FLEXIHEAT 300 Ecodense Cell Condense User Manual

FLEXIHEAT 300 Ecodense Cell Condense

Product Information

Specifications:

• Models: CELL CONDENSE 300, 420, 480, 600, 720, 900, 1040, 1210,1310, 1510, 1810
• Manufacture Date: 18.11.2022
• Revision: 02

Product Usage Instructions

Warnings

Warning Symbols and Descriptions

• Important Information: Indicates important information and useful hints.
• Danger Warning: Warns of danger to life or property.
• Electrical Voltage Warning: Warns of electrical voltage presence.
• Clean Gas Line Warning: Indicates the need to clean the gas line.
• Handling Instructions: Carry the product upright to protect against damage.

Terms of Warranty
The warranty conditions are provided with the product. Refer to the warranty documentation for details.

General Characteristics of Condensing Boiler
The condensing boilers are designed for efficient and environmentally friendly use. The CASCADE feature allows for versatile usage.

Usage of CASCADE
The CASCADE feature enables connection of multiple boilers for enhanced performance.

ECODENSE Components
The ECODENSE components enhance the efficiency and eco-friendliness of the boilers.

Condensing Boiler Gas, Flue Gas and Heating Water Schema
Refer to the provided schema for understanding the gas, flue gas, and heating water flow in the boiler system.

Circuit Schemes
Detailed circuit schemes are available for proper installation and maintenance procedures.

Boiler Water Flow Table
Use the provided table to ensure proper water flow within the boiler system.

Closed Circuit Components
Understand the closed circuit components for efficient operation and maintenance.

FAQ:

Q: What should I do if I encounter an issue not covered in the manual?
A: If you face any problem not explained in the manual or require further assistance, please contact Flexiheat for support.

DEAR USER,
The Condensing Boilers CELL CONDENSE 300, CELL CONDENSE
420, CELL CONDENSE 480, CELL CONDENSE 600, CELL CONDENSE 720, CELL CONDENSE 900, CELL CONDENSE 1040, CELL CONDENSE 1210, CELL CONDENSE 1310, CELL CONDENSE 1510, CELL CONDENSE 1810, are constructed and manufactured according to the most advance technological inventions and the safety rules. It is easy to use for our customers.

We recommend that you read this manual and safety warnings thoroughly before the use of the device in order to ensure safe, cost-effective and environmentally friendly use.

If you encounter any issue that is not explained clearly in this manual or you do not understand, please contact Flexiheat

This Operating Manual is an integral part of the device and must be maintained in a plastic dossier and hung at a clearly visible place by the device.

WARNINGS

Warning Symbols and Descriptions

General Safety Rules

• All personnel engaged in installation, disassembly, commissioning, operation, control, maintenance and repair should have received the necessary training, qualified and fully read and understood this manual.
• No changes that might damage the safety of the device must be made by persons and/or organizations on the device.
• All operation, commissioning and installation works (except for burning adjustment) should be carried out when the device is not operating and after disconnecting the power supply. Noncompliance with these rules may lead to serious bodily injuries and even death by electrical shocks or uncontrolled flame formation.
• Repairs concerned with safety elements should be carried out only by the manufacturing company.
• The device should never be used by children, mentally handicapped and inexperienced persons.
• Children must not be allowed to play with the device.
• Keep the device away from explosive and flammable materials.
• Device must intake air, and ventilation and air discharge holes must not be closed.

If you sense gas leakage;

• Shut down valves of all gas devices.
• Open all doors and windows.
• Do not turn on electric devices or do not turn them off if they are working.
• Do not use burner derived tools such as match and lighter.
• Inform the gas company.

Do not store any inflammable materials in boiler room.

Wear hearing protectors if there is noise in boiler room.

In case of fıre or other emergency;

• Switch off the main switch
• Close the main fuel shut-off valve outside the plant.
• Take appropriate actions

Products should be stored in a dry, cool or dry conditioned places . Storage life of our products (service life) is 10 years.

Preventing damage caused by the presence of particles such as dirt, sediment, metal burrs on the heating circuit installation and condensing boiler, for the comfortable and longer service life of the boilers, It is recommended that the installation circuit is separated by plate heat exchanger as primary and secondary circuit

For The High-rise Buildings, If height of structure more than 25 mt. Or more than 10 th floor ,in order to ensure that condensing boiler cascade system operates comfortably at low pressures, a plate heat exchanger must be installed to distinguish the high pressure between 2nd circuit and the Primary circuit. the static pressure appearanced due to the height of building , the boiler system is not allowed to operate under the influence of high pressure.

BOILER ROOM
Condensing Boilers must be installed in a suitable room/floor with minimum external air openings and sufficient to ensure optimum gas-air mixture combustion, in compliance with the regulations.
Air openings of the boiler room, burner fan intake vents or air ducts must stay open to the atmosphere and Bird cage should be installed in order to prevent any Bird, foreign body entrance

• The build up of toxic / explosive gas mixtures in the boiler room,
• Combustion with insufficient air, resulting in hazardous, anti-economical and polluting operation.

The Condensing boiler must be always protected from rain, snow and frost to prevent corrosion and paint deformations.
Keep the condensing boiler room clean and free of solid volatile substances, which could be sucked into the fan and clog the internal boiler or combustion air ducts.
Every 6-12 months, after first commissioning of boiler, the boiler devices should be cleaned with protective chemicals to prevent calcification and resultant blocking and corrosion on the metallic surfaces.

Flushing;
On the Currently operating systems, appropriate chemical solution with the pH range of 4-6 should be selected for cleaning the pipeline installation for safety commissioning the condensing boiler.
In the new building installations and boiler heat exchangers, maintenance should be applied with chemicals with neutral pH (neutral) effect and preventive maintenance must be carried out periodically.

TERMS OF WARRANTY

Main and auxiliary equipment and all components used in CELL CONDENSE 300,
CELL CONDENSE 420, CELL CONDENSE 480, CELL CONDENSE 600, CELL CONDENSE 720, CELL CONDENSE 900, CELL CONDENSE 1040, CELL CONDENSE 1210, CELL CONDENSE 1310, CELL CONDENSE 1510, CELL CONDENSE 1810, Condensing Boilers are guaranteed for 1 year by Flexiheat UK,starting from the date of commissioning under the maintenance, adjustment, operating conditions and relevant mechanic, chemical and thermal effects explained herein.

Please note that this warranty is only valid if the device(s) is commissioned and maintained by our authorized services.

Our company reserves the right to make any modifications on the product and all instructions thereof for improvement purposes.

Out-of-Warranty Conditions

• Any damage arising out of or in relation to customers’ non-compliance to their responsibilities with regards to installation, commissioning, operation and maintenance,
• Any damage arising out of or in relation to commissioning, repairs and maintenance carried out by unauthorized services,
• Any damage that may occur during transportation or storage of the product,
• Not preserving the product in its original packaging until the installation stage,
• Incorrect and poor electrical connections, Failures due to incorrect voltage applications, frequent repetition of voltage fluctuations,
• Any damage that may occur as a result of incorrect fuel usage or, foreign substances in the fuel used or using of the product without any fuel,
• Any damage that may occur due to foreign particles entered into the product during installation and operation,
• Failures due to incorrect device selection,
• Any damage to unit due to natural disasters,
• Devices without any warranty certificates,
• Warranty Certificates without the stamp and signature of the authorized dealer or service,
• Devices with any falsification on the warranty certificate or without an original serial number.
• The risks during transportation of device under the responsibility of customer belong to the customer.
• Presence of misuse faults are indicated in the reports issued by authorized service stations or our authorized agent, dealer, representative or our factory in case of unavailability of authorized service stations.
• Customers may apply consumer protection arbitrator committee with regards to this report and request for an expert report.

GENERAL CHARACTERISTICS OF CONDENSING BOILER

ECODENSE CELL CONDENSE 300, CELL CONDENSE 420, CELL CONDENSE 480, CELL CONDENSE 600, CELL CONDENSE 720, CELL CONDENSE 900, CELL CONDENSE 1040, CELL CONDENSE 1210, CELL CONDENSE 1310, CELL CONDENSE 1510, CELL CONDENSE 1810 are heating devices operating with natural gas with a very low suction power, and equipped with high-duty, premix condensing control system with micro- processor. The boiler is composed of a stainless steel heat exchanger and a steel premix burner equipped with ignition and ionization flame control, modulating fan and gas valve. ECODENSE CELL CONDENSE 300, CELL CONDENSE 420, CELL CONDENSE 480, CELL CONDENSE 600, CELL CONDENSE 720, CELL CONDENSE 900, CELL CONDENSE 1040, CELL CONDENSE 1210, CELL CONDENSE 1310, CELL CONDENSE 1510, CELL CONDENSE 1810 are designed for use as standalone as well as cascade.
The structure of cascade to be formed by the product group increases the usability in collective housing and individual building applications with its efficient composition.

Usage of CASCADE

Premix condensing technology is used in CELL CONDENSE 300, CELL CONDENSE 420, CELL CONDENSE 480, CELL CONDENSE 600, CELL CONDENSE 720, CELL CONDENSE 900, CELL CONDENSE 1040, CELL CONDENSE 1210, CELL CONDENSE 1310, CELL CONDENSE 1510, CELL CONDENSE 1810 wall type condensing boilers in order to reach higher efficiency and energy-saving. With suitable connections and approval from gas distribution companies,CELL CONDENSE 300, CELL CONDENSE 420, CELL CONDENSE 480, CELL CONDENSE 600, CELL CONDENSE 720, CELL CONDENSE 900, CELL CONDENSE 1040, CELL CONDENSE 1210, CELL CONDENSE 1310, CELL CONDENSE 1510, CELL CONDENSE 1810 boilers can be connected as much as required capacity. Maximum operation pressure of these boilers is 6 bar. Circulation pump, expansion tank and safety valve are not present in these boilers. These are required to be provided by customer and are mandatory to use.

• High efficiency with premix condensing technology and micro-flame metal fiber steel burner,
• 11 different wide thermal capacity options in the range of 300 – 1810 kW,
• High performance and long-lasting durability with expanded surface area and sheet thickness in the stainless steel heat exchanger,
• Heat exchanger protection with magnetic residue protection integrated in the boiler,
• Enhanced combustion efficiency with flash back flap,
• Easy operation and manitenance with compact design,
• Up to 10:1 modulation rate and maximum energy-saving,
• Allows user friendly control with illuminated LCD panel which provides ease of use; and error codes and boiler information can be displayed on the panel,
• Daily and weekly operation schedule can be programmed,
• Seasonal heat program can be prepared during summer and winter times,
• Option of use with natural gas and LPG,
• Operation in lower noise values,
• Eco-friendly with lower CO and NOx emission rates.

ECODENSE Components

CONDENSING BOILER GAS, FLUE GAS AND HEATING WATER SCHEMA

CONNECTIONS

• A – CH Inlet
• B – CH Outlet
• C – Gas Inlet
• D – Condensate Water Outlet

MAIN PARTS

1. Stainless Stell Heat Exchanger
2. Premix Burner
3. Modulating Fan
4. Backflow Clap
5. Venturi
6. Gas Valve
7. Water Pressure Sensor
8. Inlet / Outlet Temperature Sensor
9. Flue Gas Sensor
10. Limit Thermostat
11. Ignition Transformer
12. Ignition and lonization Electrode
13. Air Vent
14. Magnetic Filter
15. Condensation Siphon
16. Ball Valve

CIRCUIT SCHEMES

BOILER WATER FLOW TABLE

The required water flow table for all boiler models is as follows.

While selecting the boiler pump, it should be determined according to the water flow in the table. Otherwise, the boiler will be considered out of warranty.

CLOSED CIRCUIT COMPONENTS

Balance Tank

Balance Tank (Separator) must be vertical.

Advantages:

• No hydraulic response occurs between the boiler circuit and the heating circuit.
• Boilers and heating zones operate under suitable water flow.

Sizing of Balance Tank:

• In order to ensure healthy operation of the balance tank, accurate sizing must be made.
• The boiler’s exit water temperature should be measured on the upper part of balance tank.
• For this, a ½” muff should be welded onto tank, and also an air relief cock should be mounted.
• Dimensions shown in the picture represent minimum dimensions required to be applied.

Sizing Table For Expansion Tank

Expansion Tank
Expansion tank fore pressures must be adjusted according to system. Expansion tank should be placed parallel to circuit return line.

Manometer
A manometer with capacity of at least 0 to 6 bar must be connected to system. Manometer should be placed to easily visible spot from filling point, preferably same point as expansion tank.

Strainer
Any dirt or residue in circuit water causes damage got boiler and circuit components and decreases efficiency by reducing heat transfer. In order to prevent this problem a strainer must be connected to circuit.

Air Separator
The air in the water dissolves due to increasing temperature and flow in the circuit. Dissolved air causes cavitation, sound and efficiency loss. By using an air separator air is removed from the system.
The hydraulic system design must comply with the circuit diagrams specified in the user manual to ensure that the system operates smoothly and that installation errors do not result in loss of efficiency. The hydraulic system must have a balance vessel, sediment trap, air separator and expansion tank in accordance with the system capacity and specifications.

In order to keep the pH value in balance, passing the water circulating in the system through a softening step (Reverse osmosis systems) will be useful in the continuity of the water quality.

WATER QUALITY

1. Before connection of condensing boilers any dirt and residue in circuit must be cleaned.
2. Water Hardness and pH measurements should be made by the authorized or central service in the field where the boiler will be commissioned before the commissioning, and it should be decided whether the water can be used in the boiler water installation.
3. Refined water must be used while adding water to heating circuit due to any loss in closed circuit.
4. Permitted water hardness for the water used in water circuit must comply with French or German (VDI 2035) hardness degree standards. The lime dissolved in water, settles on hot surfaces and forms an insulation layer when water temperature rises. This prevents heat transfer and high temperature might damage the heat exchanger. If boiler water cycles through water circuit, all circuit water must meet above requirements. If a plate heat exchanger separates boiler water and heating circuit water, only the water between boiler and heat exchanger must meet these requirements.
   In order to prevent sedimentation, properties of the water to be used or to be reinforced in the water line should not exceed the following table values according to below mentioned capacities. Boiler Type| Capacity| (Total Hardness)
   ---|---|---
   ppm| (°F) French| VDI German
   Single Boiler| 0-50 kW| 250| <| 25| <| 14
   Single Boiler| 50-200 kW| 110| <| 11| <| 6,16
   Single Boiler| 200- 600 kW| 40| <| 4| <| 2,24
   Single / Cascade| >600 kW / All capac.| 2| <| 0,2| <| 0,112

Volume to capacity ratio of water in circuit must be higher than 20 I/kW. Total volume of first filled water and additional water must be less than volume of system.

5. The customer or contract company should analyze the water to be used in the water line by an accredited organization prior to commissioning and a water quality report should provided containing Minimum Hardness, pH and conductivity values, total dissolved solid values .
6. pH value of unrefined water must be 7<pH<9. This pH value can be achieved after filling the circuit with main circuit water with pH value of 7 and air separation. pH value of refined water must be between 7-8,5 pH.
7. In new building installations, periodic preventive maintenance must be carried out by using organic solutions with a chemical pH effect [neutral].
8. Prior to commissioning of condensing boilers in old building water installations, a suitable type of organic solution with a pH value (acidic) between 4 and 6 should be washed.
9. The boiler water pipeline and heat exchanger should be treated with a suitable type of organic solution over a period of 6 to 12 months to prevent calcification and deposits that may occur over time in the installation.
10. If the water quality is outside the value ranges given above, it is mandatory to use a water softening filter or electrolytic limescale reducer in the system for water installations.

TECHNICAL DATA

Capacity Table

CELL CONDENSE-SS FLOOR TYPE CONDESING BOILER

TECHNICAL SPECIFICATIONS

| ****

Unit

| CELL

CO NDENSE 300

| CELL

CO NDENSE 420

| CELL

CO NDENSE 480

| CELL

CO NDENSE 600

| CELL

CO NDENSE 720

| CELL

CO NDENSE 900

| CELL

CO NDENSE 1040

| CELL

CO NDENSE 1210

| CELL

CO NDENSE 1310

| CELL

CO NDENSE 1510

| CELL

CO NDENSE 1810

Thermal Capacity
Maximum Heating Capacity| kW| 284| 400| 463| 565| 695| 849| 1003| 1151| 1242| 1418| 1700
Minimum Heating Capacity| kW| 40| 56,8| 79,5| 80| 119| 119,5| 160| 197| 200| 200| 241
Maximum Heat Output (80°C / 60°C)| kW| 276| 392| 450,8| 552| 676,2| 828| 980| 1127| 1225| 1380| 1656
Minimum Heat Output (80°C / 60°C)| kW| 39| 55,6| 77,6| 78| 116,4| 117| 156| 194| 195| 195| 234
Maximum Heat Output (50°C / 30°C)| kW| 302| 420| 484| 604| 726| 906| 1048| 1210| 1310| 1510| 1812
Minimum Heat Output (50°C / 30°C)| kW| 43| 61,6| 85.2| 86| 127.8| 129| 172| 213| 215| 215,0| 258
Thermal Efficiency
Efficiency @ Pmax. (80°C / 60°C)| %| 97.2| 98.0| 97.4| 97,7| 97.3| 97,5| 97.7| 97,9| 98.6| 97,3| 97.4
Efficiency @ Pmin. (80°C / 60°C)| %| 97.5| 97,9| 97.6| 97,5| 97.8| 97.9| 97,5| 98.5| 97.5| 97.5| 97.1
Efficiency @ Pmax. (50°C / 30°C)| %| 106.3| 105| 104.5| 106,9| 104.5| 106.7| 104,5| 105.1| 105.5| 106,5| 106.6
Efficiency @ Pmin. (50°C / 30°C)| %| 107.5| 108.5| 107.2| 107.5| 107.4| 107.9| 107.5| 108.1| 107.5| 107.5| 107.1
Efficiency @ %30 (30°C)| %| 108.2| 108.3| 108.1| 108.2| 108.4| 108.5| 108.6| 108.3| 108.5| 108.7| 108.9
Domestic Hot Water Circuit
Temperature adjustment range with external storage tank usage| °C| 10-65| 10-65| 10-65| 10-65| 10-65| 10-65| 10-65| 10-65| 10-65| 10-65| 10-65
Central Heating Circuit
Maximum Operating Temperature| °C| 90| 90| 90| 90| 90| 90| 90| 90| 90| 90| 90
Water Volume| L| 14| 28| 28| 36| 42| 56| 56| 70| 90| 84| 108
Maximum Operating Pressure| bar| 6| 6| 6| 6| 6| 6| 6| 6| 6| 6| 6
Minimum Operating Pressure| bar| 1| 1| 1| 1| 1| 1| 1| 1| 1| 1| 1
Gas Specifications
Gas Type| –| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31| G20-G31
Gas Inlet Pressure (G20)| mbar| 20| 20| 20| 20| 20| 20| 20| 20| 20| 20| 20
Gas Inlet Pressure (G31)| mbar| 37| 37| 37| 37| 37| 37| 37| 37| 37| 37| 37
Maximum gas consumption| Nm³/h| 29.81| 41.70| 47.95| 59.63| 71.93| 83.39| 104,24| 119.90| 149.10| 143.88| 178.92
Minimum gas consumption| Nm³/h| 4.16| 5.92| 8.32| 8.32| 12.48| 11.84| 16.64| 20.80| 20.80| 24.96| 24.96
Combustion Specifications
Maximum Flue Gas Temperature (50°C / 30°C)| °C| 45| 45| 45| 45| 45| 45| 45| 45| 45| 45| 45
Maximum Flue Gas Temperature (80°C / 60°C)| °C| 65| 65| 65| 65| 65| 65| 65| 65| 65| 65| 65
NOx Emission Class (EN 15502-1+A1)| –| 6| 6| 6| 6| 6| 6| 6| 6| 6| 6| 6
Electrical Specifications
Electrical Supply| V / Hz| 230/50| 230/50| 230/50| 230/50| 230/50| 230/50| 230/50| 230/50| 230/50| 230/50| 230/50
Protection Class| IP| X4D| X4D| X4D| X4D| X4D| X4D| X4D| X4D| X4D| X4D| X4D
Energy Consumption| W| 600| 800| 800| 1200| 1200| 1600| 1600| 2000| 2000| 2400| 3600
Fuse Current| A| 6| 6| 6| 6| 6| 6| 6| 6| 6| 6| 6
Heat Exchanger – Stainless Steel
Heat Exchanger Quantity| Number| 2| 4| 4| 4| 6| 6| 8| 10| 10| 10| 12
Circuit Specifications
Gas Connection Diame ter| inch| 1 1/2″| 2″| 2″| 2″| 2″| 2″| 2″| 2″| 2″| 2″| 2″
Central Heating Circuit Inlet/Outlet Diameter| inch| 3″| 3″| 3″| 3″| 3″| 5″| 5″| 5″| 5″| 5″| 5″
General Specifications
Net Weight| kg| 258| 420| 476| 515| 714| 840| 986| 1190| 1288| 1428| 1546
Flue Diame ter (Ø)| mm| 200| 200| 200| 200| 250| 250| 250| 300| 300| 350| 350
G 20 Natural Gas, G 31 LPG

Condensing Boiler Dimensions

• Prevent strong impacts on top of the product and vibration while handling the product.
• Do not leave the product in wet environment.

Clean the inside of fuel line thoroughly before installing the burner to the fuel line. Any damage that may occur due to solid objects and metal particles from the fuel line shall not be covered by our company.

Noise Level
When the condensing boiler is in operation, the maximum noise level released is <90 dBA. The noise level value corresponds to the value measured with semi- anekoik (semi-unreflecting acoustic) room testing according to the product standards at the time of expansion of the smoke release system, when the condensing boiler operates at the maximum heating power.

INSTALLATION

General Controls

• The heating capacity of the device should be determined based on the heat requirement calculated.
• All parts necessary for the system must be available.
• Make sure that all protection and safety devices are available.
• In order to prevent accumulation of dirt in the system, prevention of boiler operation and damage given to the boiler by clogging, a filter must be mounted onto the system’s return pipe.
• The device is equipped with a freezing protection system to switch the device to the heating mode when the temperature of distribution water drops below + 4 ˚C.
• Ensure that the gas connections are made with pipes confirming to the standards, and that there is no leakage on these connections.
• Ensure that the electric connections are proper.
  During cascade installation, do not forget to mount an external gas cut-off valve suitable to the devices.

Electrical Connection
Perform electrical connections according to the diagram provided. Follow general security rules during installation of electric wiring and making connections. Connect the earthing terminal in electric panel to the earthing installation.

External Outdoor Sensor (Optional)
Connect the sensor to the relevant terminal. The length of electric cable for external sensor connection is max. 25 m. A 2×1.5 cable should be used. The sensor must not be exposed to the morning sun and if possible, to direct sunlight. Since the values to be read by the sensor will be affected, it must not be mounted close to any window, door, vent hole and heat sources.

Unsuitable places to mount external sensor;

STACK CONNECTIONS

1. Horizontal stack extensions must be connected to boiler at 1.5°-3° angle in order to drain condensing fluid.
2. Stack setup must be according to local ventilation conditions.
3. Stack connections must be leak proof.
   Some examples of stack setup can be seen below:

• According to the EN 13501-1 8.102.2.7 clause, all the materials used in the boilers are in the Reaction to Fire limit Class F.
• The combustion products discharge materials used in the boiler have 0 (zero) heat resistance according to the EN 13501-1 8.102.1 clause.

ASSEMBLY

Assembly Instructions

Condensing boilers are designed to work as CASCADE; they are compatible for side by side or back to back operation. They provide suitable space utilization for every stokehold design at required capacities.

Single/CASCADE Assembly Instructions

1. Mount the boiler to wall by using assembly equipment shipped with your boiler.
2. 500 mm of gap between boilers is advised.

There must be at least 500 mm of gap between adjacent boilers and at least 500 mm of space in front of the boiler for ease of service.

Assembly of Condensing Fluid Drain

1. Ensure that siphon is fully filled with water before activation of boiler.

2. Drain direction must allow flow of condensing fluid. Drain pipe must be planned to prevent any clogging due to external effect like frost, etc. Drain parts must be plastic.

3. Boiler condensing outlet must be at least 19mm.

• Condensing drain must not be changed or clogged after assembly. Clogging of condensing drain causes the boiler to automatically shut down or causes the siphon to overflow. It will be helpful to pour some hot water to the open parts of drain if there is a possibility of frost. Drain must be open at all times to ensure proper functioning of the boiler.
• Condensing Water Syphon should be cleaned from dust and dirts in every 3 months and also beginning of every winter.

CONTROL INSTRUCTIONS BEFORE START-UP

1. Ensure that boilers are mounted on fixed, firm and robust wall. Use metal hangers on improper walls.
2. Ensure that every boiler has connected to their own 6A fuse.
3. Maximum operation pressure is 6 bars in the closed circuit. Ensure that in CASCADE SYSTEMS, Balance tank is used below 6 bars and plate heat exchanger is used above 3 bars. In situation where plate heat exchanger is used, Expansion tanks with proper capacities must be used at both outgoing and return lines.
4. In single or CASCADE applications, safety valve fixed to 6 bars must be used. Adjustable safety valve must not be used. As a minimum requirement of the system, use the safety valve as shown in the package/hydraulic schematic.
5. Control the sufficiency of capacity of circulation pump used in primer circuit (between boiler and balance tank).
6. In single and cascade-type condensing boiler systems, flue pipe connections should be assembled in a compatible direction and angle and also in a sealed manner according to the boiler condensate outputs. Chimney connections must be made in the form of air suction or hermetic chimney connection directly from the environment in accordance with the standard rules.
7. Ensure that there are components such as automatic air vent, air separator and dirt/sediment retainer on the system and that it is used in sufficient volume and quantity according to the scheme for the relevant installation model.
8. A manometer to monitor system pressure must be present in system, control if it is mounted on the system.
9. Control if the condensing fluid siphon is made of plastic, isolated against frost, at correct radius and connected to condensing fluid drain with an angle. It should not be connected to rain drain.
10. Ensure that circuit and system are tested against leakage and systempressure is sufficient.
11. Ensure that gas pressure complies with boiler operation instructions. In situations where gas pressure is higher than required pressure, a regulator must be used.
12. Ensure that sensors on boiler feed and circuit (outgoing-return temperature, ambient temperature, boiler temperature sensors) are wired correctly. Wires of boiler feed and other equipment on circuit belong to user.
13. Shut-off valve must be installed as safety device on the line where gas pressure is reduced from 300 mbar to 21 mbar pressure by regulator.
14. In boiler installations with 6 or more capacity of 200 kW and higher, depending on design and consumption of the gas line, it must be divided into 2 or more sections and should be installed with the additional regulators.
15. In case of an imbalance in electrical installation’s voltage value, It is recommended to install a voltage regulator of 1 kw, up to 550 kw capacity and 2 kw; for capacities over 550 kW in order not to damage the electronic card on the device.
16. In the regions with cold and minus winter conditions, only Propylene Glycol containing Anti-freeze liquid is allowed to use as a frost protection liquid for boilers, Content suitability It is advised to interview with the manufacturer about Suitable liquid content.

On first start-up if there is deficiency in the system detected by authorized service technicians, technicians are not allowed to activate the system.

Do not connect the circulation pump as the engine will be above and the engine will be below.

Cleaning of Water and Gas Line

1. Before the installation of condensing boiler gas lines, the internal surfaces of the gas pipes must be thoroughly cleaned. Damage to the solids, metal particles and contaminants accumulated in the gas line should be considered except for the warranty.
2. During the assembly of newly manufactured water line installations, harmful objects such as metal, slag, stone, sludge, which remain in the pipe, must be washed and emptied before commissioning the boilers.
3. In areas where there is deep water or transportation type water, condensate boilers should not be allowed to be commissioned before the water in the system has passed through a number of processes such as conditioning and softening.
4. In case of obsolete and deformed area and installation conditions where the risk of corrosion is particularly intense and in which the risk of sedimentation is high, it is necessary to ensure effective protection of the boilers after commissioning by adding a magnetic dirt retainer to the water line.

ELECTRICAL DIAGRAM

1. IGNITION TRANSFORMER
2. GAS VALVE
3. FLUE GAS SENSOR
4. CASCADE SENSOR
5. CASCADE SENSOR
6. BOILER SENSOR
7. OUTSIDE SENSOR
8.  PRESSURE SENSOR 0-4 bar
9.  CASCADE MODULE
10. RETURN WATER TEMPERATURE
11. FLOW WATER TEMPERATURE
12. BMS
13. DISPLAY
14. FAN
    • A – PWM 24V DC
15. CH PUMP
16. BOILER PUMP
17. CONDENSING BOILER PUMP
18. LIMIT THERMOSTAT 0-130 °C

COMMISSIONING

Before Commissioning

• Open all open/closed valves between the device and systems.

• Check gas connections by using foam and water solution for determining leakages on connections carefully.

• Check the initial pressure of expansion tank.

• Fill the water system.

• You should check that air separator works and cap of automatic air discharge is open while the gas valve is closed.

• First adjust the plumbing pressure proper value (1-3 bar is advised), hold the Manual
  Mode button down for 5 sec. The deaeration function will be active on the screen. When this function is active, observe that the boiler is performing the aeration process.The circulation pump will circulate the water and air in the system will be purged from automatic air separator.The boiler will start deaerating and this will continue for 10-15 minutes.

• Remove the air in radiators.

• Check the air in the system after removing air form radiators.
  If there is air in the system repeat the deaeration process.

• Check if the system pressure is over 1 bar. If it is under 1.2 bar there will be a warning on the screen. If it is under 1 bars, system will give an error code (118). In this case check the system pressure and air in the system (If plumbing pressure drops often do not start the boiler without determining the cause and call an authorized service).

• Fill the condensing siphon according to manual before starting the boiler. There is a risk of gas spreading to boiler room while the siphon is empty.

• Ensure that there is no leakage in the water circuits, connections and boiler.

• Make sure that the electrical connections are correct and the grounding is sufficient.

• Check the accuracy of required gas pressure value.

• Make sure that there is no flammable material adjacent to the boiler.

This product has an automatics air separator. While performing filling or first start up operations, be sure that there is no air in the system via air separator or manually.

For automatic water filling, equip the system with proper equipment.

Checks During Commissioning

• Switch on the device.
• Ensure the soundness of oil circuit and water system.
• When the boiler is in operation, check sufficiency of flue and water pipes.
• Check the soundness of condensation system and ensure its correct operation.
• Make sure that water circulation takes place properly.
• Make sure that gas valve is operating correctly.
• Check the eligibility of values at minimum and maximum capacities by using a flue gas analyz
• Check the compatibility of gas consumption with the values on the technical data table.
• Make sure that parameters are programmed correctly.

ADJUSTING COMBUSTIN PARAMATERS

Instructions below are specially prepared for the manufacturers service technicians. Before shipment ,parameters of all the boilers are adjusted at suitable capacity and pressure at factory’s test stand. Settings mentioned below are for combustion optimisation at field conditions. Appropriate allen keys and wrenchs must be used for screws and caps. Gas and air values must be adjusted by using a flue gas analyser.

Adjustment and Measurement Points

• A: Throttle Adjustment Point
• B : Gas Feed Pressure Measurement Point
• C: Offset Adjustment Point
• D: Burner Gas Pressure Managament Point

During adjusting parameters follow below step;

1. Minimum capacity activation and combustion adjustment
2. Medium capacity emission control
3. Maximum capacity combustion adjustment and control
4. Minimum-maximum capacity combustion adjustment control

CONTROL PANEL BUTTON SPECIFICATIONS

Control of all boilers and fault information of auxiliary boilers can be viewed on the screen and fault lamps.

Adjusting Minimum Capacity

1. Connect probe of flue gas analyzer to measurement point.
2. Connect a manometer to the gas feed pressure measurement point and control if the pressure is at suitable value.
3. In order to operate the boiler at minimum capacity activate protection mode via A button.
4. Press selecting heating button for 4 seconds (“Controller stop function on “)will be seen on the screen, by pressing Displaying information button, capacity value can be seen on the screen). Via Adjusting of room Comfort setpoint button set boiler capacity to 10%. Later when you press OK button, boiler will start working at minimum capacity.
5. According to flue gas measurement values at minimum capacity, use A and C points for gas flow rate. Use A point for coarse setting for gas flow rate and C point for precise gas flow rate. For both points, turning clockwise increases flow rate and turning counterclockwise decreases flow rate.

Adjusting Medium Capacity

1. Via Adjusting of room Comfort setpoint button set boiler capacity to 50%. Later when you press OK button, boiler will start working at medium capacity. Control the flue gas values and start adjusting maximum capacity if flue gas values are ok.

Adjusting Maximum Capacity

1. Via Adjusting of room Comfort setpoint button set boiler capacity to 100%. Later when you press OK button, boiler will start working at medium capacity.
2. According to flue gas measurement values at maximum capacity, use A and C points for gas flow rate. Use A point for coarse setting for gas flow rate and C point for precise gas flow rate. For both points, turning clockwise increases flow rate and turning counter clockwise decreases flow rate.

Check the emission values at minimum and maximum capacities again and adjust combustion parameters precisely by following above steps.
After adjustment of parameters are finished, close all measurement points as they will be leak proof.

Flue gas emission values and flue gas temperature limit values are given at below table:

Adjsuting Time Schedule

1. Press ESC button several times in order to get main screen.
2. Press “OK” button when you are at main screen. “Time and day adjusment” line will be seen on the screen. Press “OK” again and select related line.
3. In order of clock, year and month informations will blink.
4. Set the blinking value and press “OK” after each setting.

MAINTENANCE

Monthly Maintenance
Monthly maintenance is a comprehensive process where general checks of condensing boiler and peripheral components are performed to prevent possible faults. After completion of maintenance and adjustment processes, make sure to perform an emission analysis.

• Clean gas and water line filters.
• Perform insulation measurements of ignition and ionization electrodes, replace electrodes should there be leakage to the body.
• Check ignition cables and sockets.
• Check all wiring points. Tighten loose connections.
• Check gas line pressure, it must be the same with the first adjusted pressure, otherwise the boiler load and emission values will also have changed.
• Check all bolts of the boiler. Tighten loose bolts.
• After starting the condensing boiler and making required adjustments, perform flue gas emission measurement and check if there is an ideal combustion.

Seasonal Maintenance

It is a comprehensive maintenance work when the condensing boiler is re- started after long periods of shut-down or interruptions. After completion of maintenance and adjustment processes, make sure to perform a combustion analysis.

• Check ignition and ionization electrodes.
• Check the operating function.
• Check the inlet/outlet water sensors.

Condensing Water Syphon should be cleaned from dust and dirts in every 3 months and also beginning of every winter.
Follow installation directions during maintenance.
Periodic maintenance shortages in condensing boilers can cause carbon monoxide poisoning.

When an operation is performed with the system water pressure, it is necessary to carry out the air removal process due to reasons such as water loss and fill from water installation during seasonal and monthly maintenance.

LIST OF ERROR CODE

Error Code| LPB

Code

| Error Description
---|---|---
10|  | Exterior temperature, sensor error
20|  | Boiler temperature 1, sensor error
25|  | Solid fuel boiler temperature, sensor error
26|  | General flow water temperature, sensor error
28|  | Flue gas temperature, sensor error
30|  | Flow water temperature 1, sensor error
31|  | Flow water temperature 1, cooling, sensor error
32|  | Flow water temperature 2, sensor error
38|  | Flow water temperature, main control device, sensor error
40|  | Return water temperature 1, sensor error
46|  | Cascade return water temperature, sensor error
47|  | General return water temperature, sensor error
50|  | DHW temperature 1 sensor error
52|  | DHW temperature 2 sensor error
54|  | Flow water temperature DHW, sensor error
57|  | DHW, recirculation sensor error
60|  | Room temperature1, sensor error
65|  | Room temperature 2, sensor error
68|  | Room temperature 3, sensor error
70|  | Storage tank temperature 1 (top), sensor error
71|  | Storage tank temperature 2 (bottom), sensor error
72|  | Storage tank temperature 3 (middle), sensor error
73|  | Collector temperature 1, sensor error
78|  | Water pressure, sensor error
82|  | LPB address conflict
83|  | No BSB cable sectional/communication
84|  | BSB cable address conflict
85|  | BSB RF communication error
91|  | Data overwork at EEPROM
98|  | Additional module 1, error
99|  | Additional module 2, error
100|  | 2 timer leader
102|  | Leader timer without redundancy
103|  | Communication error
105|  | Maintenance message
109|  | Boiler temperature control
110|  | STB (SLT) locking
111|  | Temperature limit safety closing
---|---|---
117|  | Water pressure is very high
118|  | Water pressure is very low
119|  | Water pressure switch disengaged
121|  | Heating circuit 1 flow water temperature not reached
122|  | Heating circuit 2 flow water temperature not reached
125|  | Maximum boiler temperature exceeded
126|  | DHW supply temperature not reached
127|  | DHW legionella temperature not reached
128|  | Flame loss in operation
129|  | Incorrect air supply
130|  | Flue gas temperature limit exceeded
132|  | Gas pressure switch safety shut down
133|  | Safety time for flame formation exceeded
146|  | Sensor/control element configuration error
151|  | LMS14… internal error
152|  | Parameter error
153|  | Device is manually locked
160|  | Fan speed threshold not reached
162|  | Air pressure switch is not closing
164|  | Flow/pressure switch, heating circuit error
166|  | Air pressure switch error, it is not opening
169|  | Sitherm Pro system error
170|  | Water pressure sensor error, primary side
171|  | Alarm contact 1 is active
172|  | Alarm contact 2 is active
173|  | Alarm contact 3 is active
174|  | Alarm contact 4 is active
176|  | Water pressure 2 is very high
177|  | Water pressure 2 is very low
178|  | Heating circuit 1 temperature limiter
179|  | Heating temperature 2 temperature limiter
183|  | Device is in parameter mode
195|  | Maximum time per charging exceeded
---|---|---
196|  | Maximum time for charging per week exceeded
209|  | Heating circuit error
214|  | Motor monitoring
215|  | Diverter valve fan air error
216|  | Boiler error
217|  | Sensor error
218|  | Pressure control
241|  | Flow sensor error for efficiency measurement
242|  | Return sensor error for efficiency measurement
243|  | Pool sensor error
260| 217| Flow water temperature 3rd sensor error
270| 215| Heat exchanger temperature difference is too high
317| 214| Mains frequency out of acceptable range
320| 217| DHW supply temperature, sensor error
321| 217| DHW outlet temperature, sensor error
322| 218| Water pressure 3 is too high
323| 218| Water pressure 3 is too low
324| 146| BX inlet, same sensor
325| 146| BX inlet/additional module, same sensor
326| 146| BX inlet/mixture group, same sensor
327| 146| Additional module, same function
328| 146| Mixture group, same function
329| 146| Additional module/mixture group, same function
330| 146| Sensor inlet BX1 no function
331| 146| Sensor inlet BX2 no function
332| 146| Sensor inlet BX3 no function
333| 146| Sensor inlet BX4 no function
335| 146| Sensor inlet BX21 no function
336| 146| Sensor inlet BX22 no function
339| 146| Collector pump Q5 is lost
340| 146| Collector pump Q16 is lost
341| 146| B6 sensor is lost
342| 146| Solar energy supply B31 sensor is lost
343| 146| Solar energy integration is lost
344| 146| Solar energy control element spare tank K8 is lost
345| 146| Solar energy control element pool K18 is lost
346| 146| Solid fuel boiler pump Q10 is lost
347| 146| Solid fuel boiler analogy sensor is lost
348| 146| Solid fuel boiler address error
349| 146| Accumulation tank return valve Y15 is lost
350| 146| Accumulation tank address error
---|---|---
351| 146| Main control device/system pump, address error
352| 146| Unpressurized cap, address error
353| 146| B10 sensor is lost
371| 209| Heating circuit 3 flow water temperature
372| 209| Heating circuit 3 temperature limiter
373| 103| Additional module 3
374| 169| Sitherm Pro calculation
375| 169| BV step motor
376| 169| Drift test limit value
377| 169| Drift test is prevented
378| 151| Internal recurrence
382| 129| Recurrence speed
384| 151| Auxiliary light
385| 151| Mains low voltage
386| 129| Fan speed tolerance
387| 129| Air pressure tolerance
388| 146| DHW sensor, no function
426| 151| Flue gas damper feedback
427| 152| Flue gas damper configuration
429| 218| Dynamic water pressure is too high
430| 218| Dynamic water pressure is too low
431| 217| Primary heat exchanger sensor
432| 151| Grounding function is not connected
433| 216| Primary heat exchanger temperature is too high

SOLUTION RECOMMENDATIONS FOR SOME OF THE PROBLEMS

is required. Be sure that measurement points are closed.
Unburned gas smell| Flue tightness| Be sure that flue connections are leak proof and measurement points are closed. Check the combustion parameters.
Incomplete combustion| Gas supply pressure| Check the gas pressure complies with stated values.
Fan problem| Check the working of fan.
State of premix combustion head and heat exchanger| ****

Check the state of combustion head and heat exchanger and ensure that both are clean.

Combustion air connection| Check that there is nothing that blocks air suction and if the impulse connection is correct.
Shaky activation of burner| Gas pressure/Combustion parameters| Check the gas pressure and combustion parameters.
No combustion after ignition| Electrode/Ionization| Check the position/state of the electrode/ionization rod.
Boiler does not work.| Electric connection| Check the fuse and electrical connections.
Sensor connections| Ensure that connections of sensors are correct and complete.
Boiler can’t reach the desired temperature.| Gas pressure| Ensure that gas pressure complies with stated values and there is constant gas flow at sufficient pressure.
Heat exchanger| Control the state of combustion chamber.
Boiler control| Control that boiler is at correct operation mod and temperature settings.
Safety valve activates often.| Safety valve| Ensure that safety valve settings are correct and works properly.
Expansion tank| Check if it works properly.
Pump does not work.| Pump malfunction| Check the pump electric connections and parameters. Change the pump if there is proble in pump operation.

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