................... page Water connections ................................................................. page 2.5.1 Water supply ................................................................. page 2.5.2 Quality of water ............................................................ page 2.5.3 C.H. flow and return connections ................................ page 2.5.4 Connection of filling and drain tap ............................... page 2.5.5 Connection of the pressure relief valve, expansion pipe and vessel ............................................................ page 2.5.6 Shunt pump .................................................................. page Furnace door: adjustment, opening, closing ........................ page 2.6.1 Important note .............................................................. page Burner .................................................................................... page 2.7.1 Conformity of the burner .............................................. page 2.7.2 Choice of the burner .................................................... page 2.7.3 Mounting of two-stage or modulating burners ............ page Connecting flame sight glass to cooling pipe of burner ...... page Casing assembly ................................................................... page

2.6 2.7

2.8 2.9

CONTROLPANEL ............................................................ page

3.1 3.2 Functions description ............................................................ page Wiring diagram for burner and single phase pump .............. page

COMMISSIONING ........................................................... page

4.1 4.2 4.3 Preliminary check .................................................................. page First commissioning .............................................................. page Switch off of the boiler ........................................................... page

MAINTENANCE ................................................................ page

5.1 5.2 5.3 5.4 5.5 5.6 5.7 General rules ......................................................................... page Ordinary maintenance ........................................................... page Extraordinary maintenance ................................................... page Cleaning of the boiler ............................................................ page Check of the boiler operation ................................................ page Check of the burner operation .............................................. page Boiler house ........................................................................... page

LEGISLATION AND WARNINGS ........................ page

6.1 6.2 6.3 6.4 6.5 General warnings .................................................................. page Summary of warnings ........................................................... page Electrical supply .................................................................... page Water supply .......................................................................... page Boiler fired by gas, oil or other fuel ....................................... page

TECHNICAL CONSTRUCTION AND DIMENSIONS

1.1 - CONSTRUCTION OF Technox3 BT BOILERS

The Technox3 BT, three pass boilers, are of horizontal type (ovals hape from model 110 to 380 and the model 840; eight shape from model 500 to 730 and cylindrical shape from model 1100 to 1900), with direct flame in the combustion chamber. The construction completely satisfies the requirements of the EN 303 - part. 1. The sheet metal parts of the pressure vessel are manufactured of certified carbon steel, type S235JRG2, according to EN 10025, with melting certificate 3.1.B, according EN 10024; whereas the pipes are of steel ST 37.0 according to DIN 1626. The welders and the WPS (Welding Procedures Specifications) have been approved according to EN 287 and EN 288 by TUEV (DE). These boilers have been also approved by - ISCIR (RO). Up to the model Technox3 380BT the furnace is linked to the rear tube plate. For larger models (Technox3 500BT to Tecnox3 1900BT) the furnace is free to dilatate [it is supported only by the double welding seam (inner and outer) to the front tube plate]. The boilers are equipped with a reversible hinged door, wich can be opened, for this reason, from L.H. or R.H. side. The outer shell is insulated with a glass wool matress, thick 100 mm, protected by a textile in mineral fiber. The upper part of the outer shel is equipped with uplift hook(s). Note: The Technox3 BT boilers are to be equipped with ON/OFF burner; alternatively they can be equipped with a two stage or

fig. 1
modulating burner, provided the minimum reachable heat input is not lower than the figure shown on the data plate for the fuel used on site. For two stage or modulating burenr see paragraph 2.7.1. The boilers are provided with two " bulb holders with inner diameter of 15 mm (for 3 bulbs each), suitable to locate the thermostats and thermometer bulbs. The casing side panels are provided with holes for the cables of the electrical supply, of the pumps, of the burner and any other auxiliary equipment.

1.2 - WORKING PRINCIPLE

The NOx formation process is strongly affected by: - the flame temperature; - the time during which the combustion gases stay in a high temperature zone; - oxigen partial pressure and its concentration. The provision to be adopted for the NOx reduction are then: - reduction of combustion temperature; - reduction of the specific thermal input; - permanence time reduction of the gases in the combustion chamber; - reduction of oxigen concentration. Baltur, to reduce the NOx formation on the Technox3 BT range of boilers, has adopted the following construction solutions: - three pass the furnace is of direct flame type and not of reversal type any more; the burner flame results more compact and shorter, thus reducing the permanence time at high 4 temperature; the direct pass allows a quicker flame cooling down by the water cooled furnace surfaces; - specific thermal input reduction the combustion chamber volume has been increased if compared with standard boilers of the same capacity. With the adoption of the modern Low NOx burners a further reduction of the NOx emissions can be obtained with: - reburning a part of the combustion gases is taken and sent again to the combustion chamber with the combustion air. In this way the partial oxygen pressure is reduced and the flame temperature is reduced too. - reduction of the partial oxygen pressure thanks to an air excess reduction. During the operation of the burner within the output range of the boiler, the combustion chamber is always under positive pressure. For the value of this pressure see tables on pages 5 to 8 under the column Smoke side pressure losses. The chimney has to be calculated in such a way that at its base there is no positive pressure.

1.3 - DIMENSIONS AND HYDRAULIC CONNECTIONS

Technox3 110BTTechnox3 380BT
A
41 11 21

1
40 23 24

N T1 O T3

B P T2

T1-T3-T2

12

13 22

14

15 30

16

17

T5

T5

3
T6
G

T6

T4

T4
S

1 2 3

Panel board Smoke chamber cleaning door Flame sight glass

Technox3 BT
Output min/max kW 93105,4 127150 191225 255300 323380 Input min/max kW 101115 137,7163 207245 276327 350414 Boiler water content l 204 270 322 408 475

T1 C.H. flow T2 C.H. return T3 Expansion vessel connection

Water side pressure drop (* ) kPa 0,60,8 0,81,0 1,72,0 2,23,5 3,25,3 Smoke side pressure drop (**) daPa 5,57,5 1216 12,517,5 912 1521 Maximum boiler working pressure bar 5 5 5 5 5 Weight with packaging kg 426 503 621 812 906

T4 Boiler drain T5 Flue connection T6 Max. burner blast tube dia.

fig. 2

CONNECTIONS
T1 T2 UNI 2278 PN 16 DN 50 DN 50 DN 65 DN 8 0 DN 80 T3 ISO 7/1 Rp 1 Rp 1 Rp 1 Rp 2 Rp 2 T4 ISO 7/1 Rp Rp Rp Rp Rp T5 mm 180 180 180 225 225 T6 mm 132 132 180 180 180

Type 110 150 225 300 380

Technox3 BT
Type 110 150 225 300 380 A mm 820 820 860 890 890 B mm 885 1145 1210 1275 1470 C mm 1082 1082 1182 1352 1352 D mm 190 190 190 190 190 E mm 140 140 140 140 140 F mm 145 145 145 145 145 G mm 748 748 828 928 928

DIMENSIONS
H mm 380 380 400 440 440 M (***) mm 1210 1210 1310 1485 1485 N mm 175 175 215 255 255 O mm 130 390 340 285 480 P mm 185 185 250 315 315 Q (***) mm 710 710 750 780 780 R (***) mm 786 1046 1111 1177 1372

(*) Pressure loss for a temperature difference of 15K.; 1 kPa = 10 mbar 102 mm H2O (**) This refers to light oil fuel. 1 daPa 1 mm H 2O (***) Minimum dimensions for boiler room access requirements.

DETAIL FOR DOOR DRILLING Technox3 110BT - Technox3 150BT

DETAIL FOR DOOR DRILLING Technox3 225BT

DETAIL FOR DOOR DRILLING Technox3 300BT Technox3 380BT

Burner plate 350x350 Burner plate insulation gasket 250x250 Fiber wool Ceramic fiber

165

180

fig. 3

fig. 4

95

150

fig. 5
5

Technox3 500BTTechnox3 730BT

2 3

fig. 6
1 2 3 Panel board Smoke chamber cleaning door Flame sight glass
Output min/max kW 425500 535630 620730 Input min/max kW 460545 579686 671795 Boiler water content l 656 737 807

T1 C.H. flow T2 C.H. return T3 Expansion vessel connection

Water side pressure drop (* ) kPa 1,01,5 1,62,3 2,33,3 Smoke side pressure drop (**) daPa 2535 3245 3549 Maximum boiler working pressure bar 5 5 5 Weight with packaging kg 1198 1304 1431

T4 Boiler drain T5 Flue connection T6 Max. burner blast tube dia.

Technox3 BT

CONNECTIONS
T1 T2 UNI 2278 PN 16 DN 100 DN 100 DN 100 T3 UNI 2278 PN 16 DN 65 DN 65 DN 65 T4 ISO 7/1 Rp 1 Rp 1 Rp 1 T5 i mm 250 250 250 T6 mm 210 210 210

Type 500 630 730

Technox3 BT
Type 500 630 730 A mm 920 920 920 B mm 1605 1800 1995 C mm 1645 1645 1645 D mm 190 190 190 E mm 135 135 135 F mm 195 195 195

DIMENSIONS
G mm 1110 1110 1110 H mm 480 480 480 M (***) mm 1735 1735 1735 N mm 298 298 298 O mm 435 630 825 P mm 440 440 440 Q (***) mm 790 790 790 R (***) mm 1505 1790 1895 S (***) mm 860 860 860

(*) Pressure loss for a temperature difference of 15K.; 1 kPa = 10 mbar 102 mm H2O (**) This refers to light oil fuel. 1 daPa 1 mm H 2O (***) Minimum dimensions for boiler room access requirements.

DETAIL FOR DOOR DRILLING Technox3 500BT Technox3 730BT

fig. 7
6

Technox3 840BT
F N
41 11 21

B T1 O T3 P T2

E T1-T3-T2

1
40 23 24

12

13 22

14

15 30

16

17

T5

T5

3
T6

2
G
T6

125

T4

H
T4

fig. 8
1 2 3 Panel board Smoke chamber cleaning door Flame sight glass T1 C.H. flow T2 C.H. return T3 Expansion vessel connection T4 Boiler drain T5 Flue connection T6 Max. burner blast tube dia.

Technox3 BT

Output min/max kW 714840

Input min/max kW 772915

Boiler water content l 932

Water side pressure drop (* ) kPa 3,55,2

Smoke side pressure drop (**) daPa 4258

Maximum boiler working pressure bar 5

Weight with packaging kg 1581

CONNECTIONS
T1 T2 UNI 2278 PN 16 DN 100 T3 UNI 2278 PN 16 DN 65 T4 ISO 7/1 Rp 1 T5 i mm 250 T6 mm 270

Type 840

Technox3 BT
Type 840 A mm 1122 B mm 2115 C mm 1432 D mm 190 E mm 195 F mm 195

DIMENSIONS
G mm 1025 H mm 480 M (***) mm 1540 N mm 298 O mm 945 P mm 440 Q (***) mm 1020 R (***) mm 2014

(*) Pressure loss for a temperature difference of 15K.; 1 kPa = 10 mbar 102 mm H2O (**) This refers to light oil fuel. 1 daPa 1 mm H 2O (***) Minimum dimensions for boiler room access requirements.

DETAIL FOR DOOR DRILLING Technox3 840BT

fig. 9

Technox3 1100BTTechnox3 1900BT

A
41 11 21

B N T3 O T1 P T2

E T3-T1-T2

1
13 22 23 40 15 30 17 24

12

14

16

T5

T5

3
T6

2
G

T6

T4

T4
185

fig. 10
1 2 3 Panel board Smoke chamber cleaning door Flame sight glass T1 C.H. flow T2 C.H. return T3 Expansion vessel connection T4 Boiler drain T5 Flue connection T6 Max. burner blast tube dia.

Technox3 BT

Output min/max kW 9351100 11221320 13601600 16151900

Input min/max kW 10121198 12141438 14701743 17452070

Boiler water content l 1580 1791 2297 2496

Water side pressure drop (* ) kPa 1,52,1 2,13,0 2,02,8 2,73,9

Smoke side pressure drop (**) daPa 4562 6185 4055 5273

Maximum boiler working pressure bar 6 6 6 6

Weight with packaging kg 2444 2965 3685 4089

CONNECTIONS
T1 T2 UNI 2278 PN 16 DN 150 DN 150 DN 175 DN 175 T3 UNI 2278 PN 16 DN 80 DN 80 DN 100 DN 100 T4 ISO 7/1 Rp 1 Rp 1 Rp 1 Rp 1 T5 i mm 350 350 400 400 T6 mm 270 270 285 285

Type 1100 1320 1600 1900

Technox3 BT
Type 1100 1320 1600 1900 A mm 1462 1462 1622 1622 B mm 2282 2652 2692 3014 C mm 1542 1542 1702 1702 D mm 190 190 190 190 E mm 230 230 260 260 F mm 290 290 290 290

DIMENSIONS
G mm 1120 1120 1245 1245 H mm 565 565 605 605 M (***) mm 1650 1650 1810 1810 N mm 561 561 661 662 O mm 510 880 670 990 P mm 550 550 700 700 Q (***) mm 1360 1360 1520 1520 R (***) mm 2176 2546 2590 2910

(*) Pressure loss for a temperature difference of 15K.; 1 kPa = 10 mbar 102 mm H2O (**) This refers to light oil fuel. 1 daPa 1 mm H 2O (***) Minimum dimensions for boiler room access requirements.

DETAIL FOR DOOR DRILLING Technox3 1100BT - Technox3 1320BT

DETAIL FOR DOOR DRILLING Technox3 1600BT - Technox3 1900BT

fig. 11

fig. 12

INSTALLATION

2.1 - PACKAGING
The Technox3 BT boilers are supplied complete with door and smoke chamber already fitted, whilst the casing with the insulation matress are contained in separate cardboard packaging(s). The panel board and the accessories are inside the combustion chamber. Before starting the installation make sure that the length and the width of the boiler body received correspond to the dimension M, Q and R of the ordered boiler, shown in the previous tables and that the carton, containing the casing, or part of it, are marked with the code(s) shown on page 14. In addition to the a.m. panel board, packaged in its own carton, in the combustion chamber, as accessories, there are also: - a carton containing the flanges for flow, return and safety connection (if applicable) with relevant gaskets and bolts, the cylindrical brush for the cleaning of the smoke pipes. cleaning brush handle extension. turbulators extractor. ceramic fiber rope for the insulation between the door and burner blast tube.

2.2 - HANDLING
The boiler can be moved into position by lifting, through the upper hook(s), or by the use of rollers placed under the strong L profiles of the basement. If it necessary, due to the dimensions of the boiler, it is possible to remove the front door and the smoke chamber to facilitate the introduction in the boiler house.

2.3 - POSITIONING IN THE BOILER HOUSE

The installation of the boiler must be in accordance with the relevant requirements of the Gas Safety Regulations, current I.E.E. Regulations, local water authority bye laws and it should also comply with any relevant requirements of the local gas supplier, local authority and the relevant Standard Codes of Practice and buildings regulations. The boiler house must be ventilated through permanent openings having a total surface not lower than 1/30th of the floor area of the boiler house, with a minimum of 0,5 m2. Ventilation by grilles communicating directly with the outside air is required at both, high and low levels. The boiler must be positioned so that there is enough space available for the following: - Access around the boiler fore servicing. - Space to open the boiler front door. - Space to access the burner. The installation of the boiler as close as possible to the chimney position is highly recommended. To allow the cleaning of the smoke pipes, in front of the boiler a clearance equal to the lenght of the boiler, has to be available. With the boiler door opened at 90, the distance between the front of the door and the adjacent wall must be equal, at least, at the lenght of the burner. The boiler must stand on a non-combustible floor (i.e. concrete or brick), of dimension Q x R (see dimensions table) which must be flat, level and of a suitable load bearing capacity to support the weight of the boiler (when filled with water) and any ancillary equipment. Once the installation has been made the boiler must result perfectly horizontal and well stable (to avoid vibrations and noise).

XX

XX

XX X

x = not shorter than the boiler body xx= sufficient to allow accessibility to all regulation, safety and control devices.

fig. 13

2.4 - CONNECTION TO THE CHIMNEY

The chimney has a foundamental importance for the good operation of the boiler. Due to the low temperature of the smokes during the intermittent operation, it is necessary that the chimney is perfectly impermeable to the condensate of the combustion products and manufactured with corrosion resistant

materials. The different connections must be sealed with an approved boiler putty so that the inlet of fresh air, with consequent increase of the possibility of condensate formation, is avoided. Furthermore the possible condensate or rain water comming from the chimney must be avoided from entering the smoke chamber of the boiler.

As far as the cross section and the high of the chimney is concerned, it is necessary to make reference to the local and national rules in force. In the flue pipe, between the boiler and the chimney, convenient sampling points for smoke temperature and combustion products analysis must be provided.

2.5 - WATER CONNECTIONS

2.5.1 - WATER SUPPLY
The boiler components fed with water are normally connected to the water mains through a PRV. Ascertain that the hydraulic pressure measured downstream the PRV is not higher than the Maximum Allowed Pressure of the boiler (see boiler data plate). Because during the operation of the boiler the pressure of the water contained in the C.H. system increased, ascertain that this value does not exceed the a.m. MAWP of the boiler. Make sure the drain of the safety valve has been connected to a discharge hopper; if not connected to a discharge hopper, the safety valve can flood the floor of the room in wich the boiler is installed. The boiler manufacturer is not responsible for such a damage. Make sure the installation pipes are not used as earthing points for the electrical or telephone installations. In a short time the installation pipes, the boiler and the radiators could suffer serious damages. Once the C.H. system, of closed type, has been filled, the filling valve has to be closed and kept in this position. Eventual water leaks will be shown by a decrease of the water pressure at the boiler pressure gauge.

2.5.2 - QUALITY OF WATER

The chemical and physical features of the water used for heating systems are fundamental to the successful functioning and safety of the boiler. Among the problems caused by poor quality feeding water, the most serious and most frequent is scaling on the surface of the heat exchanger. Less frequent but equally serious is corrosion

of the water side surfaces of the whole circuit. Lime scaling is known to reduce heat transfer because of its low conductivity. A few millimetres of lime is enough to cause dangerous localised overheating. Water should be treated in the following cases: A very hard water (over 20 f). B very large systems. C large quantities of water added due to leakage. D subsequent filling as a result of servicing.

To treat water feeding the heating systems it is advisable to contact specialists. The specialist will remove scaling from the boiler. All systems need water to be added either because of evaporation, minor or major leakage, or servicing. The amount of water to be added needs to be controlled through a flow-meter to avoid problems.

2.5.3 - C.H. FLOW AND RETURN CONNECTIONS

The dimensions of flow and return connections are shown, for each boiler model, in the table DIMENSIONS.

Before connecting the boiler to the C.H. system, this one has to be throughly cleaned. Make sure in the system there is a sufficient number of air venter. When connecting flow and return pipes avoid to create mechanical stress onto the boiler

flanges. The boiler is not made to support the piping of the C.H. system, which needs dedicated supports. Once the complete C.H. system is finished, check for water leaks all the connections.

2.5.4 - CONNECTION OF FILLING AND DRAIN TAP

For the filling and drain of the boiler a dedicated tap can be connected to the point T4, which is in rear part of the boiler.

2.5.5 - CONNECTION OF THE PRESSURE RELIEF VALVE, EXPANSION PIPE AND VESSEL
An expansion vessel is necessary, to compensate the water volume increase due to the heating. The Technox3 BT boilers are suitable for fully pumped system, wich can be open vented or sealed. In the 1st case the height of the hydrostatic column must be, at least, 3 m above the boiler casing and the capacity of the expansion cistern shall be able to contain, between the water surface and the overflow pipe, the volume increase of all the water of the C.H. system. 10

Preference shall be given to high and narrow cistern, to expose to the air a surface as small possible, thus reducing the water evaporation. In the 2nd case the vessel capacity has to be calculated taking into consideration: - The total volume of the water contained in the system. - The maximum Working Pressure of the system (see setting of PRV). - The maximum working pressure of the expansion vessel. - The initial preloading of the expansion vessel. - The maximum working temperature of the boiler (the maximum setting of the thermostat fitted onto the panel board is

90C; under this aspect it is suggested to consider 100C). The expansion pipe connects the C.H. system to the expansion vessel. This pipe which starts from the connecting point T3 (see table DIMENSIONS), must have NO gate valve on it. Fit onto the point T3 or onto the supply pipe, within 0.5 m from the flow flange, a pressure relief valve properly dimensioned for the boiler capacity and in conformity with the local rules in force. It is forbidden to put any gate valve between the boiler and the pressure relief valve. For maximum working pressure of the boiler, see table DIMENSIONS.

2.5.6 - SHUNT PUMP

The Technox3 BT boilers must always operate in forced circulation hot water systems and with a minimum return temperature of 50C. So, it is suggestable to adopt a shunt pump, having also an anti-condensation purpose, installed between the flow and return connections upstream an eventual 3 or 4 way mixing valve. This pump will be sized according to the following formula: Q = P x 22 where Q = Water flow rate in liter/h P = Boiler nominal output in kW and the manometric head 1 - 2 m w.c.

2.6 - FURNACE DOOR: ADJUSTMENT, OPENING & CLOSING

A special attention has been paied to the design of the front door, because in all the pressurised boilers a good quality of the doors is a necessary condition for the best operation of the boiler. With the furnace working in positive pressure, in fact, every minimum fissure could cause a leakage of high temperature combustion products, with consequent burning of the gasket and overheating of the door up to its permanent deformation. For these reason the door structure of the Technox3 BT boilers, in addition to the fact to be very strong, has also the possibility to be adjusted: it can be lifted, lowered and also slanted, getting, thus, always the perfect centering of the sealing gasket. The special inner lining in ceramic fiber reduces, furthermore, the time to reach the boiler steady state condition and then reduces drastically the formation of condensate at the boiler start. IMPORTANT It is necessary to open the door when the boiler is cold to avoid damages to the insulating fibre, due to thermal shocks. The door insulating fibre, after a short operating period, can present some cracks; in any case this does not compromise its insulating capacity and its operating life. The door insulating fibre is easily replaceable and is two year guaranteed.

2.6.1 - IMPORTANT NOTE

Before opening the furnace door it is necessary to adopt the following precautions: - Close the fuel cock (oil or gas) to the burner. - Cool down the boiler by keeping the water circulating through it, and only then switch off the power. Put the boiler a Warning notice with the following text: DO NOT USE, BOILER UNDER SERVICE, OUT OF ORDER.

2.7 - BURNER
2.7.1 - CONFORMITY OF THE BURNER
All the burner equipping the Technox3 BT boilers must be CE certificated and must conform to the following directives and standards: - Gas Appliances Directive (90/396/CEE); - EMC Directive (89/336/CEE). - EN 267 - Automizing oil burners of monobloc type - Testing - EN 676 - Automatic forced draught burners for gaseous fuels. Before fitting the burner it is necessary to verify the position of the turbulators inside the smoke pipes: each pipe must have its turbulator and this one has to be positioned as indicated in the table on page 23. On the next page table are listed the matings boiler/burner for the Technox3 BT series, according to the different types of gas. The table beside the fig. 14 shows the minimum lenght and the maximum diametre of the burner blast tube that can pass through the front door. The working range of the burner (fuel flow rate - pressure in the combustion chamber) must correspond to the features of the boiler. When mounting the burner to the boiler front door, check for soundness around the burner flange and its gasket.

BOILER TYPE Technox3 110150BT Technox3 225BT Technox3 300380BT Technox3 500730BT Technox3 840BT Technox3 11001320BT Technox3 16001900BT

A
mm

L
mm

120 140 165 185 230 245 245

180 180 200

280 320 350

A
fig. 14
BURNER BLAST TUBE DIMENSIONS gas feeding line to burner must have the possibility to be removed, via a threaded or flanged connection.

230

Each boiler is supplied with a length of ceramic fibre rope. This rope has to be put around the burner tube to completely seal the tube and the hole in the door insulation. Be careful not to leave fissures between the burner tube and the hole in the door. In case a cone, having a diameter larger than the burner tube, the cone is to be removed before fitting and refitted later on. After the burner has been fitted, check that the flexible hoses for the oil and electrical cables are long enough to allow the 90 opening of the boiler door. For gas burners the use of flexible pipes for the gas is not allowed; so the final part of the

11

2.7.2 - CHOICE OF THE BURNER

The correct choise and the adjustment of the burner are foundamental for the best operation of the boiler and then they shall be accurate and not undervaluated. The burner will be selected by verifying that the working diagram (fuel flow rate - pressure in the furnace) is compatible with the same features declared for the boiler. Remember that the smoke side resistance, i.e. counterpressure in the furnace, are referred to 0 draught at the chimney base. It is also convenient that the burner blast tube have its length not shorter than that shown in the table 16 and that the flame have a shape suitable to the characteristics of the Technox3 BT furnace. In fact to better exploit all the heating surface of the reversed flame furnace it is necessary to use burners capable to guarantee a long and narrow flame at all operating conditions or also at minimum input in case of two stage or modulating burners. Too short flames can cause a localized overheating of the front part of the furnace, and the combustion products, not sufficiently cooled down, entering the smoke pipes at a too temperature, can cause important damages to the boiler. The burner manufacturing companies are able to supply the flame dimensions developped by their burners. More informations are given in the paragraph Commissioning.

2.7.3 - MOUNTING OF THE TWO-STAGE OR MODULATING BURNERS

The boilers Technox3 BT range may be equipped with a two-stage or modulating burner provided the following conditions, in terms of combustion, smoke temperature and boiler temperature are complied with: 1) Combustion: - with light oil having a maximum viscosity of 1,5E at 20C: CO 12 to 13%. - with natural gas: CO 9 to 10%. 2) Smoke temperature: within 160 to 180C in any working condition. 3) Boiler working temperature: the temperature has to be adjusted through the boiler thermostat within 60 to 80C, so that the return temperature cannot go below 50C in any working condition. Make sure, then, there is no condensate formation in the smoke pipes or onto the rear tube plate when a two-stage or modulating burner is in operation at its minimum input. Pay attention when building the chimney: it must be perfectly sound, to avoid damages to the walls, due to the smoke condensate, and properly insulated.

12

2.8 - CONNECTING FLAME SIGHT GLASS TO COOLING PIPE OF BURNER

The flame sightglass is equipped with a 1/8" threaded connection on wich a pressure test nipple (9 mm dia.) is fitted. This can be used with a silicon pipe for the measurement of the counterpressure in the combustion chamber. At the place of this pressure test nipple, which must be held, a special microbore pipe will connect the flame sightglass directly to the pressure room downstream the fan of the burner. The air, blown by the fan, will cool down and clean the sightglass. If the sightglass is not cooled down it can be brocken down. WARNING: In the proximity of the sightglass the temperature is very high: be careful!!! For all the matings with SPARKGAS 30 LX and BGN...LX burners, drill a hole 12 mm dia. onto the burner plate, to insert the pressure test nipple (metallic pipe) in the combustion chamber. Alternatively it is possible to connect the blue PVC hose, supplied with the burner, to the pressure test nipple placed onto the flame sight (see fig. 15), replace the pressure test nipple supplied with the flame sight, by the fitting (part code 88790421) to be ordered separately (see technical spare part list Technox3 BT).

Pressure test nipple onto the flame sight

Hose in blue PVC

Fit the plug of 1/4 Combustion chamber test nipple Hose transfering combustion chamber pressure
fig. 15

13

2.9 - CASING ASSEMBLY

N.B. It is suggested to verify that the boiler is positioned in its final place and that all the hydraulic connections are made correctly before starting the casing assembly. Before opening the casing carton(s) make sure they are stamped with the right boiler model, corresponding to the boiler to be installed. N.B.: The packaging containing the panel board is delivered inside the combustion chamber, as well as the documents and the guarantee certificate.

N.B. For the models Technox3 110BT to Technox3 380BT (ref. fig. 16 & 17), the casing and the insulation are contained in one carton stamped: N.B. For the models Technox3 500BT to Technox3 730BT (ref. fig. 18 & 19), the casing and the insulation are contained in 3 cartons stamped:

packing packing packing packing packing packing packing packing packing packing

1/1 1/1 1/1 1/1 1/3 2/3 3/3 1/3 2/3 3/3

(casing (casing (casing (casing

for Technox3 for Technox3 for Technox3 for Technox3

110BT) 150BT) 225BT) 300BT)

packing 1/1 (casing for Technox3 380BT)

(casing for Technox3 500BT) (casing for Technox3 500BT) (insulation Technox3 500BT) (casing for Technox3 630BT) (casing for Technox3 630BT) (insulation Technox3 630BT)

packing 1/3 (casing for Technox3 730BT) packing 2/3 (casing for Technox3 730BT) packing 3/3 (insulation Technox3 730BT)

N.B. For the model Technox3 840BT (ref. fig. 20 & 21), the casing and the insulation are contained in 3 cartons stamped: N.B. For the models Technox3 1100BT to Technox3 1600BT (ref. fig. 22 & 23), the casing and the insulation are contained in 4 cartons stamped:

packing 1/3 (casing front side parts Technox3 840BT) packing 2/3 (casing rear side parts Technox3 840BT) packing 3/3 (casing upper parts Technox3 840BT)

packing 1/4 (casing front side parts Technox3 1100BT) packing 2/4 (casing rear side parts Technox3 1100BT) packing 3/4 (casing upper parts Technox3 1100BT) packing 4/4 (casing rear panel Technox3 1100BT) packing 1/4 (casing front side parts Technox3 1320BT) packing 2/4 (casing rear side parts Technox3 1320BT) packing 1/5 (casing front side parts Technox3 1900BT) packing 2/5 (casing rear side parts Technox3 1900BT) packing 3/5 (casing upper parts Technox3 1900BT) packing 4/5 (casing central parts Technox3 1900BT) packing 5/5 (casing rear panel Technox3 1900BT)

packing 3/4 (casing upper parts Technox3 1320BT) packing 4/4 (casing rear panel Technox3 1320BT) packing 1/4 (casing front side parts Technox3 1600BT) packing 2/4 (casing rear side parts Technox3 1600BT) packing 3/4 (casing upper parts Technox3 1600BT) packing 4/4 (casing rear panel Technox3 1600BT)

N.B. For the model Technox3 1900BT (ref. fig. 22 & 23), the casing and the insulation are contained in 5 cartons stamped:

14

Assembly of the casing for Technox3 110BT to Technox3 380BT should be carried out in the following steps: Refer to diagram on fig. 16 & 17 for details: A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. B) Locate the side panels (3) and (4) with the lower bend inside the bottom L profiles and the upper bend in the seats of front and rear tube plates. To determine which is the left and right panel ensure that the cable glands are positioned facing toward the front edge. C) Open the combustion chamber door and fit the front insulation (5), inserting the hinges in the pre-cuts. Insert the side ends of the insulation under the bend of the two side panels (3 & 4). D) Fit the rear insulation (pos. 6), fix the rear lower, intermediate and upper panels (pos. 7, 15 & 8) with the self tapping screws. Fit the plastic cable clamps (9) to the upper rear panel (8). Note: because the rear insulation is suitable for two different boiler ranges, before removing the pre-cut insulation, follow the instructions supplied with the insulation it self. E) Remove the cover from the panel board; fix the base onto the upper panel (pos. 10) threading the electric wiring in through the central hole and the capillaries out through it. Fit the upper panel (pos. 10), complete with the panel board, to the side panels (3 and 4). F) Insert the probes of the thermostats in the bulbs holders on the back sides of the boiler (above the smoke chamber)(Ref. fig. 17); the probe of the thermometer (pos. 1), of the working thermostat (pos. 2) and the minimum temperature thermostat (pos. 3) must be inserted in the largest bulb holder ( = 15 mm), the probe of the safety thermostat (pos. 4), must be inserted in the smallest bulb holder ( 7 mm). We recommend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. 5). Connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. Close the panel board. Guide the burner plug through the side cable clamp plate (11) on the preferred side and clamp the cable using a PG 11 cable clamp. Fix the side cable clamp plates (11) to the casing side panels (3 & 4). Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (9). G) Fit the longitudinal upper panels (pos. 12 and 13) to the side panels. H) Remove the protective paper film from data plate and ventilation requirement label (14) and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope.

Technox3 110BT to Technox3 380BT

12 10

13

3
8

15

2 5

14

1 4 11

fig. 16
15

Technox3 110BT to Technox3 380BT

1 2 3 4 5

Thermometer probe Boiler thermostat probe (with knob) Minimum thermostat probe (screwdriver) Safety thermostat probe Probe retaining clip

fig. 17

Assembly of the casing for Technox3 500BT to Technox3 730BT should be carried out in the following steps: Refer to diagram on fig. 18 & 19 for details: A) Fit to the front and rear tube plates the four upper brackets (pos. 1), supporting the side panels, using the screws, washers and nuts supplied (pos. 2, 3 and 4). B) Fit to the front and rear tube plate the four intermediate and lower brackets (pos. 5) supporting the side panels, using the screws, washers and nuts supplied (pos. 2, 3 and 4). C) Fit the insulation blanket (6) onto the boiler shell and secure it in to place using the elasticated straps (7) provided, ensuring that the metal clips grip in to the external surface of the insulation. D) Position the side lower panels (pos. 9 and 18) onto the lower and intermediate brackets (pos. 5). To determine which one is the left or right hand side panel ensure that the cable glands are positioned facing toward the front edge. E) Position the side upper panels (pos. 8 and 17) onto the upper brackets (pos. 1) and fix their pivots on the lower side. F) Fit the 8 screws (pos. 10) to the upper part of the front and rear counter bend of the upper panels (pos. 8 and 17). G) Fit the front insulation (pos. 11), inserting the hinges in the insulation pre-cuts. 16 Note: because the front insulation is suitable for two different boiler ranges, before removing the pre-cut insulation, follow the instructions supplied with the insulation it self. H) Fit the rear insulations (pos. 16 and 27) and fix the rear lower panel (pos. 26). I) Position the panels 12 and 19 between the side upper panels (pos. 8 and 17). L) Remove the cover from the panel board; fix the base onto the upper panel (pos. 13) threading the electric wiring in through the central hole and the capillaries out through it. Fit the upper panel (pos. 13), complete with the panel board, to the side panels (8 and 17). Guide the burner plug through the side cable clamp plate (14) on the preferred side and clamp the cable using a PG 11 cable clamp. M) Insert the probes of the thermostats in the bulbs holders on the back sides of the boiler (above the smoke chamber)(Ref. fig. 19); the probe of the thermometer (pos. 1), of the working thermostat (pos. 2) and the minimum temperature thermostat (pos. 3) must be inserted in the largest bulb holder ( = 15 mm), the probe of the safety thermostat (pos. 4), must be inserted in the smallest bulb holder ( 7 mm). We recommend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. 5). Connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. Close the panel board. N) Fit the cable clamps (pos. 20) onto the rear panel (pos. 19). Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (20). O) Fit the longitudinal upper panels (pos. 21 and 25) to the side panels. P) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope.

Technox3 500BT to Technox3 730BT

fig. 18

Technox3 500BT to Technox3 730BT

2 6

4
1 2 3 4 5 6 Thermometer probe Boiler thermostat probe (with knob) Minimum thermostat probe (screwdriver) Safety thermostat probe Contact spring Probe retaining clip

fig. 19
17

Assembly of the casing for Technox3 840BT should be carried out in the following steps: Refer to diagram on fig. 20 & 21 for details: A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. B) Locate the side panels (pos. 3, 4, 5 and 6) hooking them to the upper and lower profiles. To determine which one is the left or right hand side panel ensure that the cable glands are positioned facing toward the front edge. C) Fit the four screws pos. 7 on the inner upper rear side panels. D) Open the combustion chamber door and fit the front insulation (pos.8), inserting the hinges in the insulation pre-cuts. E) Remove the cover from the panel board; fix the base onto the upper panel (pos. 9) threading the electric wiring in through the central hole and the capillaries out through it. Fit the upper panel (pos. 9), complete with the panel board, to the side panels (3 and 5). Guide the burner plug through the side cable clamp plate (16) on the preferred side and clamp the cable using a PG 11 cable clamp. F) Insert the probes of the thermostats in the bulbs holders on the back sides of the boiler (above the smoke chamber)(Ref. fig. 21); the probe of the thermometer (pos. 1), of the working thermostat (pos. 2) and the minimum temperature thermostat (pos. 3) must be inserted in the largest bulb holder ( = 15 mm), the probe of the safety thermostat (pos. 4), must be inserted in the smallest bulb holder ( 7 mm). We recommend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Fix then the capillaries with the retaining clips (pos. 5). Connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. Close the panel board. G) Fit the longitudinal upper panels (pos. 10 and 11) to the side panels. H) Fit the rear insulation (pos.12) and fix the rear lower panel (pos. 13). I) Fit the rear upper panel (pos. 14). L) Fit the plastic cable clamps (pos. 15) onto the rear upper panel (pos. 14). Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (15). M) Remove the protective paper film from data plate and ventilation requirement label and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope.

Technox3 840BT

10 11 7

4 9 1 14

15

2 3

13 12

16

fig. 20

18

Technox3 840BT

2 5

1 2 3 4 5

Thermometer probe Boiler thermostat probe (with knob) Minimum thermostat probe (screwdriver) Safety thermostat probe Probe retaining clip

fig. 21

Sequence of probes introduction Introduce the bulb into the bulb holder, in the upper part of the boiler body, in the following sequence (Ref. to fig. 22): - (pos. 1) thermometer - (pos. 2) working thermostat - (pos. 3) high limit thermostat - (pos. 4) minimum temperature thermostat. It is recommended to introduce the bulbs up to the bottom of the bulb holder to have a better response. Introduce then the contact spring (pos. 6) to improve the contact and secure the capillaries in position by the clip (pos. 5).

Technox3 1100BT to Technox31900BT

6 5 2 1 3 4

1 2 3 4 5 6

Thermometer probe Boiler thermostat probe (with knob) Safety thermostat probe Minimum thermostat probe (screwdriver) Probe retaining clip Contact spring

fig. 22
19

Technox3 1100BT to Technox31900BT

13 12

11

10 3b 3a 9

5 7
14

4b

4a 5

fig. 23
Assembly of the casing for Technox3 1100BT to Technox3 1900BT should be carried out in the following steps: Refer to diagram on fig. 22 & 23 for details: D) A) Fit the insulation blanket (1) onto the boiler shell and secure it in to place using the elasticated straps (2) provided, ensuring that the metal clips grip in to the external surface of the insulation. Make a convenient cut in the upper part of the insulation blanket to get easy access to the bulb holders. B) Position the side panels (3a, 3b and 4a, 4b) with the lower bend inside the bottom L profiles and hook them to the screws fitted to the upper profiles. To determine which one of the front side panels is the left or the right ensure that the cable clamp plates (5) are positioned facing toward the front edge. C) Open the combustion chamber door and 20 E) F) fit the front insulation (pos. 6), inserting the hinges in the insulation pre-cuts. Insert the side ends of the insulation under the bend of the two side panels (3a and 4a). Fit the rear insulation (pos. 7) and fix the rear lower panel (pos. 8). Fit the rear upper panel (pos. 9) and fit onto it the plastic cable clamp (pos. 10). Remove the cover from the panel board; fix the base onto the upper panel (pos. 11) threading the electric wiring in through the central hole and the capillaries out through it. Fit the upper panel (pos. 11), complete with the panel board, to the side panels (3a and 4a). Guide the burner plug through the side cable clamp plate (5) on the preferred side and clamp the cable using a PG 11 cable clamp. Insert the thermometer and thermostats probes in the bulbs holders as shown in fig. 22. We recommend to push all the probes to the bottom into the relevant bulb holder to improve its contact. Connect the mains, the burner, the pump(s) and any ancillary equipment to the panel board. Close the panel board. Fix the side cable clamp plates (5) to the casing side panels (3a & 4a). Fit the cables, leaving the boiler from the back side, with the plastic screws of the cable clamps (10). H) Fit the longitudinal upper panels (pos. 12 and 13) to the side panels. I) Remove the protective paper film from data plate and ventilation requirement label (14) and fit them at the top front corner of the most accessible side panel after removal of dust from the surface. The data plate and label are in the documents envelope.

G)

Electrical cables positioning The control panel is equipped with a 7 pole burner cable, see wiring diagram on fig. 26. When installing the panel board, connect the leads of the 7 pole cable, to the burner teminal strip or to the 7 pole plug (see wiring diagram on page 22), after the inserting of the cable into the cable gland (pos. 2 - fig. 24). The seven pole plug and the cable must come out from the casing through the cable clamp plate (pos. 1), onto which the cable gland must be fixed. Cable clamps are located on the rear upper panel of the boiler to fix the service cables.

1 2

fig. 24

21

CONTROL PANEL
0002722781

3.1 - FUNCTIONS DESCRIPTION

The mains switch 11 turns on the panel and equipment attached to it. Switches 12 - 13 cut off the supply to the burner and pump. Thermostat 21 controls the working temperature of the boiler. The low thermostat 24 stops the main pump until the temperature in the boiler is lower than 40C. If there are burners and/ or a three stage system pump or in the event of absorption over 3A, a remote control unit should be used between the boiler panel and the load. A switch with protective fase should be applied to the supply line feeding electricity to the control panel.
31 32 33 34 41 11 18 21 25 26

23 12 13 22

14

15 24

16

17

30

40

11 12 13 21 22 24 30

Luminous main switch Burner switch System pump switch Boiler high/low regulating thermostat (with knob) Safety thermostat with manual reset Minimum thermostat of priority (screwdriver adjusted) Thermometer

fig. 25

3.2 - WIRING DIAGRAM FOR BURNER AND SINGLE PHASE PUMP

230 V~ 50 Hz ( MAX 4 A)

N 2 S1 3

L F1 1

S4
1 2 c

TS J (100C)

21

11

22

(50-90C)

14

12

TC J (44-84C) S2

Tm *** J (40C)

11

13 TA OP J CI

12

14

15

**
4 5 6 7 8 MC
4-4

H0

P1 H 9
10-10

H1

H2

P2 H 16 17 18 19

LEGEND S1- Luminous main switch S2- System pump switch S4- Burner switch CI- System pump B- Burner F1- F 4A/250V fuse H0- Burner lock-out lamp H1- Operating lamp H2- II stage operating lamp MC- Boiler's terminal board P1- Hour meter P2- II stage hour meter TC- High/low regulating thermostat Tm- Minimum thermostat or precedence TS- Safety thermostat with manual reset X1S- Boiler connecting plug X2S- Boiler's II stage connecting plug TA- Room thermostat OP- Programmer timer Not included

4
5-5

5
6-6

6 7
7-7 8-8

8
9-9

10

L1

T1 T2 S3 B4

B5 T6 T7 T8 X1S DIN 4791 B

X2S

L1- PHASE - GROUND

N- NEUTER T1 - REGULATIONS SYSTEM T2 S3- LOCKOUT B4- VALVE OPERATION B5- Ii STAGE OPERATING LAMP T6 T7 - Ii STAGE REGULATION T8

fig. 26

N.B. : With three-phase line the motor must be connected directly; in this case the instrument panel feeds only the line of the auxiliares of the burner. In case the burner is not provided with the connector, it will be necessary to follow the instructions reported on the burner's instruction manual. (*) - Disconnect the bridge between the terminals 11 and 12 of the terminal board (MC) prior of mounting the room thermostat (TA). (**) - When the burner is not provided with connector complying with DIN 4791 norms connect, the bridge between the terminals 4 and 7 of the terminal boards (MC). (***) - The panel is supplied with the "Tm" set at 40C, as standard. In case the panel is mounted on a boiler with integrated sanitary water tank: The "Tm" thermostat gives way to sanitary water and has therefore to bes set at 70C at the first start. The room thermostat "TA" is to be connected to the pump in series.

22

0002700871

COMMISSIONING AND OPERATION

A

POSITIONING OF THE TURBULATORS The Technox3 BT boilers are designed to be used in an output range to improve the seasonal efficiency and the possibility to be adopted in all the heating installations. The output must be adjusted at the commissioning stage, according to the system designer indications and, in any case, within the operation range for each boiler model shown on pages 5 to 8, by the burner technician, which will determine the fuel throughput. In any case the turbulators will be placed, inside the relevent smoke pipes, at a distance, from the front tube plate, as shown in fig. 27. When using the boiler at minimum output the smoke temperature will not be lower than 160C. In contrary case, before get in touch our After Sale Service Dept, ascertain that the turbulators are in all the smoke pipes. The commissioning of the burner must be performed under the responsibility of a specialized and well trained burner technician, authorised by the burner manufacturer. In that occasion a commissioning report has to be filled out.

Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3 Technox3

110BT 150BT 225BT 300BT 380BT 500BT 630BT 730BT 840BT 1100BT 1320BT 1600BT 1900BT

A A A A A A A A A A A A A

= = = = = = = = = = = = =

100 100 200 400 400 200 200 200 200 1100 1500 1500 1800

fig. 27

Turbulators removal Detail 1: Fit the brush handle extension onto the turbulator remover. Whitdraw the pin from turbulator. Detail 2: Fit the pin in the radial hole with a hammer. Detail 3: Screw the turbulator remover onto the turbulator.

Detail 4: Turn up to unblock the turbulator.

Detail 5: Withdraw the turbulator.

Detail 6: Turn the remover counterclockwise to release the turbulator.

The procedure from detail 3 to 6 has to be repeated for all the turbulators.

fig. 28

23

4.1 - PRELIMINARY CHECK

Once all the hydraulic, electrical and fuel connections have been made, before starting the boiler we suggest to ascertain that: - The expansion vessel and the pressure relief valve are correctly connected and are in no way interceptable. - The probe of thermometer, working, high limit and minimum thermostats are well secured into their proper bulb holder. - The turbulators are correctly fitted in all the smoke pipes. - The C.H. circuit has been washed and rinsed and is free from solid impurities. - The C.H. circuit is filled with water and

has been completely purged. The pumps operate properly. The flow switch, the pressure relief valve, and the overheating discharge valve, if any, are adjusted at the right value. The fuel, hydraulic, electrical and safety connections are executed in conformity with national and local requirements in force. There are no water leaks. The burner has been fitted according to the instructions of the burner manufacturer. The mains voltage and frequency are compatible with the burner and the electrical equipment to boiler. The burner is adjusted for the fuel type, among those listed in the burner data plate,

available on the installation site, and the burner output range is compatible with the boiler output. In the boiler house there also the burner instructions. The C.H. pipes are properly insulated. The C.H. system is capable to absorb the heating quantity produced at the first start of the burner, during the test period. The sunt pump is installed as prescribed in the paragraph 2.5.6.

4.2 - FIRST COMMISSIONING

Al the commissioning stage of the boiler a qualified technician has to perform the following checks: - Internal and external sound test of burner and fuel feeding pipe; - Adjustment of the fuel throughput according to the nominal input of the boiler (it is convenient to remember that the nominal input can be adjusted between the minimum and the maximum shown in the table of pages 5 to 8), by sharing the output between the 1st and the 2nd stage, knowing that the 1st stage flame can go down to the 60% of the nominal output (wich at its turn can vary between the minimum and the maximum depending on the output requested by the C.H. system). Proceed, then, in the following way: - Open the fuel feeding cock and check that there are no leaks in the feeding line. - Ascertain that all the switches of the panel board are in OFF position and adjust the working thermostat to the minimum position. - Switch ON the panel board through the main switch. - Switch ON the C.H. pump; it will start to rotate as soon as the minimum water temperature thermostat detects 50C. - Switch the burner ON. - Position the working thermostats of 1st and 2nd stages to the maximum setting to create a heat request. During this phase check that: - There are no smoke leaks from the front door, the burner plate and the chimney connection. - There is a draught at the chimney base between 2 and 4 mm w.g. - There are no water leaks. - The different thermostats and the other installation safety devices work properly. - The shunt pump operates correctly. - The burner ignition as good. - The burner characteristics (main adjustments and nozzle type) correspond to the boiler data plate. With a burner properly adjusted it must be possible to reach easily, from a smoke sample taken at the chimney base, the values given below: 1) With light oil having a maximum viscosity of 1,5E at 20C: - CO 1213% - Smoke index <1 - Smoke temperature 180200 C 2) With Natural Gas: - CO = 910% - Smoke temperature 160180C (values related to a clean boiler, with water at 70C). It is suggested to adjust the fuel throughput to the actual needs of the C.H. installation (avoid to overcharge the boiler), without exceeding the a.m. smoke temperatures (never go below 160C). The HIGH EFFICIENCY Technox3 BT boilers are foreseen to operate with a return water temperature never below 50C when operated on light oil, and never below 60C when operated on gas, to avoid, (or, at least, to reduce) the smoke acid condensation phenomenon, which can be the reason of a premature deterioration of the steel boiler body. The working thermostat, pos. 21 of the panel board, must be set at a temperature of approximately 80 to 85C. The room temperature will be compulsorily adjusted through a mixing valve and, eventually, an outer compensator. To homogenise the water temperature, or avoid as maximum as possible, returns into the boiler at a temperature below 50C when operated on oil, or 60C when operated on gas, a properly dimensioned shunt pump must be fitted between flow and return pipes of the boiler. N.B. The metal sheet corrosion due to the acid condensate is not covered by the guarantee because its depends only from the operation of the C.H. system. The Technox3 BT panel board is equipped with a low temperature thermostat not allowing the operation of the pump when the boiler temperature is below 50C (protection against cold starts).

4.3 - SWITCH OFF OF THE BOILER

Switch OFF the burner (switch No 12 to 0 position).

Leave the pumps working up to when they are not stopped by the minimum thermostat. Switch OFF the power to the boiler panel board.

If it is decided not to use the boiler for a long period close also the gate valves of the fuel.

24

MAINTENANCE
The non respect of the above can jeopardize the safety of the boiler. To guarantee the efficiency of the boiler and for its correct operation it is essential to submit the boiler to an annual maintenance, through a professionally qualified technician, according to the indications of the manufacturer. When it is decided not to use the boiler anymore, the parts which can be potential sources of danger shall be made harmless. After a month of boiler operation, open the front door and ascertain the smoke pipes are clean. In case of a heavy dirtiness: - Remove the turbulators from smoke pipes. - Clean all the smoke pipes using the brush delivered with the boiler. - Open the cleaning door on the smoke chamber and remove, with a vacuum cleaner all the soot. - Relocate the cleaning door and the turbulators; then close the boiler front door and check for soundness all around the sealing rope. - Then adjust the burner. Note: With a burner properly adjusted only a cleanup at the season end is necessary.

5.1 - GENERAL RULES

Before effecting any operation of cleaning or maintenance, disconnect the boiler from the electrical supply acting on the main switch onto the panel board. In case of failure or bad operation of the boiler, switch it off, abstaining your self from any attempt of reparation or direct intervention. Exclusively address to professionally qualified personnel. The possible reparation of the boiler must be effectued by an authorized service center using only original spare parts.

5.2 - ORDINARY MAINTENANCE

The boiler operating condition are very different from one case to the other and depend on the fuel used, on the adjustment of the burner, on the number of starting, on the C.H. system characteristics, etc. and for that reason it is not possible to establish, in advance, the frequency of the maintenances. It is, then, necessary that the technician, who performs the first cleaning, establish the cleaning of frequency on the base of the boiler status. Generally, we suggest the following frequency, according to the fuel used: - Gas fired boilers: once a year. - Oil fired boilers: twice a year or more often if there is reason to doubte of their adjustment. In any case the local rules in force have to complied with. We suggest to shake the turbulators, without removing them from the smoke tubes, at least once a month of operation, not to allow the soot blocking them and making them extremely difficult to be removed. During the operations of ordinary maintenance it will be necessary to brush the tube bundle - after the removal of the turbulators - and

the furnace and collect the soot through the cleaning door on the smoke chamber. Besides it will be necessary to verify the good operation of the protection and control devices (thermostats, thermometers) of the boiler and of the plant (manometers, flow and pressure switches, expansion vessels) and all the safety devices. In this occasion it will be necessary to notice the quantity of reinstatement water used and decide, also in base to its hardness, an intervention of preventive descaling. It must be considered that the calcium and magnesium salts dissolved in the raw water, with repeated reinstatements, can cause deposits in the boiler that hinder the inner circulation and subsequent overheating of the wall plates with possible serious damages that cannot be attributed to be constructive geometry and/or to the materials used and to the constructive technique and, therefore, they are not covered by guarantee . On the occasion of the ordinary maintenance it is useful to perform a small discharge from the boiler to verify if sludges escape. In affirmative case, it will be necessary to prolong the discharge up to get clear water. At the end of the drainage it will be necessary to reestablish the level of the water in the system.

At the end of the smoke circuit cleaning, to the next restart check around the burner plate and the smoke chamber for smoke leaks. In the case some smoke leaks were noticed, first of all tighten the nuts fitting the smoke chamber and, not getting result, it will be necessary to replace the sealing gasket. Similarly it will be necessary to act on the front door, increasing at first the tightening the screws (Technox3 110BT to Technox3 730BT) - or alternatively - the nuts (Technox3 840BT to Technox3 1900BT) (after having loosened the inner counternuts) and then, if necessary, by replacing the whole gasket. If it was necessary to center the sealing gasket on the sealing ring of the door it is possible to adjust the door position by acting as suggested on the paragraph 2.6. At the end check and, if necessary, restore the sealing of the connection of the chimney and of the burner with the door. The performed operations must be recorded on the log book of C.H. system.

5.3 - EXTRAORDINARY MAINTENANCE

Extraordinary maintenance of end season or for long periods of inactivity. It will be necessary to perform all the operations described in the preceding chapter and besides: - Check the state of consumption of the turbulators to replace them in time. - To facilitate the extraction of the turbulators, with the Technox3 BT boilers, a special extractor is supplied. - After the cleaning of the smoke circuit it is convenient to pass in the smoke pipes

and in the furnace with a rag soaked of diluted solution of caustic soda. After having let to dry cross again all the surfaces with a rag soaked or oil. Pefectly close the burner air intake to avoid a continuous passage of damp air through the boiler recalled by the chimney it self. It is advisable to put inside the furnace some alive mortar that has an hygroscopic action. Do not empty the C.H. system and the boiler. Protect the screws with graphitized fat, nuts and pivot of the door. Show all the operations that must be perform to the following put into operation

particularly the operation of the shunt pump must be checked.

25

5.4 - CLEANING OF THE BOILER

Follow the next sequence: - Close the feeding of the oil. - Cooldown the boiler to the ambient temperature. - Switch OFF the electrical supply to the

boiler and the burner. Open the front door. Shake and remove the turbulators every 15-20 days of activity of the boiler to avoid that the residues of combustion can stop them so much to make difficult their removal. Clean the turbulators and the smoke pipes by brushing them with the brush supplied.

Reposition the turbulators (see fig. 27). Remove the cleaning door and all the soot from the smoke chamber. Re-fit the cleaning door. Verify the state of the refractory insulation of the combustion chamber door. Verify the state of the door sealing rope. Close the door of the furnace.

5.5 - CHECK OF THE BOILER OPERATION

For a sale operation of the boiler it is necessary to check: - The good operation of the working

thermostat. The good operation of the high limit thermostat. The adjustment and the good operation of the minimum thermostat. The good operation of the shunt system. The good operation of the outer

compensator (if fitted). The good operation of all the other safety and control devices imposed by a local requirements.

5.6 - CHECK OF THE BURNER OPERATION

See the burner instruction manual. Follow all the local requirement in terms of burner maintenance.

5.7 - BOILER HOUSE

For the combustion of oil or gas burner needs air. Accordingly wide openings are foreseen for the entry of the air in the boiler house. These openings never have to be obstructed.

Maintain the boiler house clean and dust free. The boiler house is not a closet: avoid to store any kind of materials. Maintain the entry of the boiler house free and easy to reach in any moment. Ascertain that the boiler house is endowed

with efficient emergency lamp.

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LEGISLATION AND WARNINGS

contact your supplier. The packing (wooden crate, nails, clips, plastic bags, expanded polystyrene, etc.) are potentially dangerous and must be kept away from children. Before starting any cleaning or servicing, switch off the electricity supply using the main switch. Do not obstruct the ventilation grilles or heat dissipation grilles. If the equipment breaks down or is not functioning correctly, switch it off and do not try to repair it or interfere it in any way. Contact only authorised personnel. Any repairs must be carried out by an authorised service centre designated by the manufacturer. Only original spare parts must be used. Failure to observe the above instructions can jeopardise the safety of the system. To guarantee efficiency and top performance the system must be serviced annually by specialised personnel. The manufacturer's instructions must be followed. If it is not to be used, the parts which could be potentially dangerous should be rendered harmless. Only original accessories must be used on systems with optionals extras or kits (including electrical parts). This equipment must be used for the purpose for which it was expressly designed. Any other use is to be considered improper and therefore dangerous. The manufacturer accepts no responsibility for damage caused by improper installation or use. The manufacturer's instructions must be fully adhered to.

6.1 - GENERAL WARNINGS

The instruction manual is an essential and integral part of the apparatus and must be handed over the user. Carefully read the instructions contained in it as they provide important advice on installation safety, use and servicing. Keep the instruction manual handy for further consultation. Installation must be carried out in accordance with the latest regulations, the manufacturer's instructions and by specially trained staff. Specially trained staff refers to those specifically trained in the field of heating systems for domestic use and domestic hot water systems, in particular the manufacturer's authorised Service Centres. Improper installation can cause injuries to people and animals and damage to the home, for which the manufacturer is not responsible. After removing the packaging check that there are no broken or missing parts. If in doubt, do not use the equipment and

6.2 - SUMMARY OF WARNINGS

This boiler must be used only for the purpose for which it was built. Important: this boiler is for heating water at a temperature below boiling point. It must be connected to a heating system and/or to a domestic hot water system and must function within its performance and output limits. Installation The boiler must be installed in a room that meets the requirements laid down in the latest regulations. Before connecting the boiler the following should be carried out by registered personnel: a) carefully wash all the pipes to remove any residue that might harm the boiler; b) check that the boiler is suited to the type of fuel available. This is shown on the label showing the technical data; c) check that the flue draught is adequate, that there are no blockages and that no other boilers are connected to the same flue stack, unless this has been done to serve more than one boiler, according to specific regulations; at this point the boiler can be connected to the flue; d) if there are connections belonging to previous flues these must be examined to check that they are perfectly clean as debris may dislodge and block the smoke passage, putting the user in great danger. The burner must be installed according to the instructions contained in the burner instruction manual.

Commissioning Commissioning must be carried out by qualified staff. Before starting up the boiler the qualified staff should check: a) that the data on the label correspond to the various supplies (electricity, water, gas, oil or other fuel); b) that the output range of the burner is compatible with that of the boiler; c) that the handbook for the burner is also kept in the boiler room; d) that the pipelines that exit from the boiler are covered with the proper heat insulating sheath; e) that the smoke evacuation duct functions properly; f) that the air is fed in and smokes evacuated correctly and in accordance with the latest regulations. Warning to the user It is dangerous and illegal to even partially obstruct the air vents in the boiler room. Do not leave the boiler on when it is not to be used for long periods; in such cases the fuel supply should be cut off and the general electricity switch turned off. Do not touch hot parts of the boiler, such as, doors, burner plate, smoke chamber, flue pipe, etc. during and after functioning these are hot and can cause burns and scalding. Do not allow children or inexperienced persons near the boiler. Do not let the boiler get wet from splashing liquids.

Do not place anything on top of the boiler. Do not allow anyone inexperienced to use the boiler. In case of temporary disuse the following steps should be carried out: a) switch off electricity, water and fuel supplies; b) empty the water system, if there is no antifreeze. If the boiler is no longer to be used at all, qualified staff should carry out the necessary operations, checking that the electricity, water and fuel supplies are switched off. If the output of the boiler requires, it must be operated by specialised staff in accordance with the latest regulations. Before carrying out any task that involves dismounting the burner or opening covers or inspection doors, switch off the electricity and fuel supply taps. Servicing Periodically check that the smoke evacuation duct is working properly. Do not clean the equipment and/or its parts using easily inflammable liquids (eg. petrol, alcohol, etc.). Do not leave containers with inflammable liquids in the boiler room. Do not clean the boiler room when the burner is switched on. At the end of the heating season the boiler should be checked by qualified staff to ensure that it is in perfectly condition. Careful servicing helps save money and guarantees safety. 27

6.3 - ELECTRICAL SUPPLY

The electrical safety of the system is ensured only if it is correctly wired up to an efficient and correctly installed earthed system that complies with the latest regulations. This fundamental requisite must be checked. If in any doubt ask for professional advice since the manufacturer is not responsible for damage caused by the system not being earthed. A professional check should be carried out to ensure that the electrical installation is

adequate for the maximum output absorbed by the system. This is indicated on the data label. It is also important to ensure that the cable section is suitable for the absorbed output of the boiler. The mains electricity supply must not be used with adaptors, multiple plugs and/or extension leads. A bipolar switch as required by safety regulations must be used for connection to the mains. Certain basic rules apply when using any electrical apparatus: - never touch the apparatus with wet or

damp parts of the body and/or with bare feet; - do not pull the wiring; - do not leave apparatus exposed to the elements (rain , sun, etc.); - do not allow inexperienced persons to use it. The cable should not be replaced by the user. If the cable is damaged, switch the apparatus off and have it replaced professionnally. If it is not to be used for some time, it is advisable to switch off the electricity supply to all the relevant components (pump, burner, etc.).

6.4 - WATER SUPPLY

The water fed components are normally connected to the supply by means of a water pressure reducing valve. Check that the water pressure measured beyond the reducing valve is not greater than the working pressure indicated on the label of the boiler, water tank, etc.). Since the pressure of the water in the heating system increases, check that its maximum value does not exceed the max. water pressure

indicated on the data plate. Check that the installer has connected the boiler safety valve drain to a collecting funnel. If not connected to a drain the safety valves, when operating, will cause flooding in the boiler room for wich the boiler manufacturer is not responsible. Check that the water and heating system pipelines are not used as earthing points for the electricity or telephone since they are wholly unsuitable; pipelines, boiler and radiators may be damaged as a result. Once a closed heating systems is filled

(closed expansion tank), the feed tap should be closed and kept closed. Leakage may be revealed a drop in water pressure indicated on the system pressure gauge.

6.5 - BOILER FIRED BY GAS, OIL OR OTHER FUEL

General warnings Boiler installation must be carried out only by registered personnel and in accordance with the latest regulations since improper installation can cause damage to persons and objects for which the manufacturer cannot be held responsible. Before installing it is advisable to carefully clean all the fuel feeding pipelines to remove any residue which may harm the boiler. To start up the boiler the registered installer should carry out the following steps: a) check the inner and outer seals of the fuel feeding system;

b) regulate the fuel flow according to the maximum output indicated on the burner label; c) check that the burner is receiving the appropriate type of fuel; d) check that the fuel feed pressure, if gas, is within the values indicated on the burner label; e) check that the flue feed system is the correct size for the flow needed by the boiler and that it has all the safety and control devices required by law.

Special indications for gas The registered installer should carry out the following steps: a) check that the feeding line and gas ramp are in accordance with the latest regulations; b) check that all gas connections are sealed; c) check that the air ventilation grilles in the boiler room are large enough to guarantee the amount of air required by law and needed for perfect combustion. Do not use gas pipes to earth electrical appliances. If there is a smell of gas: a) do not operate electrical switches, telephones or any other object that might cause sparks; b) immediately open doors and windows to create a draught; c) turn off gas taps; d) ask for professional help. Do not obstruct air vents where a gas boiler is situated to avoid dangerous situations such as toxic or explosive mixture.

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This catalogue is purely indicative. The manufacturers reserve the right to modify technical data and any other parts of the contents.

For any information about our service centers telephone

BALTUR S.p.A.
Via Ferrarese 10 - 44042 CENTO (Ferrara) ITALIA Tel. 051.684.37.11 Fax 051.90.21.02 - (International Tel. ++39.051.684.37.11 - Fax ++39.051.683.06.86) http://www.baltur.it - http://www.baltur.com - E-MAIL info@baltur.it