IST 03 C 192 - 01
BALI B
BTNE 25 - BTNE 32 - BTNE 42
BTFSE 24 - BTFSE 32 - BTFSE 36
GB
INSTALLATION, USE
AND MAINTENANCE
Dear Customer,
Thank you for choosing and buying one of our boilers. Please read these instructions carefully in order to
install, operate, and maintain this equipment properly.
1
General information for the installer, maintenance technicians and users
This INSTRUCTION MANUAL,
which is an integral and indispensable part of the product, must be
delivered to the user by the installer
and must be kept in a safe place for
future reference. The manual must
accompany the boiler should it be
sold or its possession transferred.
Keep the packaging out of the reach Should there be a risk of freezing,
of children as by its nature it may add antifreeze: it is not advisable
represent a hazard.
to empty the system as this may
result in damage; use specific antiIn the event of failure and/or faulty freezing products suitable for multifunctioning, switch off the boiler. Do metal heating systems.
not attempt to repair it and contact a
qualified service technician.
IMPORTANT
The boiler must be used for the
purposes for which it has been
intended. Any other use shall be
considered incorrect and therefore dangerous.
Manufacturer-approved parts must Should gas smell be perceived probe used for all repairs to the boiler. ceed as follows:
Non-observance of the above requirements may affect the safety of
the boiler and endanger people,
The boiler must be installed in com- animals and property.
pliance with applicable laws and
standards and according to the The manufacturer recommends
manufacturer’s instructions given in our Customers to have the boiler
this manual. Incorrect installation serviced by an Authorized Service
may cause injury to persons and/or Centre.
animals and damage to property.
The manufacturer shall not be held In order to guarantee efficient
liable for any such injury and/or and correct functioning of the
damage.
equipment it is legally binding to
have the boiler serviced once a
Damage and/or injury caused by year, according to the schedule
incorrect installation or use and/or specified in the relevant section
damage and/or injury due to non- of this manual.
observance of the manufacturer’s
instructions shall relieve the manu- In the event of long periods of inacfacturer from any and all contractual tivity of the boiler, disconnect it from
and/or extra-contractual liability.
power mains and close the gas tap
(Warning: the boiler anti-frost funcBefore installing the boiler, check tion is disabled).
the technical data to be compatible
with the requirements for its operation in the system.
Check that the boiler is intact and it
has not been damaged during transport and handling. Do not install
equipment which is damaged and/
or faulty.
Do not obstruct the air suction and/
or heat dissipation openings.
Only manufacturer-approved accessories and optional kits are to be
installed.
- do not turn on or off electrical switches and do not turn on
electrical appliances;
- do not ignite flames and do not
smoke;
- close the main gas tap;
- open doors and windows;
- contact a Service Centre, a qualified installer or the gas supply
company.
Never use a flame to detect gas
leaks.
WARNING
This boiler has been built for installation in the country indicated on
the technical data plate: installation in any other country may be source of danger for people, animals and property.
Properly dispose of the packaging
as all the materials can be recycled.
The packaging must therefore be
sent to specific waste management
sites.
2
TABLE
OF CONTENTS
General information for the installer, maintenance technicians and users page 2
1. Instructions for the user page 4
1.1.Control panel 1.2.Operating the boiler 1.2.1. Switching on 1.2.2. Operation
1.2.2.1. AQUA PREMIUM system
1.2.2.2. Instantaneous DHW production
1.2.2.3. Thermal unit managing one high temperature CH area and DHW supply
1.2.2.4. Thermal unit managing one mixed water CH area, one high temperature CH area and DHW supply (V version)
1.2.2.5. Anti-Legionella function
1.2.2.6. Pump anti-seizure function
1.2.2.7. Phone operation function
1.2.3. Electronic programmer setup
1.2.4. Boiler shutdown 1.2.5. Burner shutdown
1.2.6. Shutdown due to overheating
1.2.7. Shutdown due to air/flue gas system malfunction
1.2.8. Shutdown due to insufficient water pressure
1.2.9. Shutdown due to malfunction of temperature probes
1.3.Maintenance 1.4.Information for the user page
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2. Technical characteristics and dimensions page 10
2.1.Technical characteristics
2.2.Dimensions 2.3.Boiler layout
2.4.Operational data
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3. Instructions for the fitter page 14
3.1.Installation standards
3.2.Installation 3.2.1. Packaging 3.2.2. Choosing where to install the boiler 3.2.3. Positioning the boiler 3.2.4. Boiler room ventilation
3.2.5. Air/flue gas system configuration
3.2.6. Verifying combustion efficiency
3.2.7. Gas main connection
3.2.8. Power main connection
3.2.9. Hydraulic connections
3.2.10. Room thermostat connection
3.2.11. Adjustable by-pass 3.2.12. Installation of original kits
3.3.Loading the system 3.4.Starting the boiler 3.4.1. Preliminary checks 3.4.2. On/off switching
3.5.Wiring diagram 3.6.Switching to different gas and burner adjustment
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4. Maintenance 5. Troubleshooting page 21
page 22
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1. INSTRUCTIONS FOR THE USER
1.1 Control panel
1
pic. 1
2 3
16
4
5
6 7 8
17
9 10
11
12
18
1. Indication light (red): when the light is on, it indicates that the
flame detection electronics have shut down the boiler. Boiler reset
is operated through switch no. 16.
2. Indication light (red): when the light is on, it indicates that the
safety thermostat has shut down the burner. The boiler will automatically resume operation by resetting the safety thermostat through
button no. 18.
3. Indication light (green): when the light is on and fixed, it indicates that power is supplied to the flame detection pcb (flame might
still not be present.
4. Indication light (red): when the light is on and fixed, it indicates
that the temperature of the water in the heating system is between
25°C and 35°C.
When the light is blinking, it indicates that the water pressure switch
has detected insufficient water pressure. When operational water
pressure is restored, the water pressure switch will resume boiler
operation and the led will turn off.
5. Indication light (red): when the light is on and fixed, it indicates
that the temperature of the water in the heating system is between
36°C and 45°C.
When the light is blinking, it indicates that the temperature probe
no. 1 (CH flow) is faulty (interrupted or out of range). The burner is
shut down, pumps still operate. As soon as the probe is replaced,
the led will turn off and the boiler will resume operation.
When indication lights no. 4 and no. 5 flash simultaneously, it indicates that the external temperature probe (optional equipment) is
faulty or disconnected. Once the probe is replaced or re-connected,
the lights will turn off.
6. Indication light (red): when the light is on and fixed, it indicates
that the temperature of the water in the heating system is between
46°C and 55°C.
When the light is blinking, it indicates that the connection between
boiler and remote control is interrupted or there are signal passage
difficulties. Once the connection is restored the light will turn off and
the boiler will resume operation.
7. Indication light (red): when the light is on and fixed, it indicates
that the temperature of the water in the heating system is between
56°C and 65°C.
When the light is blinking, it indicates that the temperature probe
no. 2 (water tank) is faulty (interrupted or out of range). The boiler
operates in CH and instantaneous DHW supply mode only. As soon
as the probe is replaced, the boiler will resume operation.
8. Indication light (red): when the light is on and fixed, it indicates
that the temperature of the water in the heating system is between
66°C and 75°C.
When the light is blinking, it indicates that the temperature probe no.
3 (plate heat exchanger) is faulty (interrupted or out of range). The
boiler operates in CH supply mode only. As soon as the probe is
replaced, the boiler will resume operation (including DHW supply).
13
14
15
19 (BTN)
9. Indication light (red): when the light is on and fixed, it indicates
that the temperature of the water in the heating system is between
76°C and 85°C.
When the light is blinking, it indicates that CH water temperature
has exceeded 85°C.
The led can also be turned on by the flue gas thermostat (BTN boiler model). Reset of the flue gas thermostat is to performed through
button no. 19.
10. Indication light (green): when the light is on and fixed, it indicates that the boiler is operating in CH mode.
11. Boiler mode selector: this selector allows to choose the boiler
mode (please, refer to paragraphs 1.2.2.3. and 1.2.2.4.).
12. DHW supply knob: the knob allows for DHW supply mode
management (please, refer to 1.2.2.3 and 1.2.2.4 paragraph).
13. CH water temperature knob: the knob allows for CH mode
management (please, refer to 1.2.2.3 and 1.2.2.4 paragraph).
14. Water pressure gauge: it shows water pressure in the heating
system.
15. Programmer: the programmer can be set for CH and DHW
supply scheduling (please, refer to 1.2.2.3 and 1.2.2.4 paragraph).
16. Reset button: press the button to restore boiler operation after
shut down due to flame non-detection.
17. Power switch: when the switch is in position I, power is supplied to the boiler and the switch is lit. When the switch is in position
O, power is not supplied to the boiler and the switch light is off.
18. Reset button: press the button to restore boiler operation after
shut down due to safety thermostat intervention.
19. Reset button (BTN model only): press the button to restore
boiler operation after shut down due to flue gas safety thermostat
intervention (BTN boiler model).
In case of malfunction or pressure switch intervention (BTFS boiler
model) the burner is shut down. Boiler operation will resume as
soon as normal pressure range values are restored.
4
1.2 Operating the boiler
1.2.1 Switching on
-Open the gas stop cock.
-Turn power mains switch to ON.
-Set boiler power switch no. 17 (pic.1) to ON (the switch lights up)
-Choose boiler mode through knob no. 11, no. 12 and no. 13 and
the programmable programmer no. 15 (please, refer to 1.2.2.3 and
1.2.2.4 paragraph).
-Adjust room temperature through room thermostat (when available).
-When CH is required, no. 10 light comes on (pic. 1).
-When the burner is on, no. 3 light comes on (the light comes on
when the flame detection electronics are powered, therefore even
if the light is on, flame might still not be present).
WARNING
should the boiler be left inactive for a long time, particularly
when boiler is fired by LPG, ignition might be difficult. Before
starting the boiler, switch on a different gas fired device (e.g.
kitchen range, oven, etc.). Beware that even by following this
procedure, the boiler might still experience some starting difficulties and shut down once or twice. Reset boiler by acting
on no. 16 button (pic. 1).
1.2.2. Operation
The boiler is equipped with patented AQUA PREMIUM system.
1.2.2.1 AQUA PREMIUM system
The boiler is equipped with a 60 l stratification water tank and a
secondary plate heat exchanger.
The boiler can either function as a standard instantaneous boiler,
when the water tank is deactivated, or through the innovative AQUA
PREMIUM system when the water tank is switched ON.
Water tank activation and deactivation can be operated by the user
via knob no. 12 and programmer on the control board
(please, refer to 1.2.2.3 paragraph, DHW section).
When the water tank is switched ON (AQUA PREMIUM mode),
and DHW is requested, the flow switch detects the water stream;
the boiler turns ON, the cut-off valve is opened and the DHW pump
is turned ON (the pump flow rate is fixed).When DHW demand is
smaller than DHW pump flow rate, DHW to the tap is supplied by
the secondary exchanger only and the excess DHW produced is
deviated to the water tank.
When DHW demand is larger than DHW pump flow rate, DHW
produced by the secondary exchanger is joined by DHW from the
water tank; the combined DHW flow rate is larger than the one that
can be produced by instantaneous boilers of identical thermal output or standard system boilers with same capacity water tank.
The boiler can also be operated as a standard instantaneous boiler, when the water tank is disabled.
1.2.2.2 Instantaneous DHW production
While the water tank is disabled, the boiler operates as a standard
instantaneous boiler: the cut-off valve is closed and the DHW pump
is always off. In this instance DHW supply is granted by the secondary heat exchanger only and maximum available DHW flow rate
depends exclusively on the boiler thermal output.
DHW flow rate in liters per minute relies upon the boiler thermal
output and water main supply temperature, according to the following formula:
l = DHW in liters per minute = K / ΔT
5
K represents:
- 344 for BTFS 24 model
- 459 for BTFS 32 model
- 523 for BTFS 36 model
- 358 for BTN 25 model
- 450 for BTN 32 model
- 610 for BTN 42 model
ΔT = DHW temperature – water mains supply temperature
E.g. In BTFS 24 model, should water mains supply temperature be
8°C and DHW required to 38°C, the value of ΔT is:
ΔT = 38 °C – 8 °C = 30 °C
and DHW liters per minute available at the required temperature
of 38°C are:
344
l = ------------- = 11.5 [liters per minute]
30
The boilers, both BTN and BTFS modes, are divided in two families:
a) Thermal unit managing one high temperature CH area and DHW
supply
b) Thermal unit managing one mixed CH water area, one high temperature CH area and DHW supply (“V” version)\\
q>.
1.2.2.3 Thermal unit managing one high temperature CH area
and DHW supply
Position no. 17 switch to I: power is connected to the boiler and the
switch lights up.
Boiler operation mode is selected through knob no. 11. In detail:
“Programmer” position
The boiler electronics manage the program set via the two-channel
programmer no. 15. The user manages CH boiler operation through
channel 1 (please, see CH section). The user manages DHW boiler
operation through channel 2 (please, see DHW section).
- CHANNEL 1 without external temperature probe.
When the programmer is OFF, CH is OFF. When the programmer
is ON, CH is managed through the room thermostat.
- CHANNEL 1 with external temperature probe.
Please, see “SLIDING” TEMPERATURE OPERATION section.
- CHANNEL 2
When the programmer is OFF, DHW is supplied by the plate
heat exchanger only.The boiler operates as a standard “instantaneous” boiler. DHW supply is not largest and enough to shower,
dishwashing, etc. When the programmer is ON, DHW is supplied
both by the plate heat exchanger and the water tank. DHW is largest in this instance.
The programmer can host up to 8 ON daily times and 8 OFF daily
times. Five programmable time areas are available in each day for
repetition of ON/OFF programs within the same week (1: single
day; 2: Mon-Fri; 3: Sat-Sun; 4: Mon-Sat; 5: Mon-Sun).
“Comfort” position.
QBoiler CH operation management only. Programmer is considered as always turned ON, regardless of its programs.
CH is turned ON or OFF by the room thermostat or thermoregulation control unit. “Comfort” position with external temperature probe: please, see “SLIDING” TEMPERATURE OPERATION section.
“Reduced” position
Boiler CH operation management only. Programmer is considered
as always turned OFF, regardless of its programs. CH is always
OFF regardless of the room thermostat or thermoregulation control
unit signals.
NOTE : boiler operation in this position without external temperature probe is the same of that in “Summer” position. “Reduced” position is desirable only when the boiler is equipped
with an external temperature probe (please, see “SLIDING”
TEMPERATURE OPERATION section).
“Anti-frost” position
Boiler is in stand-by mode. All boiler functions are inactive besides
“Anti-frost”. “Anti-frost” function protecting CH flow: when the flow
probe detects a temperature below 5°C, the boiler turns ON until
the flow temperature reaches 50°C or 15 mins.
“Anti-frost” function protecting DHW: when the water tank probe detects a temperature below 5°C, the boiler turns ON until the water
in the tank reaches 10°C or 15 mins.
“Summer” position
Boiler operates in DHW supply mode only.
DHW
DHW supply supersedes any other boiler function.
The user might set DHW parameters through knob 12, programmer
15 and the mixing valve (pic. 2).
- knob 12 allows for selection of DHW production mode (with AQUA
PREMIUM SYSTEM or “instantaneous production”) and to set
DHW temperature in the water tank (50°C to 65°C); it is recommended to set storage tank water temperature around 60°C (turn
knob clockwise almost fully);
- programmer 15 allows for selection of automatic water tank
switching on and off;
- mixing valve (pic. 2) allows to set DHW temperature to the tap.
In detail the user might choose to have DHW supplied in “instantaneous“ or “AQUA PREMIUM” system mode.
By turning knob 12 fully counter-clockwise, after a couple of seconds LED
will switch on or off.
led ON indicates “enabled water tank” mode (AQUA PREMIUM
system).
led OFF indicates disabled water tank (“instantaneous mode
boiler”).
In AQUA PREMIUM mode, setting channel 2 through the programmer, it is possible to select automatic switching on/off programs for
the water tank (see sect. 1.2.3 “Electronic programmer setup”).
NOTE
When the boiler is set to AQUA PREMIUM system mode, channel
2 settings of programmer 15 manages DHW also.
When the programmer is ON, the boiler is in “enabled water tank”
mode (AQUA PREMIUM system), when the programmer is OFF,
the boiler operates as a standard “Instantaneous” boiler (
led
is always ON).
DHW flow temperature is to be adjusted through the thermostatic
valve located in the rear area of the boiler (pic. 2).
Turn valve knob counter-clockwise (+ position) to increase DHW
temperature, turn valve knob clockwise (- position) to decrease
DHW temperature.
In order to adjust DHW flow temperature to approximately 50°C,
shut the valve off by turning its knob fully clockwise, then turn it
three and a half rotations counter-clockwise.
CH
Boiler electronics manage temperature and operation of the radiators through adjusting knob 13 and mode selecting knob 11. Knob
13 sets CH flow temperature and “warm boiler ON” – “warm boiler
OFF” functions.
In addition to that, when the boiler is equipped with an external
temperature probe, the user sets a fictitious room temperature value via knob 13 (please, see “SLIDING” TEMPERATURE OPERATION section).
Knob 13 is used to adjust two settings:
1. CH flow temperature (50°C to 90°C range).
2. Set boiler to “warm boiler ON” – “warm boiler OFF” mode.
pic. 2
When the boiler is in “warm boiler ON” mode (
led ON), the
primary heat exchanger, when CH or DHW are not required, is kept
to a constant 50°C temperature.
When the boiler is in “warm boiler OFF” mode (
led OFF), the
primary heat exchanger, when CH or DHW are not required, is not
heated and the boiler stays OFF.
In order to select “warm boiler ON” – “warm boiler OFF” mode,
proceed as follows.
-Turn CH temperature adjusting knob fully counter-clockwise.
-Wait for two seconds until the led which indicates the boiler operation mode changes its status (from ON to OFF or vice-versa)
(please, see above instructions).
-Now CH temperature can be set through the adjusting knob.
NOTE
It is convenient to set the boiler to “warm boiler ON” mode, particularly during summer and when the boiler is set to “instantaneous”
mode, because, being the boiler heat exchanger already warm, it
supports the plate heat exchanger in providing DHW more promptly.
1.2.2.4 Thermal unit managing one mixed water CH area, one
high temperature CH area and DHW supply (V version)
Boiler operation indications, malfunction diagnosis, and DHW
supply mode are identical to the thermal unit managing one high
temperature CH area and DHW supply; CH operation mode is different.
The following instructions refer to what changes in boiler without
mixed water CH area management.
Position no. 17 switch to I: power is connected to the boiler and the
switch lights up.
Boiler operation mode is selected through knob 11. In detail:
“Programmer” position
The boiler electronics manage the program set via the two-channel
programmer 15. The user manages CH boiler operation through
channel 1 (please, see CH section). The user manages DHW boiler
operation through channel 2 (please, see DHW section).
-CHANNEL 1 with external temperature probe.
Channel 1 ON: CH flow temperature (high and low temperature
areas) is managed in order to maintain the COMFORT room temperature set through knob 13.
Channel 1 OFF: CH flow temperature (high and low temperature
areas) is managed in order to maintain the REDUCED room temperature.
REDUCED room temperature = COMFORT room temperature minus 4°C; when CM4 jumper is positioned to 0 – please, see wiring
diagram section;
REDUCED room temperature = COMFORT room temperature minus 2°C; when CM4 jumper is positioned to 1).
Room thermostats turn ON or OFF the relevant zone pumps, and
when all room thermostats are set to OFF, CH demands terminate.
6
-CHANNEL 2
As described in the “thermal unit managing one high temperature
CH area and DHW supply” section.
The programmer can host up to 8 ON daily times and 8 OFF daily
times. 5 programmable time areas are available for each day, for
repetition of ON/OFF programs within the same week (1: single
day; 2: Mon-Fri; 3: Sat-Sun; 4: Non-Sat; 5: Mon-Sun).
“Comfort” position.
Boiler CH operation management only. Programmer is considered
as always turned ON, regardless of its programs. Room temperature is the one set as “COMFORT”.
Room thermostats turn ON or OFF the relevant zone pumps, and
when all room thermostats are set to OFF, CH demands terminate.
time display stops flashing also); press button 1...7 in order to set
the day of current week (displayed by indicator 8), press button h
in order to set current hour, press button m in order to set current
minutes (when h and m are simultaneously pressed, the digital
display runs fast).
Wait for approximately ten seconds until the two dots dividing hours
and minutes display start flashing. Now the day of the week and
current time setup procedure is completed.
“Reduced” position
Boiler CH operation management only. Programmer is considered
as always turned OFF, regardless of its programs. Room temperature is the one set as “REDUCED”.
Room thermostats turn ON or OFF the relevant zone pumps, and
when all room thermostats are set to OFF, CH demands terminate.
Knob 13 is disabled for CH flow temperature adjusting, it sets the
fictitious room temperature (please, see “SLIDING” TEMPERATURE OPERATION section).
KEY CHART
1 Operating mode selector
2 Programming selector
3 Channel indicator
4 Channel activation indicator
5 Indication of the programmed
period
“SLIDING” TEMPERATURE
The boiler adjusts the temperature of CH flow to the high temperature zone (temperature of the radiators) and the temperature of the
low temperature zone (floor heating) following the signals from:
-external temperature readings from the external probe
-desired room temperature to be set through knob 13. 12°C to
28°C range.
Knob 13 turned fully counter-clockwise correspond to 12°C room
temperature; knob 13 set to 09:00 hours correspond to 15°C; knob
13 set to 12:00 hours correspond to
20°C; knob 13 set to 03:00 hours correspond to 25°C; knob 13 turned fully clockwise correspond to 28°C; for
best CH curve setup, turn knob 13 to
position corresponding to 20°C;
1.2.2.5 Anti-Legionella function
Anti-Legionella function is activated
every 15 days, it consists in heating
up the water tank to 65°C for 30 mins,
regardless of all other setups.
1.2.2.6 Pump anti-seizure function
When the pumps or electric valves are left inactive for 24 hours,
the pump anti-seizure function operates the pumps and electric
valves for 3 mins.
1.2.2.7 Phone operation function
When a phone operation module is connected to the boiler pcb, the
“COMFORT” function and the loading of the boiler can be remotely
activated regardless of knob 11 position.
1.2.3 Electronic programmer setup
A. Initialization
When setting up the programmer for the first time or re-programming it, it is advisable to reset it by turning selector 2 to RUN and
pressing the reset micro-switch R: Time, ON and OFF programs
will be deleted (time display will flash 0:00).
In order to set the day of the week, current time, ON and OFF programs, please see below sections B and C.
B. Setting the day of the week and current time
Position selector 2 to RUN and press h and m buttons at the same
time, until the two dots dividing hours and minutes display stop
flashing (If the reset micro-switch R was previously pressed, the
7
6 SKIP function button
7 SKIP function indication
8 Week-day indicator
9 Current time indicator
pic. 3
C. ON and OFF program setup
Set selector 2 to P1 in order to program channel 1 and to P2 in
order to program channel 2 (display 3 indicates the number of chosen channel, indication 4 displays
symbol to indicate that we
are setting an ON time, display 5 indicates 1 as the first program is
being set; up to 8 ON and OFF intervals are available for programming, that is 16 times).
Follow the below described procedure in order to set the ON time:
- press button 1...7 in order to set the desired of the week (or days
of the week (1));
- press button h and then button m in order to set hour and minutes
of the ON time;
- press button
in order to confirm the programmed ON time and
proceed to the programming of the OFF time (indicator 4 is off and
it indicates that an OFF time is being set; indicator 5 displays 2
indicating the second time is being set).
Follow again the above described procedure, in order to set the
OFF program and after that, press
button.
Now one boiler operation interval is set through its ON and OFF
programmed times, indicator 5 displays 3; In order to set an additional ON time, follow the above instructions, or move selector 2 to
RUN in order to terminate the programming procedure.
(1)
By repeatedly pressing button 1...7, the following programmable
time areas are available in order to automatically repeat the ON
and OFF programs within the same week:
No. 1 programmable time area: single week day
No. 2 programmable time area: Monday through Friday
No. 3 programmable time area: Saturday and Sunday
No. 4 programmable time area: Monday through Saturday
No. 5 programmable time area: Monday through Sunday
When programming an ON time in a multi-day programmable time
area (e.g. no. 2), the OFF time must be set in the same programmable time area in order to make it effective to all days included in
the area.
D. Programmer operation modes
Selector 1 on the programmer sets the following boiler operation
modes:
I
permanently ON mode (the selected channel or channels
are always active)
AUTOoperation through programmed setup (the two channels, 1
and 2, are activated or deactivated following the
programmed setup; please see paragraph C for
programming procedure)
O
permanently OFF mode (the selected channel or channels
are always off)
Permanently ON mode (I)
In order to have one channel always active, proceed as follows:
Position selector 1 to position I, press once button 6 to activate
channel 1, press it twice to activate channel 2; the selected channel
will flash for 3 secs (indicator 3), after that it will be displayed fixed
and
symbol will be displayed (indicator 4), now the channel will
remain permanently active.
Selector 1 must remain set to position I.
In order to have both channel active, repeat the above described
procedure, by selecting the channel not previously activated. Indicator 3 will display 1 and 2, confirming activation of both channels
When only one of the channel is permanently activated, the other
channel is operative following its programmed setup (please, see
paragraph C for detailed programming procedure).
In order to cancel the permanent activation of channels, set selector 1 to AUTO.
Operation through programmed setup (AUTO)
This mode allows for channels to be active or inactive following the
programming setup (please, see paragraph C for programming
procedure).
When an ON/OFF interval is active,
symbol (indicator 4) and the
number of the active channel are displayed (indicator 5).
Permanently OFF mode (O)
When one channel is to be always inactive, proceed as follows:
Set selector 1 to position O, press once button 6 in order to select
channel 1, press it twice in order to select channel 2; the selected
channel will flash (indicator 3), do not press any button for 3 secs,
now the channel will be permanently inactive (indicator 3 will keep
flashing the selected channel).
Selector 1 is to be kept in position O.
In order to set both channel inactive, repeat the above described
procedure by selecting the channel that was not previously chosen.
Indicator 3 will flash 1 and 2, confirming de-activation of both channels.
When one channel is permanently deactivated, the other channel
operates following its programmed setup (please, see paragraph C
for detailed programming procedure).
In order to cancel the permanent de-activation of channels, set selector 1 to AUTO.
It is also possible to permanently activate one channel and permanently de-activate the other.
In order to implement the above described program, proceed as
follows:
set selector 1 to position I, press once button 6 in order to activate
channel 1, press it twice in order to activate channel 2; the selected
channel will flash for 3 secs (indicator 3), after it will be displayed
fixed and
symbol will be displayed (indicator 4), now the channel will be permanently active.
Rapidly set selector 1 to position O, without stopping in position
AUTO, press once or twice button 6 to select the channel to be permanently deactivated; the selected channel will flash (indicator 3),
while the previously activated channel will continue to be displayed
fixed, and
symbol will remain on (indicator 4), do not press any
button for 3 secs, now the channel will remain permanently deactivated (indicator 3 will keep flashing the selected channel).
E. SKIP function programming procedure
The SKIP function (program skipping) allows to change the operational status of the programmer from ON to OFF and vice-versa,
after pressing button 6. the SKIP function stays active until the next
programmed intervention. The activation of the function is displayed
by the
symbol.
In order to deactivate the SKIP function, press again button 6. The
SKIP function is active only when the programmer is set to AUTO
mode.
The
symbol is displayed to show the boiler ON status (indicator 4).
Technical characteristics
Power supply: 220-240V approx. 50/60Hz
Relay output: 2 x 5A; 250V approx. single poled contact
Lithium battery maintaining program memory for 5 years
Minimum commutation intermission: 1 minute
1.2.4. Boiler shutdown
When the boiler malfunctions, the burner is automatically shutdown.
Please, see the troubleshooting section in this manual, for possible
shutdown cause detection.
1.2.5 Burner shutdown
When the burner malfunctions, the boiler automatically shuts down
and light 1 turns on.
Should this happen, proceed as follows:
• check the gas stopcock to be open, and the presence of gas in the
network pipes, by lighting the burner of a kitchen stove.
• after verifying gas supply availability, reset the burner by pressing button 16 on the control panel: should the boiler not resume
operation within the third attempt, have the boiler serviced by an
Authorized Service Centre or qualified personnel.
Should the burner shut down frequently, showing a recurring malfunction, have the boiler serviced by an Authorized Service Centre
or qualified personnel.
1.2.6 Shutdown due to overheating
Should the overheating red light 2 come on, signalling the safety
thermostat intervention due to a malfunction, contact an Authorized
Service Centre or qualified personnel for service.
1.2.7 Shutdown due to air/flue gas system malfunction
Should a malfunction occur, causing air intake and/or flue gas discharge system failure, the boiler stops operating.
Natural draught boiler model (BTN) shuts down, no. 9 red light starts flashing, and this boiler status continues until correct air/flue gas
system correct operation is restored and reset button 19 is pressed.
Forced draught boiler model (BTFS) stands-by, and this boiler status continues until correct air/flue gas system correct operation is
restored.
WARNING
The only solution to this condition is accessible by having the
boiler serviced by qualified personnel or an Authorized Service Centre.
8
1.2.8 Shutdown due to insufficient water pressure
In the event of boiler shutdown due to water pressure switch intervention, no. 4 red light starts blinking, signalling insufficient water
pressure in the CH system.
In order to restore water pressure, proceed as follows (see pic. 4):
- open the loading tap by rotating it counter-clockwise in order to
allow water in the boiler, and keep it open until the water pressure
gauge (14 in pic.1) displays a pressure of 1-1,3 bars; close the
loading tap by rotating it clockwise.
WARNING
Once the loading procedure is completed, fully close the inlet
tap. Should the tap not be properly closed, as pressure increases, boiler CH safety valve may open and water flow out.
Should boiler frequently shut down due to insufficient water pressure, have it serviced by an Authorized Service Centre or qualified personnel.
LOADING TAP
1.2.9 Shutdown due to malfunction of temperature probes
Should the burner shut down due to malfunctioning of temperature
probes, the following lights turn on and flash:
- red light 5 (pic.1) for probe 1 (CH)
- red light 7 for probe 2 (water tank)
- red light 8 for probe 3 (plate heat exchanger)
In this instance, contact an Authorized Service Centre or qualified
personnel for service.
1.3 Maintenance
The user may only clean the external boiler casing, by means
of commonly marketed household products.
Do not use water!
As provided by law, the boiler is to be serviced once a year. Correct
maintenance ensures boiler to function efficiently, environmentally
friendly, preventing any danger to people, animals or property.
Only qualified personnel are lawfully allowed to service the boiler.
The manufacturer recommends Customers to contact an Authorized Service Centre for maintenance and repairs.
1.4 Information for the User
The user may only access boiler parts that can be reached
without using technical equipment and/or tools: the user is
not authorized to remove boiler housing and operate on any
internal part. No one, including qualified personnel, is authorized to modify the boiler.
The manufacturer shall not be held responsible for damage to
people, animals, or property, due to tampering with the boiler
or improper intervention.
Should the boiler be left inactive for a long time and power
main supply disconnected, it might be necessary to unlock
the pump.
Pump service includes boiler housing dismounting and access to boiler internal parts, therefore only qualified personnel
may perform it.
Pump blockage may be avoided by mixing to water, filming
additives suitable for multi-metal systems.
CH system can be properly protected from frost by using specific anti-frost additives suitable for multi-metal systems. Do
not use automotive products and verify the additive efficiency
over time.
The boiler is equipped with a thermometer allowing for water
temperature verification.
9
pic. 4
2. TECHNICAL CHARACTERISTICS AND DIMENSIONS
2.1 Technical characteristics
The boiler is equipped with a high output cast iron heat exchanger
and atmospheric gas burners.
All versions are equipped with electronic ignition, ionization flame
detection device, AQUA PREMIUM system for DHW supply employing a 60 ltrs stainless steel stratification water tank and a plate
secondary heat exchanger.
The following versions are available:
BTN E 25: open chamber, natural draught boiler with 25.1 kW heat
output;
BTN E 32: open chamber, natural draught boiler with 31.4 kW heat
output;
BTN E 42: open chamber, natural draught boiler with 42.5 kW heat
output.
BTFS E 24: sealed chamber, forced draught boiler with 24.0 kW
heat output;
BTFS E 32: sealed chamber, forced draught boiler with 32.0 kW
heat output;
BTFS E 36: sealed chamber, forced draught boiler with 36.5 kW
heat output.
All models are available in V version, equipped with collector, mixing
valve and two additional pumps for management of one high temperature zone and one low temperature zone.
In addition, the boiler is manufactured in accordance to laws and
standards in force in the country named on the boiler technical
data plate.
Installation in a different country from the one mentioned might
endanger people, animals and cause damage to property.
The main technical characteristics of the boiler are listed below:
Manufacture characteristics
- High-output cast iron heat exchanger
- Stainless steel plate DHW heat exchanger
- Stainless steel horizontal stratification 60 l water tank with
sacrificial magnesium anode
- Glass wool, aluminium layered, high thickness (50mm) insulation
- Plastic layered, metal sheet casing
- Gas valve
- Motorized deviating valve
- Three-speed CH circulation pump
- Single-speed DHW circulation pump
- 12 lt. CH expansion vessel (18 lt. for BTN E 42 model)
- 5 lt. DHW expansion vessel
- CH water, water tank and plate heat exchanger temperature
probes
- Adjustable by-pass
- CH system air purging device
- DHW priority flow switch
- Safety limit thermostat (110°C)
- Air pressure switch (BTFS model)
- Flue gas thermostat (BTN)
-DHW filter
- CH system loading tap
- CH system unloading tap
- Insufficient water pressure safety switch
- Electronics ready to host an additional pcb for management
of three different CH zones (optional kit).
User interface
- Selector managing the following functions: PROGRAMMER,
COMFORT TEMPERATURE, REDUCED TEMPERATURE,
ANTI-FROST,SUMMER
- CH water temperature adjusting knob
- DHW water temperature adjusting knob
- Power switch with light
- Led thermometer
- Pressure gauge
- Control panel with lights indicating:
• Power supply
• CH water supply
• Communication to remote control error
• Flame detecting device shutdown
• Overheating shutdown
• Low water pressure shutdown
• Temperature probe malfunction shutdown
• Air inlet/flue gas system malfunction shutdown.
2.2. Dimensions
Model BTN E
G: Gas inlet
C: DHW flow
F: Cold water inlet
M: CH flow
R: CH return
D: Flue gas outlet
(130 mm for BTN 25,
150 mm for BTN 32 and BTN 42)
pic. 5A
10
Model BTN EV
G: Gas inlet
C: DHW flow
F: Cold water inlet
M: CH flow
R: CH return
M1: Low temperature zone flow
M2: Low temperature zone return
D: Flue gas outlet
(130 mm for BTN 25,
150 mm for BTN 32 and BTN 42)
pic. 5B
Model BTFS E
G: Gas inlet
C: DHW flow
F: Cold water inlet
M: CH flow
R: CH return
pic. 5C
11
Model BTFS EV
G: Gas inlet
C: DHW flow
F: Cold water inlet
M: CH flow
R: CH return
M1: Low temperature zone flow
M2: Low temperature zone return
pic. 5D
2.3. Boiler layout
Boiler layout BTN E / BTFS E
Cold water inlet
Water tank
Water tank probe
VM (2-way)
DHW
Thermostatic
valve
Plate heat
exchanger
probe
Zone 1 high temperature
DIE-CAST
HEAT
EXCHANGER
BURNER
Cold water inlet
Water storage tank
Boiler layout BTN EV / BTFS EV
Plate heat
exchanger
probe
BURNER
Thermostatic
valve
DHW
Zone 1 high temperature
COLLECTOR
DIE-CAST
HEAT
EXCHANGER
Water storage probe
VM (2-way)
Low temperature zone flow probe
Zone 2 low temperature
S1: CH PROBE
TS:
LIMIT THERMOSTAT
V3V: 3-WAY MOTORIZED VALVE
VM: 2-WAY MOTORIZED VALVE
PR: CH PUMP WITH AIR
PURGING
DEVICE
PS: DHW PUMP
F: PRIORITY FLOW METER
SE: EXTERNAL PROBE
(OPTIONAL EQUIPMENT)
VMI: MIXING VALVE
TS1: LOW TEMPERATURE ZONE
SAFETY THERMOSTAT
pic. 6
12
2.4. Operational data
Burner pressures must be verified after a three minute boiler operation time
BTN 25
BTN 32
BTN 42
BTFS 24
BTFS 32
BTFS 36
II2H3+
II2H3+
II2H3+
II2H3+
II2H3+
II2H3+
Category
-
Type
-
Number of elements of primary heat exchanger
-
4
5
6
3
4
4
Number of nozzles of burner
-
3
4
5
3
3
3
Max heat input
kW
27.87
34.80
47.00
26.6
34.4
39.2
Max heat output
kW
25.05
31.40
42.54
24.0
32.0
36.5
Max output efficiency rate
%
89.9
90.22
90.51
90.20
93.10
93.10
Reduced output efficiency rate (30% of max output)
%
89.0
90.00
89.75
89.23
92.08
92.14
92/42/CEE efficiency rating
-
Casing heat loss
%
0.40
0.50
0.50
2.20
1.90
1.50
Flue gas heat loss with burner on
%
9.7
9.28
8.99
7.6
5
5.4
CH min. flow rate
l/h
540
690
900
520
690
780
Min. CH water pressure
bar
0.8
0.8
0.8
0.8
0.8
0.8
Max CH water pressure
bar
3
3
3
3
3
3
Max CH water temperature
°C
90
90
90
90
90
90
Min. CH water temperature
°C
40
40
40
40
40
40
Capacity of expansion vessel
l
12
12
18
12
12
12
Max CH system capacity
l
240
240
360
240
240
240
Water content
l
16.4
19.8
23
13
16.4
16.4
Water tank capacity
l
60
60
60
60
60
60
DHW supply ∆T=30K EN 625
l/10’
220
242
280
215
245
253
prEN 13203 efficiency rating
-
B11BS
C12 - C32 - C42 - C52 - C82
Min. DHW flow rate
l/min
3
3
3
3
3
3
Min. DHW pressure
bar
1
1
1
1
1
1
Max DHW pressure
bar
6
6
6
6
6
6
Max DHW water temperature
°C
65
65
65
65
65
65
Min. DHW water temperature
°C
50
50
50
50
50
50
l
5
5
5
5
5
5
CH Flow/return pipe diameter
inches
G1
G1
G1
G1
G1
G1
DHW inlet/outlet pipe diameter
inches
G3/4
G3/4
G3/4
G3/4
G3/4
G3/4
Gas inlet diameter
inches
G1/2
G1/2
G1/2
G1/2
G1/2
G1/2
Flue gas pipe diameter
mm
130
150
150
--
--
--
Air/flue gas coaxial pipe system diameter
mm
--
--
--
100/60
100/60
100/60
Air/flue gas split pipe system diameter
mm
--
--
--
80+80
80+80
80+80
Voltage/frequency
V/Hz
230/50
230/50
230/50
230/50
230/50
230/50
Power consumption
W
160
200
200
200
250
250
Power fuse
A
4
4
4
4
4
4
Control panel protection rating
IP
X4D
X4D
X4D
X4D
X4D
X4D
Height
mm
1370
1370
1370
1370
1370
1370
Length
mm
600
600
600
600
600
600
Depth
mm
800
800
800
800
800
800
Net boiler weight
Kg
172
189
206
189
223.5
223.5
Capacity of DHW expansion vessel
13
G20 gas
CO2 content
Flue gas temperature
%
BTN 25
BTN 32
BTN 42
BTFS 24
BTFS 32
BTFS 36
5.1
4.5
6
7.6
8.3
8.2
°C
111
103
121
120/130
110/120
120/130
kg/h
101.16
133.56
162
55
67
76
Max output gas consumption
stm3/h
2.95
3.7
4.97
2.81
3.64
4.15
Gas pressure
mbar
20
20
20
20
20
20
Gas to burner pressure
mbar
11.5
9.5
11.5
11
9.5
12
Main burner nozzle diameter
mm
2.6
2.6
2.6
2.4
2.9
2.9
Pilot burner nozzle diameter
mm
2 x 0.27
2 x 0.27
2 X 0.27
2 x 0.27
2 x 0.27
2 x 0.27
CO2 content
%
6.2
5.4
7.1
9.8
9.7
11.1
Flue gas temperature
°C
110
105
122
120/130
120/130
120/130
Flue gas mass flow rate
kg/h
101.16
133.56
162
55
67
76
Max output gas consumption
kg/h
2.2
2.76
3.7
2.1
2.7
3.1
Gas pressure
mbar
29
29
29
29
29
29
Gas to burner pressure
Flue gas mass flow rate
G30 gass
mbar
26.5
26.5
26.5
26
25.5
26
Main burner nozzle diameter
mm
1.55
1.55
1.55
1.5
1.7
1.8
Pilot burner nozzle diameter
mm
1 x 0.22
1 x 0.22
1 X 0.22
1 x 0.22
1 x 0.22
1 x 0.22
3. Instructions for the fitter
3.1. Installation standard
The boiler is to be installed in compliance with the country applicable standards, laws and regulations which are intended as fully
transcribed to this manual.
3.2. Installation
3.2.1. Packaging
The boiler is packaged in a strong cardboard box fixed by two
screws to a wooden pallet. Once the cardboard box is removed,
check the boiler to be undamaged. The packaging material can be
recycled and it must be disposed of accordingly.
Keep the packaging out of the reach of children as it may represent a hazard.
The manufacturer shall not be held liable for injury to persons
and animals or damage to property resulting from non-observance of the above.
The packaging contains:
- Installation, use and maintenance instruction manual
- Four legs with threads
3.2.2 Choosing where to install the boiler
When choosing where to install the boiler, follow the instructions
below:
- indications in paragraph 3.2.5 Air/flue gas system configuration
- leave a 50 cm clearing on each side of the boiler to facilitate
maintenance operations
- do not install the boiler in a high humidity room
- do not install a natural draught boiler (BTN model) in a corrosive
vapor or dusty air room like hairdressers’, laundrettes etc. as boiler components life span might result considerably shorter than
average,
- Boiler room is not to be accessible by people, children and animals
3.2.3 Positioning the boiler
Before connecting the boiler to DHW and CH system pipes, clean
the pipes removing any trace of metal from processing and welding
as well as any oil and grease which could damage the boiler or
interfere with its operation.
NB: Do not use solvents which could damage the components.
The manufacturer shall be waived from all liabilities for injury to
persons and animals or damage to property resulting from nonobservance of the above.
In order to install the boiler, after laying it where is to be positioned,
proceed as follows:
- detach the front panel
- detach the two screws fixing it to the wooden pallet (pic. 7A)
-In order to remove the boiler from the wooden pallet it is necessary to raise it: proceed carefully and delicately. Insert two 2” thick
metal bars in the openings under the boiler chassis which supports
the heat exchanger (pic. 7B), raise the boiler avoiding to damage
the hydraulic connections and position it on the ground.
-fix the four threaded legs to the boiler and adjust them for best
installation stability;
-connect the boiler to CH flow, CH return, cold water network,
DHW flow, and gas network pipes
-connect the boiler to air and gas flue pipes as needed
-connect the boiler electronics to the room thermostat (when available)
-connect the boiler to the power main supply
14
SCREWS
pic. 7A
The following mandatory requirements for air/flue gas system ducts
are to be followed:
- Their diameter is not to be not less than that of the boiler outlet.
- They are to be made of water proof material that can withstand
flue gas temperature and related acid condensate.
- They are to have low thermal conductivity, sufficient mechanical
strength, be properly sealed, and bear proper height and crosssection dimensions.
- The vertical inclination (chimney system) and section are to be
constant, without any bottlenecks.
- Where horizontal flue gas pipe are installed, these must bear an
inclination toward the ground of at least 5%.
- The terminal is to ensure efficient, constant evacuation of flue gas
in any weather condition.
- The flue gas terminal is to stand at least 0.5 m above any adjacent
structure within a 5 m radius.
FORCED DRAUGHT BOILER (BTFS)
BTFS boiler model is equipped with air and flue gas couplings which are to be connected to 80mm diameter pipes.
As far as flue gas system exhaust to the atmosphere is concerned,
comply with current laws which are considered as fully transcribed
in this manual.
Type C12
PRE-ARRANGED
OPENINGS
This boiler is designed for horizontal air/flue gas terminals, connected to the outside by means of a coaxial or split pipe system.
The distance between the air intake pipe and the flue gas exhaust
pipe is to be at least 250 mm and both terminals are to be positioned within a square having sides of 500 mm.
• Air / flue gas coaxial pipe system, 60/100 mm diameter.
pic. 7B
3.2.4. Boiler room ventilation
The boiler is to be installed in an adequate room according to law
requirements, which are considered as fully transcribed in this manual.
BTN, open combustion chamber boiler model is to be connected
to a chimney system: combustion air is taken from the boiler room.
An air replenishment opening is to be provided according to law
requirements.
BTFS, sealed combustion chamber boiler model does not take
combustion air from the boiler room, therefore no air replenishment
opening is to be provided.
3.2.5. Air/flue gas system configuration
As far as flue gas system exhaust to the atmosphere is concerned,
comply with current laws which are considered as fully transcribed
in this manual.
NATURAL DRAUGHT BOILER (BTN)
BTN boiler model is equipped with a flue gas coupling which is ready to be connected to a flue gas exhaust system, which diameter is
specified in the technical data tables.
As far as flue gas system exhaust to the atmosphere is concerned,
comply with current laws which are considered as fully transcribed
in this manual.
The flue gas pipe is to be connected to a chimney system in compliance with current laws which are considered as fully transcribed
in this manual.
15
Allowable configuration:
1 flanged stub pipe
3 meter long coaxial pipe
1 air/flue gas terminal.
Notes:
- Reduce the maximum length by 1 meter for each 90° elbow.
- Reduce the maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: in installations with an equivalent length of less
than 1 meter, install a 75 mm diaphragm.
- BTFS 32 model: in all installations, install a 78 mm diaphragm.
- BTFS 36 model: in installations with an equivalent length of less
than 1 meter, install a 78 mm diaphragm.
• Air / flue gas 80 mm diameter split pipes
Allowable configuration:
2 flanged stub pipes
19 meter long air intake pipe
19 meter long flue gas pipe
1 air intake terminal
1 flue gas terminal
Notes:
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: for installations with an equivalent length of less
than 2+2 meters, install a 42 mm diaphragm on the air intake.
- BTFS 32 and BTFS 36 models: for installations with an equivalent length of less than 9+9 meters, install a 40 mm diaphragm on
the air intake.
Type C32
This boiler is designed for vertical air/flue gas terminals, connected
to the outside by means of coaxial or split pipes.
The distance between the air intake pipe and the flue gas pipe is
to be at least 250 mm and both terminals
are positioned within a square having 500 mm sides.
• Air / flue gas coaxial pipe, 60/100 mm diameter.
Allowable configuration:
1 flanged stub pipe
4 meter long coaxial pipe
1 air/flue gas roof terminal.
Notes:
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
• Air / flue gas 80 mm diameter split pipes
Allowable configuration:
2 flanged stub pipes
19 meter long air intake pipe
19 meter long flue gas pipe
1 air intake terminal
1 flue gas terminal
Notes:
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: in installations with an equivalent length of less
than 2+2 meters, install a 42 mm diaphragm on the air intake.
- BTFS 32 and BTFS 36 models: in installations with an equivalent
length of less than 9+9 meters, install a 40 mm diaphragm on the
air intake.
Type C42
This boiler is designed for a collective flue gas exhaust system
consisting of two pipes, one for air intake and the other for flue gas,
by
means of a coaxial or split pipes.
The collective flue gas exhaust system must comply with
current laws.
• Air / flue gas 80 mm diameter split pipes
Allowable configuration:
2 flanged stub pipes
2 meter long air intake pipe
2 meter long flue gas pipe
Notes:
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: install a 42 mm diaphragm on the air intake.
- BTFS 32 and BTFS 36 models: install a 40 mm diaphragm on
the air intake.
Notes:
- 1 meter of air intake pipe is equivalent to 2 meters of vertical
flue gas pipe.
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: in installations with an equivalent vertical flue
gas pipe length, less than 18 meters, install a 40 mm diaphragm
on the air intake.
- BTFS 32 and BTFS 36 models: in installations with an equivalent vertical flue pipe length, less than 4 meters, install a 42 mm
diaphragm on the air intake.
Wall-mounted flue gas pipe
Allowable configuration for max length of split pipes:
2 flanged stub pipes
19 meter long air intake pipe
19 meter long flue gas pipe
1 air intake terminal
1 flue gas terminal
Notes:
- 1.6 meters long air intake pipe is equivalent to 1 meters horizontal flue gas pipe.
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: in installations with an equivalent length of less
than 9+9 meters, install a 40 mm diaphragm on the air intake.
- BTFS 32 and BTFS 36 models: in installations with an equivalent length of less than 2+2 meters, install a 42 mm diaphragm
on the air intake.
Type C82
This boiler is designed to be connected to a terminal for intaking of
combustion air and an individual or collective flue gas system.
The flue gas system is to comply with current standards.
• Air / flue gas 80 mm diameter split pipes
Allowable configuration for max length of split pipes:
2 flanged stub pipes
4 meter long air intake pipe
1 meter long flue gas pipe
1 air intake terminal
Notes:
- 1.6 meter long air intake pipe is equivalent to 1 meter long horizontal flue gas pipe.
- Reduce maximum length by 1 meter for each 90° elbow.
- Reduce maximum length by 0.5 meter for each 45° elbow.
- BTFS 24 model: install a 42 mm diaphragm on the air intake.
- BTFS 32 and BTFS 36 models: install a 40 mm diaphragm on
the air intake.
Type C52
This boiler is to be connected to a split pipe system.
The pipes can operate at different pressure. Terminals cannot
be placed on walls facing each other.
• Air intake/ flue gas 80 mm diameter split pipes
Roof mounted flue gas terminal.
Allowable configuration for max length of split pipes:
2 flanged stub pipes
1 meter long air intake pipe
30 meter long flue gas pipe
1 air intake terminal
1 roof-mounted smoke flue terminal
16
3.2.6. Verifying combustion efficiency
In order to determine combustion efficiency, the following measurements are to be performed:
-combustion air temperature
-flue gas temperature and CO2 concentration, from the relevant
opening on the flue gas pipe.
Perform the above measurements when the boiler has reached
working temperature.
3.2.7. Gas main connection
Gas supply pipe section must be equal or larger than boiler’s.
The applicable section of the pipe depends on its length, path, and
flow rate. Its section is to be calculated.
Refer to applicable installation standards and laws. They shall
be considered as incorporated in full in this manual.
An internal, brand new gas supply network, before supplying
any gas or being connected to the gas meter, is to checked
for leaks.
When sections of the network are concealed, the leak test
must be carried out prior to covering the pipes.
The leak test must not be conducted using fuel gas: use air
or nitrogen.
When gas is flowing through the pipes, gas leaks should never be detected using an open flame device.
Use appropriate products, readily available on the market.
3.2.8. Power main connection
The boiler is to be connected to a 230V-50Hz power main supply
via a triple-poled wiring (not included).
The wires are to be connected to position 5 (EARTH), 6 (PHASE),
and 7 (NEUTRAL) of M terminal board in picture 9 (BTN E and
BTFS E models), or to position 12 (EARTH), 13 (PHASE), and 14
(NEUTRAL) of M terminal board in picture 10 (BTN E V and BTFS
E V models).
Verify phase, neutral and ground connections are correctly performed, following the instructions in this manual.
When installing the boiler, comply with applicable standards which
shall be considered fully incorporated to this manual.
A bipolar switch, with 3 mm minimum distance between the contacts, in an easy to reach position, must be installed externally
to the boiler to enable interruption of power supply and to ensure
maintenance operations to be carried out safely.
The power main line to the boiler must be protected by a differential
thermal-magnetic switch with the adequate interruption power.
Power mains is to be properly earthed.
The above instruction is an indispensable safety requirement and
is to be verified prior to operating the boiler; in case of doubt, ask
for a professionally qualified technician to check the electrical system.
When size dimensioning central heating pipes, it is necessary to
consider load losses induced by radiators, presence of thermostatic valves, radiator cut-off valves and general configuration of the
central heating system.
It is advisable the discharge of the safety valve to be conveyed
into the sewer.
If this precaution is not taken, activation of the safety valve
may result in flooding of the room where the boiler is installed.
The Manufacturer shall not be held responsible for damage
caused by omission of the above mentioned technical precaution.
DOMESTIC HOT WATER
DHW flow and water main inlet pipes must be connected to the their
3/4” connections, marked C and F (pic. 5A and pic. 5B).
Hardness of water increases frequency of service to the secondary
plate heat exchanger.
WARNING
Should water hardness be far above average, it is advisable to
install a water softener device.
Water showing 20°F or more hardness should be treated.
WARNING
Due to its pH value, water supplied from normal water softeners may not be compatible with some components of the heating system.
3.2.10. Room thermostat connection
The boiler can be connected to a room thermostat: its contacts
must be properly sized in consideration of a 5 mA load at 24
Vdc.
Room thermostat wirings must be connected to positions 1 and 2
of M terminal board shown in pic. 9 (BTN E and BTFS E models),
after removing the jumper supplied as standard to the boiler.
Room thermostat wires are NOT to be grouped together with power
main supply cables.
BTN E V and BTFS E V models can be connected to two room
thermostats: one managing a high temperature CH area to no. 8
and no. 9 positions of M terminal board, one managing a low temperature CH area to no. 6 and no. 7 positions of M terminal board.
3.2.11. Adjustable by-pass
The boiler is equipped by an adjustable by-pass (located on the
three-way motorized valve hydraulic assembly). By-pass operation
can also be inhibited.
Pic. 8A shows the adjusting by-pass screw, set for by-pass operation preclusion, pic. 8B shows the adjusting by-pass screw set for
by-pass operation.
A
Closed
by-pass
The manufacturer shall not be held liable for damage or injury caused by failure to properly earth the power main.
Gas lines, DHW and CH pipes are not suitable for earthing purposes.
3.2.9. Hydraulic connections
Before connecting the boiler it is advisable to clean the pipes in
order to remove any alien material that could damage boiler components such as pump and heat exchanger.
B
CENTRAL HEATING
Central heating flow and return must be connected to their relevant
1” connections, marked M and R in pic. 5 and 5B).
17
pic. 8
Open
by-pass
3.2.12. Installation of original kits
3.4 Starting the boiler
The manufacturer provides original kits for thermoregulation control unit installation.
The kits are to be installed as described in their relevant instruction
manuals.
3.4.1 Preliminary checks
3.3. Loading the system
After completion of all hydraulic connections the central heating
system is ready for loading.
Water filling procedure must be performed as follows:
- open air purging valves on the radiators and check operation of
the boiler automatic air purging valve
- gradually open the boiler water main inlet tap and check operation
of all air purging valves in the system
- close the air purging valves on the radiators as soon as water
comes out
- check the water pressure gauge on boiler, its reading is not to
exceed 1-1.3 bars
- close the water main inlet tap and purge any air still in the system
through the radiator valves
- turn the boiler on and wait for the CH system to reach working
temperature. Stop the pump and purge any left air
- allow the CH system to cool and adjust water pressure to 1-1.3
bars.
WARNING
For best performance, safe, trouble-free and long lasting operation of boiler and its components, in order to minimise energy consumption, thus complying with standards and laws, it is essential to
treat the water using specific products compatible with multi-metal
systems.
Prior to starting the boiler verify the following:
- correct installation of flue gas outlet duct and terminal section:
when the boiler is operating, no flue gas leaks are to be
detected.
- power supply to the boiler must be 230 V- 50 Hz;
- system is correctly filled with water (manometer reading is to be
1-1.3 bars);
- any cut-off taps in the system are to be open;
- the gas type supplied matches the gas type for which the boiler
has been calibrated: otherwise, convert the boiler to the gas type
available (see section 3.6: “SWITCHING TO DIFFERENT GAS
AND BURNER ADJUSTMENT“): this operation is to be performed
by qualified technicians;
- the gas supply tap is open;
- no gas leaks are detected;
- the power switch external to the boiler is on;
- no water leaks are detected
- the pumps are not blocked
- the boiler’s safety valve is not locked;
WARNING
The boiler pump is factory set to III speed and the by-pass is closed.
Adjust them following the system requirements.
3.4.2 On/Off switching
To switch the boiler on and off follow the indications in the “Instructions to the user”.
Note
The boiler is equipped, in its front lower section, with a tap for
unloading water from the system.
WARNING
A low water pressure safety switch prevents burner to ignite when
water pressure is lower than 0.4 / 0.6 bar. Water pressure in the
central heating system should not be lower than 1-1.3 bar; restore correct pressure through water mains inlet tap on the boiler as
necessary.
Water pressure adjustment must be performed when the system
is cold. The thermo-manometer gauge on the boiler allows for checking the pressure in the system.
IMPORTANT:
After a period of inactivity the pumps could be blocked.
Before switching on the boiler it may be necessary to unlock
the pumps as follows: loosen the protective screw on the
pump motor housing, insert a screwdriver in the hole and then
manually rotate the pump shaft clockwise.
After restoring pump operation, tighten the protective screw
and check for water leaks.
WARNING
When removing the pump protective screw a little water may
leak out. Before replacing the cover of the boiler dry any wet
surfaces.
18
3.5. Wiring diagrams
Model BTN E
Model Btfs e
M: Terminal board for connection to power mainS, external temperature probe, room thermostat
M6: telemetry connection
M1- M24: available connectors
TA: room thermostat
SE: 10k Ohm B = 3977 external temperature probe (optional equipment)
CT: phone connection device (optional equipment)
FUSE: 2AF 250 VAC fuse
P4: CH curve selection potentiometer
P3: boiler operating mode selector
P2: DHW temperature adjusting potentiometer
P1: CH temperature adjusting potentiometer
IG: two-poled main power switch
BC: flame detection pcb
VG: gas valve
E. RIV: flame detection electrode
pic. 9
19
E. ACC: ignition electrode
PSB: reset button
TS: safety thermostat
TF: flue gas thermostat
DK: low water pressure safety switch
FL: flow meter
PR: recirculation pump
PS: DHW pump
EV: two-way water tank intercepting valve
MVD: three-way motorized valve
TIMER: TIMER
SB: 10k Ohm B = 3435 water tank probe
SR: 10k Ohm B = 3435 CH probe
SS: 10k Ohm B = 3435 DHW PROBE
MOD. BTN E V and BTFS E V
SP
SZ
BC
SP: MAIN PCB
SZ: ZONE PCB
IG: TWO-POLED MAIN POWER SWITCH
BC: FLAME DETECTION PCB
VG: GAS VALVE
V: FAN
PV: FAN PRESSURE SWITCH
E.RIV: FLAME DETECTION ELECTRODE
E.ACC: IGNITION ELECTRODE
PSB: RESET BUTTON
TS: SAFETY THERMOSTAT
TF: FLUE GAS THERMOSTAT
DK: LOW WATER PRESSURE SAFETY SWITCH
FL: FLOW METER
PR: RECIRCULATION PUMP
PS: DHW PUMP
EV: TWO-WAY WATER TANK INTERCEPTING VALVE
MVD: THREE-WAY MOTORIZED VALVE
VM: CIRCUIT 2 MOTIRIZED MIXING VALVE
PR1: CIRCUIT 1 CH PUMP (HIGH TEMPERATURE)
PR2: CIRCUIT 1 CH PUMP (LOW TEMPERATURE)
M: TERMINAL BOARD FOR CONNECTION TO EXTERNAL TEMPERATURE PROBE,
THERMOSTATS
pic. 10
SE: 10K Ohm B=3977 EXTERNAL TEMPERATURE PROBE
TA1: ZONE 1 THERMOSTAT (HIGH TEMPERATURE) (OPTIONAL EQUIPMENT)
TA2: ZONE 2 THERMOSTAT (LOW TEMPERATURE) (OPTIONAL EQUIPMENT)
TSM: LOW TEMPERATURE SAFETY THERMOSTAT (OPTIONAL EQUIPMENT)
M6: TELEMETRY CONNECTION
M1-M24: AVAILABLE CONNECTORS
X1-X8: AVAILABLE CONNECTORS
CT: PHONE CONNECTION DEVICE (OPTIONAL EQUIPMENT)
FUSE (SP): 2 AF 250 Vac FUSE
FUSE (SZ): 2.5 AF 250 Vac FUSE
P4: HIGH TEMPERATURE CH CURVES ADJUSTING POTENTIOMETER
R4: LOW TEMPERATURE CH CURVES ADJUSTING POTENTIOMETER
P3: BOILER OPERATING MODE SELECTOR
P2: DHW TEMPERATURE ADJUSTING POTENTIOMETER
P1: CH TEMPERATURE ADJUSTING POTENTIOMETER
TIMER: TWO-CHANNEL TIMER (CHANNEL 1 CH - CHANNEL 2 = DHW)
SB: 10k Ohm b=3435 WATER TANK PROBE
SR: 10k Ohm b=3435 CH PROBE
SS: 10k Ohm b=3435 DHW PROBE
SM: LOW TEMPERATURE ZONE PROBE ON FLOW 10k Ohm b=3435
T (°C)
0
2
4
6
8
0
27203
24979
22959
21122
19451
10
17928
16539
15271
14113
13054
20
12084
11196
10382
9634
8948
30
8317
7736
7202
6709
6254
40
5835
5448
5090
4758
4452
50
4168
3904
3660
3433
3222
60
3026
2844
2674
2516
2369
70
2232
2104
1984
1872
1767
80
1670
1578
1492
1412
1336
90
1266
1199
1137
1079
1023
Relation between temperature (°C) and nominal resistance (Ohm) of CH probe (SR), DHW probe (SS), water tank probe (SB) and low temperature zone probe on flow (SM).
20
3.6. Switching to different gas and burner adjustment
Converting the boiler from LPG to natural gas
Boiler conversion from natural gas to LPG and vice-versa is striclty
to be impelmented by qualified personnel.
In order to verify nozzle and gas inlet pressure, connect a manometer to checks on the gas valve.
Boilers are factory-set according to gas type requested upon order.
Any later conversion must be performed by qualified technicians,
employing the conversion kit (supplied with boiler) and the instructions for conversion and adjustment.
Follow the instructions below:
- remove the pilot burner LPG nozzle after removing the bi-cone
fixing bolt and removing the pilot burner gas supply pipe;
- install the natural gas nozzle, verifying its compliance with the
technical data table and, after re-installing the gas supply pipe, tighten the bi-cone fixing bolt;
- remove the main burner LPG nozzles and install the natural gas
ones verifying their compliance with the technical data table;
- unscrew the cap of the pressure adjuster of the gas valve and untighten the screw of the pressure adjuster so to obtain the pressure
value compliant with technical data table;
- screw the cap of the pressure adjuster of the gas valve back on
and seal it (e.g. by means of paint or self-sticking label);
- check for gas leaks, especially from the gas connections that were
part of the above procedure;
- position the self-sticking label provided with the conversion kit,
indicating the type of gas and pressure for which the device was
adjusted.
Converting the boiler from natural gas to LPG
Follow the instructions below:
- remove the pilot burner natural gas nozzle after removing the bicone fixing bolt and removing the pilot burner gas supply pipe;
- install the LPG nozzle, verifying its compliance with the technical
data table and, after re-installing the gas supply pipe, tighten the
bi-cone fixing bolt;
- remove the main burner natural gas nozzles and install the LPG
ones verifying their compliance with the technical data table;
- unscrew the cap of the pressure adjuster of the gas valve and fully
tighten the screw of the pressure adjuster;
- screw the cap of the pressure adjuster of the gas valve back on
and seal it (e.g. by means of paint or self-sticking label);
- check for gas leaks, especially from the gas connections that were
part of the above procedure;
- position the self-sticking label provided with the conversion kit,
indicating the type of gas and pressure for which the device was
adjusted;
4. Maintenance
The boiler is to be yearly serviced to ensure efficient and troublefree operation following to the below described plan.
Maintenance (and repair) operations are to be exclusively performed by qualified personnel.
The manufacturer recommends Customers to have an Authorized
Service Center implement any maintenance and repair procedure.
Disconnect the boiler from power mains prior to performing any
maintenance procedure either involving replacement of components and/or internal cleaning.
Maintenance plan
Routine maintenance must include the following checks:
- boiler general integrity;
- leak test involving the boiler gas pipes and the gas network;
- boiler ignition sequence;
- boiler combustion parameters test, through flue gas analysis (to
be performed on a two-year basis if boiler is individually installed.
Annually to cascade-installed boilers);
- integrity and leak test of flue gas pipe system;
- general integrity of boiler safety devices;
- water leak check and presence of oxide deposit on boiler connection pipes;
- water pressure switch efficiency;
21
the following cleaning operations (the boiler is to be cool):
- general internal cleaning;
- burner cleaning and adjustment as necessary;
- heat exchanger flue gas side cleaning: to be performed by means
of a swab or vacuum cleaner in order to remove combustion leftovers from the heat exchanging surfaces and fins.
As an alternative, specific chemical products may be employed,
following their use instructions.
When cleaning the heat exchanger, do not employ petrol, solvents or similar substances.
In the event of boiler first maintenance operation, verify:
- boiler room characteristics according to boiler requirements;
- room ventilation grilles;
- flue gas system dimensions, diameters and lengths of ducts;
- correct installation of the boiler in compliance with the instructions
in this manual.
Should the boiler not be correctly operating, and in no immediate hazard to people, animals and property, notify the system supervisor, both verbally and in writing.
5. Troubleshooting
BOILER STATUS
The boiler has shut down, the red
light no. 1 is on.
The boiler has shut down and
red light no. 2 is on.
Reset by pressing no. 18 button.
The boiler has shut down and red
light no. 4 is flashing.
Restore correct water pressure
MALFUNCTION
Burner does not ignite.
Reset by pressing no. 16 button
PROBABLE CAUSE
SOLUTION
Gas supply failure
Check gas network pressure
Check gas network safety valves to
be open
Gas valve is disconnected
Reconnect gas valve
Gas valve is faulty
Replace it
PCB is faulty
Replace it
Burner does not ignites, there is no
spark.
Reset by pressing no. 16 button.
Spark electrode is faulty
Replace the electrode
Flame detection PCB is faulty
Replace PCB
Burner ignites for a few seconds and
turns off.
Reset by pressing no. 16 button.
PCB does not detect flame: inverted
phase and neutral
Verify correct neutral and phase
connections
Flame detection electrode wire is
disconnected or faulty
Connect flame detection electrode
wire or replace it
Flame detection electrode is faulty
Replace electrode
Flame detection PCB does not detect
flame: it is faulty
Replace flame detection PCB
P ACC Ignition value set point
is too low
Adjust P ACC ignition value set point
Min heat input in not set correctly
Check burner adjustment
Water is not flowing in the CH system:
pipes are clogged, thermostatic
valves are closed, intercepting valves
in the system are closed
Check CH system
Pump is blocked or faulty
Check the pump
Plate heat exchanger is clogged
Check the plate heat exchanger
Possible water leaks
Check system for leaks
Pressure switch is disconnected
Reconnect it
Water pressure switch is faulty
Replace it
Flow probe is disconnected
Reconnect it
Flow probe is faulty
Replace it
Safety thermostat has shut the boiler
down
Insufficient water pressure
The boiler has shut down, red light
no. 5 is flashing.Boiler will
automatically resume operation as
soon as the problem is solved
Flow probe is faulty
The boiler has shut down and red
light no. 6 is flashing.
Boiler will automatically resume
operation as soon as the problem is
solved
Boiler communication to and from
remote control is faulty
Connecting wire is faulty
Check connecting wire
The boiler has shut down, red light
no. 7 is flashing.
Boiler will automatically resume
operation as soon as the problem is
solved
Water tank is faulty
Water tank probe is disconnected
Reconnect it
Water tank probe is faulty
Replace it
The boiler has shut down, red light
no. 8 is flashing.
Boiler will automatically resume
operation as soon as the problem is
solved
Plate heat exchanger probe is faulty
Plate heat exchanger probe is disconnected
Reconnect it
Plate heat exchanger probe is faulty
Replace it
The boiler has shut down, red light
no. 9 is flashing (BTN model only).
Reset by pressing no. 19 button.
Flue gas thermostat is not consenting
to boiler operation
Flue gas thermostat is faulty
Check flue gas thermostat operation:
replace when faulty
Air inlet or flue gas discharge flow is
not adequate
Check air inlet/flue gas discharge
ducts: clean or replace as necessary
22
BOILER STATUS
Red light no. 9 is flashing and the
boiler has not shut down.
Boiler will automatically resume
operation as soon as the problem is
solved
Boiler is not supplying DHW
Burner does not ignite and the boiler
has not shut down (BTFS model only)
23
MALFUNCTION
Boiler water temperature has exceeded 85°C
Flow meter is not operating
Flue gas pressure switch is not consenting to boiler operation. Boiler will
automatically resume operation as
soon as the problem is solved
PROBABLE CAUSE
SOLUTION
Water is not flowing in the system: pipes are clogged, thermostatic valves
are closed, intercepting valves in the
system are closed
Check the system
Pump is blocked or faulty
Check the pump
Plate heat exchanger is clogged
Check the plate heat exchanger
The system has not sufficient pressure or flow rate
Check DHW system
Flow meter sensor is faulty or disconnected
Replace or reconnect it
Flow meter is blocked
Replace it
Flue gas pressure switch is faulty
Check flue gas pressure switch operation: replace when faulty
Silicone pipes are disconnected or
damaged
Reconnect or replace as necessary
Air inlet or flue gas discharge flow is
not adequate
Check air inlet/flue gas discharge
ducts: clean or replace as necessary
Fan is faulty
Replace it
PCB is faulty
Replace it
Check flow meter filter
24
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26
0LIBISEN23
Fondital S.p.A.
25079 VOBARNO (Brescia) Italia - Via Cerreto, 40
Tel. +39 0365 878 31 - Fax + 39 0365 878 576
e mail: fondital@fondital.it - www.fondital.it
The MANUFACTURER reserves the right to implement any necessary and/or useful variation
to products, without modifying fundamental characteristics
Uff. Pubblicità Fondital IST 03 C 192 - 01 Ottobre 2005 (10/2005)
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