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Boyertown Furnace Savio Installation manual
BOILER INSTALLATION, OPERATION
INSTRUCTIONS
Savio
FP
WALL HUNG GAS BOILER FOR
CENTRAL HEATING SUPPLY
Please Read Instructions Carefully
Save for Future Reference
WARNING: If the information in this manual is not followed
exactly, a re or explosion may result causing property damage, personal injury or loss of life.
— Do not store or use gasoline or other ammable vapors and liquids
in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your
building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
• If you can not reach your gas supplier call the re department.
— Installation and service must be performed by a quali ed installer,
service agency or the gas supplier.
SAVIO FP MANUAL
Dear Customer:
Thank you for buying a SAVIO FP Boiler System.
The SAVIO FP is a high efficiency, non-condensing, wall mounted gas boiler which provides
central heat supply water.
We realize that it is not possible to answer all questions about the SAVIO boiler system in this
manual. Reading this installation manual does not make the reader an expert in all aspects
of installation and operation, and does not replace the need for a qualified, licensed heating
contractor. We urge you to contact your installing contractor or distributor if you are in question
about any aspect of your boiler’s performance. Our main concern is that you are satisfied with
your boiler and its performance. We require that your contractor complete efficiency tests using
instruments.
The external controls and accessories listed in this manual (excluding those supplied inside
the boiler) are intended to serve as guidelines rather than specific recommendations. We realize that other makes and models of such devices are available and can be used as successfully as those we specify. The installing contractor is the best judge of a system’s specific
requirements, as well as the local availability of certain makes and models of controls and
accessories. The preceding does not apply, however, to the equipment that comes with every
boiler, such as the overheat control and pressure relief valves. The installation of the speci c devices supplied with every boiler is absolutely necessary to the safe operation of
the boiler and protection of the heating system.
All SAVIO wall hung boilers are built in accordance with the ASME boiler and pressure vessel
code, and bear the “H” stamp. The Entire range of applications for the SAVIO boiler has been
tested to standard CSA 4.9 and is CSA compliant.
This FP boiler has a 2 year warranty on the boiler, and 10 years on the heat exchanger, a copy of
which is provided with the boiler. Please be sure to return the warranty registration card as the
warranty will be void without your boiler’s serial numbers (located on the ratings label affixed to
the boiler), date of installation and the name of your installer being on record in our files.
Thank you for purchasing our SAVIO FP boiler. If you have questions or comments, please
don’t hesitate to contact us immediately. Our goal is 100% customer satisfaction
BOYERTOWN
2
SAVIO FP MANUAL
Table of Contents
Section Title
Section Number
Warnings
Important Information
General Information
Technical Information (M130.30CM)
Parts List
Internal Piping and Parts List
Electric Diagrams
Sequence of operation
Installation Location
Exhaust Pipe Location
Mounting Bracket
Venting
Restrictor Sizing
Fitting the Flue System
Choice of Flue
Pipe Connections
Gas Pipe Connections
Electrical Connections/Wiring
Power Connection
Connection to the Electricity Supply
Room Thermostat Connection
Relay Panel Control Connection
Zone Valve Microswitch Connection
Finishing
Circulator Sizing
Circ. Cap. as a Function of Flow Rate
Expansion Vessel
SAVIO FP MANUAL
1
2
3
4
5
5.1
6
7
8
9
9.1
9.2
9.3
10
11
12
12.1
12.2
12.3
12.4
12.5
12.6
13
13.1
13.2
Page Number
5-6
7
8
8-9
10
11
12-13
13
14
15
16
17-24
18
18
19-24
25
26
27-29
27
27
28
28
29
29
30
30
30
3
Table of Contents
Section Title
Piping
Section Number
14
Primary – Secondary Piping
14.1
Primary-Secondary with Zone Valves
14.2
Manifold Piping with Zone Valves or Circ.
14.3
Commissioning
15
Initial Filling of the System
15.1
Lightning the Boiler
15.2
Checking the Gas Pres. at the Burner
15.3
Adjustment of the Gas Pressure
15.4
Checking the Ignition Device
15.5
Checking the Burner Ignition
15.6
Adjustment of the Useful c.h. Output
15.7
Labels Placement
15.8
Checking the Flue System and Comb
15.9
Instructing the User
15.10
Gas Conversion
16
Annual Maintenance
17
Warnings
17.1
Dismantelling the External Panels
17.2
Emptying the C.h. System
17.3
Emptying the D.h.w Circuit
17.4
Cleaning the Primary Heat Exch.
17.5
Checking the Pressuris. in C.h. Vess.
17.6
Cleanig the Burner
17.7
Cleaning the domestic hot water exchanger 17.8
Checking the Flue
17.9
Visual Inspection of Appliance
17.10
Gas Pressures and Soundness
17.11
Vent part spares
18
Installer Notes
18
4
SAVIO FP MANUAL
Page Number
31-34
32
33
34
35-40
35
35
36
37
37
38
38
39
40
40
41
42-43
42
42
42
42
43
43
43
43
43
43
43
44-46
47
WARNING
Boiler is certified as an indoor appliance. Do not install boiler outdoors or locate where it will
be exposed to freezing temperatures.
WARNING: If the information in this manual is not followed
exactly, a re or explosion may result causing property damage, personal injury or loss of life.
— Do not store or use gasoline or other ammable vapors and liquids in the
vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your building.
• Immediately call your gas supplier from a neighbor’s phone. Follow the
gas supplier’s instructions.
• If you can not reach your gas supplier call the re department.
— Installation and service must be performed by a quali ed installer, service agency or the gas supplier.
DANGER
Caution: Do not store or use ammable materials, chemicals or ammable liquids,
especially gasoline, in the vicinity of this heating appliance.
Caution: Should overheating occur or the gas supply fail to shut off, do not turn off
or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a
location external to the appliance.
Caution: Do not use this boiler if any part has been under water. Immediately call a
quali ed service technician to inspect the boiler and to replace any part of the control
system and any gas control which has been under water.
SAVIO FP MANUAL
5
WARNING
Any appliance that burns natural gas, propane gas, fuel oil, wood or coal is capable of producing carbon monoxide (CO). Carbon Monoxide (CO) is a gas which is odorless, colorless
and tasteless but is very toxic. CO is lighter than air and thus may travel throughout the
building.
BRIEF EXPOSURE TO HIGH CONCENTRATIONS OF CO, OR
PROLONGED EXPOSURE TO LESSER AMOUNTS OF CO MAY
RESULT IN CARBON MONOXIDE POISONING. EXPOSURE CAN BE
FATAL AND EXPOSURE TO HIGH CONCENTRATIONS MAY RESULT
IN THE SUDDEN ONSET OF SYMPTOMS INCLUDING UNCONSCIOUSNESS.
Symptoms of CO poisoning include the following:
dizziness
headache
nausea
vision problems
loss of muscle control
weakness
shortness of breath
unclear thinking
unconsciousness
The symptoms of CO poisoning are often confused with those of influenza, and the highest
incidence of poisoning occurs at the onset of cold weather or during flu season.
A victim may not experience any symptoms, only one symptom, or a few symptoms.
Suspect the presence of carbon monoxide if symptoms tend to disappear when you
leave your home.
The following signs may indicate the presence of carbon monoxide:
•
•
•
•
•
•
Hot gasses from appliance, venting system pipes or chimney, escaping into the living
space.
Flames coming out around the appliance.
Yellow colored flames in the appliance.
Stale or smelly air.
The presence of soot or carbon in or around the appliance.
Very high unexplained humidity inside the building.
If any of the symptoms of CO occur, or if any of the signs of carbon monoxide are
present, VACATE THE PREMISES IMMEDIATELY AND CONTACT A QUALIFIED
HEATING SERVICE COMPANY OR THE GAS COMPANY OR THE FIRE
DEPARTMENT.
ONLY QUALIFIED, LICENSED SERVICE CONTRACTORS SHOULD PERFORM WORK
ON YOUR SAVIO FP BOILER.
6
SAVIO FP MANUAL
IMPORTANT INFORMATION
Please read this page carefully.
•
ALL BOILERS MUST BE INSTALLED IN ACCORDANCE WITH NATIONAL,
STATE AND LOCAL PLUMBING, HEATING AND ELECTRICAL CODES
AND ORDINANCES, AS WELL AS THE REGULATIONS OF THE SERVING
ELECTRICAL, WATER AND GAS UTILITIES.
•
All systems should be designed by competent contractors, and only persons
knowledgeable in the layout and installation of heating systems should attempt
the installation of any boiler. It is the responsibility of the installing contractor
to see that all controls are correctly installed and operating properly when the
installation is completed.
•
This boiler is intended for use, only with propane or natural gas. All ammable
liquids (especially gasoline), chemicals, rags, paper, wood scraps, debris, etc.,
should be kept away from the boiler at all times. Keep the boiler area clean and
free of all re hazards.
•
Please read the literature and warranties supplied by the manufacturers of the
various accessory equipment. This equipment is warranted by the respective
manufacturers, not by Boyertown, Inc. Each piece of equipment must be
installed and used according to the recommendations of the manufacturer.
Codes and Regulations:
Installation of the boiler and related equipment must conform to national, state and
local regulating agencies and codes applicable to the installation of the equipment. In
the absence of local requirements, the following codes apply:
A. ANSI/NFPA
B. ANSI/NFPA
C. ANSI/NFPA
C. ANSI/NFPA
D. CAN/CGA
E. ANSI/ASME
-
#70 National Electric Code
#211 Chimneys and Vents
#Z223.1 National Fuel Gas Code
Domestic Gas Conversion Burner
B149 Installation Codes
CSD-1
The above codes are available from:
National Fire Protection Association (NFPA)
Battery March Park
Quincy, Massachusetts, 02269
http://www.nfpa.org
SAVIO FP MANUAL
CSA International
8501 E. Pleasant Valley Road
Cleveland, OH 44134-5575
http://www.csa-international.org
7
1. General Information
The SAVIO FP is a high efficiency, non-condensing, wall mounted gas boiler which provides
central heat. The boiler features a gas valve which modulates the energy input from 49,476
BTU/h to 122,837 BTU/h. The boiler is shipped fully assembled with the components listed on
page 11. All units are pressure and combustion tested at the factory prior to shipping.
Key Features:
• Wall mountable - saving valuable floor
space.
• Several flue options available
• Electronic spark ignition
• Safety flow switch - positioned on the
main circuit, which monitors the flow and
protects the main heat exchanger from
thermal shock should there be a lack of
water in the system.
• Frost protection - contains an integral frost
protection system to prevent frost damage which can occur in areas susceptible
to very cold weather conditions.
• Boiler operation recognition system should the boiler not be used for longer
than 24 hours, it then performs a controlled system test to ensuring the motorized
components within the boiler do not become inoperable due to lack of use.
• Gas valve modulation - the gas input
modulates based off central heating and
domestic hot water temperature to within
± 2 ºF
• Diagnostic information system equipped
with three LED diagnostic lights for quick
error assessment.
2. Technical Information (M130.30CM)
GENERAL
INJECTORS
No.
Size
Height
in
27.7
Natural
14
130
Width
in
15.7
Propane
14
89
Depth
in
12.8
Weight
lb
78.7
Maximum working temp.
°F
185
Temp. Regulation range*
°F
100-176
120
Maximum pressure
psi
30.0
psi
4.35
ft
9.9
ELECTRICAL
Voltage
V
Frequency
CENTRAL HEATING
Hz
60
Minimum pressure
Current
A
1.6
Max head loss (at 4.4 GPM)
Power consumption
W
180
*At the minimum useful output
8
SAVIO FP MANUAL
2. Technical Information Cont.
ENERGY CAPACITY
GAS FLOW RATE
Nominal heat input
(0/2000ft)
MBH
122.8
Nominal heat input
(2000/4500ft)
MBH
Minimum heat input
Gas
Min
Max
Natural
ft³/h
48.7
121.1
116.7
Propane
lb/h
2.2
5.6
MBH
49.5
CLEARANCE TO COMBUSTIBLES
Maximum useful output
(0/2000ft)
MBH
100.7
Front
in
18
Maximum useful output
(2000/4500ft)
Back
in
0
MBH
95.9
Top
in
8
Minimum useful output
MBH
37.0
Sides
in
2
Bottom
in
8
Flue pipe enclosed
in
2
Flue pipe free air
in
0
Hot water pipes
in
1”
GAS SUPPLY PRESSURE
Gas
Normal
Min
Max
Natural
inwc
7.0
3.0
10.0
Propane
inwc
11.0
8.0
13.0
GAS PRESSURE AT BURNER
Gas
Min
Max
Ignition
Natural
inwc
0.8
5.3
2.4
Propane
inwc
1.4
9.0
5.2
FLUE DESIGN
Minimum Venturi pressure
inwc
0.66
Flue pipe diameter
Coaxial
in
2.25/4
3.25/5
Twin split pipes
in
3.25/3.25
Nominal heat flow rate
(0/2000ft)
MBH
122.8
Nominal heat flow rate
(2000/4500ft)
MBH
116.7
Min Exhaust temperature
°F
262
Max Exhaust temperature
°F
324
SAVIO FP MANUAL
FLUE GAS FIGURES
Gas
Min
Max
CO2
2.5%
7.2%
O2
16.5%
8.1%
DOMESTIC HOT WATER
Maximum temperature
°F
131
Minimum temperature
°F
95
Maximum pressure
psi
145
Minimum pressure
psi
4.35
D.h.w. ΔT 25K
gpm
4.5
D.h.w. ΔT 30 K
gpm
3.7
D.h.w. ΔT 35 K
gpm
3.2
D.h.w. ΔT 40 K
gpm
2.8
9
3. Parts List
Primary Components:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Pump
Pump vent plug
Automatic air purger valve
Modulation gas valve
Flame-detecting electrode
Ignition electrodes
Burner
Combustion chamber
Primary heat exchanger
Fan
Air pressure switch
Air switch pres. Test points
Safety thermostat
Modulation operator
Gas valve outlet pres. Test point
Gas valve inlet pres. Test point
Central heating expansion vessel
Central heating temp. probe NTC
Central heating pressure relief valve
10 SAVIO FP MANUAL
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Primary circuit flow switch
Main circuit drain cock
By-pass valve
Three-way diverter valve
Venturi device
Flue outlet pipe
Air intake pipe
Control panel
Safety thermostat probe
Pressure reducing automatic fill valve
Backflow preventer
D.h.w. heat exchanger
D.h.w. flow switch
Domestic water circuit filter
D.h.w. flow limiter
Domestic hot water temp.probe NTC
Domestic cold water inlet valve
D.h.w. outlet pipe
Gas supply line cook
Water supply inlet cock
4. Internal Piping & Parts List
26
24
25
19
11
10
9
28
31
7
3
1
6
5
15
14
18
4
34
20
17
16
33
23
21
32
22
35
38
36
29
30
37
39
Note: Pressure Relief Valve (#19) should be piped to a drain or to the floor as lose as possible to a drain.
SAVIO FP MANUAL
11
5. Electric Diagrams
Air pressure switch
Fan
L
Safety
thermostat
External
controls
Terminal
block
Ignition electrodes
NO
NC
N
M
bn
bu
rd
COM
wh
1
2
3
~
bn
gny e
bk
bu
wh
rd
Flame detection
electrode
Electric supply
terminal block
gy
gnye
bu
ye
wh bu
bk gy rd
gnye
rd
bu bn
gny e
gnye
ye bk wh gy bu
rd
wh
rd
wh
gy
bk
wh
bk
rd
bk rd bu bu
bu
bk bk
gy gy
bn
bu gy
gnye
rd rd rd wh bu
gy
wh
bu
bk
bk
rd
rd
bu
rd
wh bk rd
3
1
M
rd
bu
COM
2
geyn gy bu
gy
gy
~
bk
t
wh
~
rd
bk
bu
D.h.w.
NTC
M
bu
rd
D.h.w.
flow switch
bk – black
bn – brown
bu – blue
gnye – green/yellow
12 SAVIO FP MANUAL
t
Three-way
diverter valve
NO
Primary circuit
flow switch
gy – grey
rd – red
C.h. temperature
probe NTC
Pump
Gas valve
wh - white
ye - yellow
Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing
5. Electric Diagrams Cont.
5.1 Sequence of Operation
YES
Is
primary circuit temp higher
than selected temp
Request for heat from
thermostat
NO
Circulator off
Ignition device off
NO
YES
Starts the circulator
Supplies the ignition device
Is the boiler in lockout?
YES
NO
Air pressure switch open?
NO
YES
Fan starts
NO
Air pressure switch closed?
YES
Begin wait period
NO
NO
Air pressure switch closed?
Presence of flame?
YES
YES
Starts ignitors
Opens gas valve
Begins ignition timing
NO
NO
Flame presence?
YES
Closes gas valve
Stops fan
Interrupts ignitor
Boiler lockout
End of ignition period?
Interrupt igniter
Gas valve open
Reset push – button
pressed
NO
YES
Close gas valve
Flame presence?
NO
YES
NO
YES
SAVIO FP MANUAL
Flame presence?
Safety thermostat
Opens the circuit?
YES
NO
13
6. Installation Location
The installation location chosen must:
• Comply with all clearances listed below.
• Provide suitable location for the exhaust and intake venting.
• Not be installed in an unheated space.
• Comply with all local codes and standards.
Note: Dimensions shown are minimums. Greater clearances will simplify installation
and service.
12.8 in
10.0 in
2.0 in
3.0 in
CLOSET INSTALLATION
2.0 in
MINIMUM PERMANANT
CLEARANCE
27.7 in
18.0 in
CLOSET INSTALLATION
8.0 in
15.8 in
SERVICECLEARANCE
FRONTVIEW
SIDE VIEW CLOSET
INSTALLATION
Figure 6.1
WARNING: Do not install the boiler on carpeting
If the boiler is to be installed in an enclosed room with no fresh air intake, the room must have
proper vent louvers installed. There should be two louvers, place each within 12” of the ceiling
and floor respectively. Each vent will have a free area of 54 square inches.
0 to 12"
Note: For boilers in an enclosed space it
is recommended to install a CO detector in
the boiler room.
Each opening free area =
1 sq. inch per 2,000 BTU/h
0 to 12"
Air Opening
Outside
Air Opening
Figure 6.2
When choosing an installation location insure the exhaust and intake pipes comply with NFPA
54. The drawing on the next page illustrates the restrictions on exhaust locations.
14 SAVIO FP MANUAL
7. Exhaust Pipe Location
CAUTION
EXTERNAL VENT SURFACES ARE HOT.
IT IS RESPONSABILITY OF THE HOMEOWNER TO KEEP THE VENT
TERMINAL CLEAR OF SNOW AND ICE
NOTE: USE ONLY LISTED COMPONENTS SUPPLIED WITH THE BOILER.
SURFACE DISCOLORATION OF THE BUILDING MAY OCCUR DUE TO
IMPROPER INSTALLATION. QHT WILL NOT ACCEPT RESPONSIBILITY OR
LIABILITY FOR SUCH DISCOLORATION.
The Exhaust Hood must be installed on the leeward side of house and conform to the
following guidelines:
1. The Vent hood shall not be less than 3 feet above any forced air inlet to the house.
2. The Vent hood shall not be less than 1 feet below, 1 feet horizontally, or 1 foot above any door,
window or gravity inlet into any building.
3. The Vent hood shall not be less than 2 feet from an adjacent building.
4. The Vent hood shall be not less than 7 feet above grade when located adjacent to public walkway.
5. The Vent hood shall be located so that flue gasses are not directed to jeopardize people, overheat
combustible structures, materials or enter buildings.
6. Minimum of 6 feet horizontal clearance from electric meters, gas meters, regulators and relief
equipment.
7. All joints in system are to be sealed to prevent leakage of products of combustion in the
building.
8. Avoid installing exhaust hood on the North, West, or the side of the house receiving the prevailing
winds.
9. The vent should not be situated so that the flue gases are directed towards brickwork,siding, or
other construction , in such a manner that may cause damage from heat or condensate from the
flue gases
SAVIO FP MANUAL
15
8. Mounting Bracket
After a suitable installation location is chosen, verify that the mounting wall is properly
braced and strong enough to support the 80 pound weight of the unit when lled with
water.
NOTE: The boiler shall be installed such that the gas ignition system components are
protected from water and liquids in general (dripping,spraying, rain, etc) during
the appliance operation and service.
Use the paper template provided with the boiler to determine the location of the mounting
bracket. Securely mount the bracket to the wall using appropriate hardware for the particular
wall construction.
Mounting Steps:
1. Tape the paper template to the wall in the chosen location. Be sure to level the template.
2. Pre-drill two holes in the center of the “oval” slots on the mounting bracket, sized for the
hardware being used.
3. Mount the bracket to the wall. Be sure to level the bracket by adjusting the screw in the
vertical slot.
4. Pre-drill the remaining hole in the mounting bracket and secure the final screw.
5. Mark and drill the exhaust/intake pipe holes through the house. If you are using a coaxial
pipe system, drill the hole marked A (ø 4”) in the drawing below and on the paper template.
If you are using a separate pipe system drill holes marked B and C (ø 3.25”) shown below
as well as on the paper template.
6. Remove paper template and hang boiler on bracket.
ø3.1
B
9.8
7.6
3.7
ø3.1
ø4.0
C A
C
9.3
7.9
5.8
A&B
0.8
4.5
4.5
1.0
27.6
0.6
3.2
4.6
5.1
2.8
15.7
13.0
Figure 8.1
16 SAVIO FP MANUAL
9. Ventilation
The SAVIO is a mechanical draft, side wall vented boiler. There are two side wall flue options
available – separate and coaxial. The coaxial option has one configuration shown on the next
page. The separate option has two possible configurations shown on the following pages.
There is also a vertical roof venting option. Regardless of what vent kit is installed, they should
all conform to the Provisions for combustion and ventilation air in accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1,
or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149, Installation Codes, or applicable provisions of the local building codes.
If the SAVIO replaces a boiler that was attached to a common vent system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to
it. To ensure the remaining appliances will function properly, the test procedure below should
be followed:
At the time of removal of an existing boiler, the following steps shall be followed with each
appliance remaining connected to the common venting system placed in operation, while
the other appliances remaining connected to the common venting system are not in operation.
(a) Seal any unused openings in the common venting system.
(b) Visually inspect the venting system for proper size and horizontal pitch and determine
there is no blockage or restriction, leakage, corrosion and other deficiencies which could
cause an unsafe condition.
(c) Insofar as is practical, close all building doors and windows and all doors between the
space in which the appliances remaining connected to the common venting system are
located and other spaces of the building. Turn on clothes dryers and any appliance not
connected to the common venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate
a summer exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust
thermostat so appliance will operate continuously.
(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
(f) After it has been determined that each appliance remaining connected to the common
venting system properly vents when tested as outlined above, return doors, windows,
exhaust fans, fireplace dampers and any other gas-burning appliance to their previous
condition of use.” (g) Any improper operation of the common venting system should be
corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1
and/or CAN/CGA B149, Installation Codes. When resizing any portion of the common
venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel
Gas Code, ANSI Z223.1 and/or CAN/CGA B149, Installation Codes.
SAVIO FP MANUAL
17
9. Ventilation Cont.
The SAVIO is a mechanical draft, side wall vented boiler. There are two flue options available
- separate and coaxial. The coaxial option has one configuration shown on the next page. The
separate option has two possible configurations shown on the following pages.
9.1 Restrictor Sizing:
Each exhaust option is shipped standard with 3 feet of exhaust pipe, 3 feet of intake air pipe.
There is also a restrictor kit in which there are some restrictors that must be placed in exhaust
breech of fan on the top of the boiler (Fig. 9.1) according to the flue configuration used.
If additional flue piping is need for a particular application, it can be ordered separately in 3 feet
increments. Depending on the final flue pipe length, an alternative restrictor may be required.
Refer to the tables 9.1 for proper restrictor ring sizing.
Coaxial 2.5/4.0
Restrictor Size
From 1.65 to 3.30 (ft)
41
From 3.30 to 8.86 (ft)
44
Separate 3.25/3.25
Restrictor Size
For 1.65 (in) and 1.65 (out)
38
From 3.30 to 39.40 (in+out)
41
Table 9.1
Figure 9.1
9.2 Fitting the flue system:
In general, it has to be taken in consideration that the horizontal sections of the flue pipe must
have an horizontal sloping not less than 1.5 degree (0.3 in per ft) away from the boiler.
In the standard horizontal flue kit the flue pipe is angled within the air duct therefore the air duct
must be horizontally installed.
If one or more exstensions have to be used they must be adequately supported so that there
is no sag in the flue pipe and a minimum fall of 1.5 degree (0.3 in per ft) over the whole lenght
towards the boiler is ensured.
18 SAVIO FP MANUAL
9. Ventilation Cont.
9.3 Choice of ue:
The following flue kits are available for connecting to the boiler:
A
Standard coaxial horizontal flue kit (Exhaust & intake outside)
Figure 9.3 (Coaxial 2.4/4.0 inches – nominal lenght 3.3 ft)
It can be fitted to allow discharge to the rear or either side of the boiler via the flanged
boiler adapter elbow. Minimum lenght required is 1 ft. Maximum equivalent lenght of 32.8
ft can be achieved utilising extensions. This flue system can only be used to discharge
horizontally, it is not designed to enable termination in the vertical plane.
Installation:
• Drill hole A (on the wall template) through the outside wall that is less than 18”thick
• Cut the pipe as necessary so that a no more than 6” protrudes from the house.
• Slide the intake and exhaust pipes through the hole.
• Slide one rubber wall trim piece on the pipe from inside and one from outside.
• Connect exhaust (inner) pipe to concentric elbow.
• Connect intake (outer) pipe to concentric elbow.
• Secure elbow to boiler using gasket and four screws provided.
• Secure end cap on the intake pipe outside the house.
SAVIO FP MANUAL
19
9. Ventilation Cont.
B
Standard separate horizontal flue kit (Exhaust & intake outside)
Figure 9.4 (Twin pipe φ 3.25 in)
Various twin (split) pipes kits and optional accessories (elbows) are available to assist in
the termination of the flue where the boiler is installed in a location remote to an outside
wall. These kits allow for separation of the air supply pipe from the pipe that discharges
the exhaust gasses. Consequently it is possible to extend the flue system to a greater
distance than that provided by the standard coaxial horizontal flue.
If either an additional 45° or 90° accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively. The sum of the
lenghts of the two horizontal part must be less than 131 ft.
Installation:
• Drill holes B & C (on the wall template) through the outside wall that is less than
18”thick
• Cut the pipes as necessary so that no more than 6” of intake pipe protrudes from the
house and the exhaust pipe is a minimum of 4 inches longer than the intake pipe.
• Slide the Intake and exhaust pipes through the respective holes.
• Slide one rubber wall trim piece on each pipe from inside and one from outside.
• Attach each collar to the boiler with the gasket and screws provided.
• Insert each elbow into its corresponding collar.
• Connect each pipe to its corresponding elbow (as shown in the diagram).
• Secure end cap on the intake and exhaust pipe outside the house.
20 SAVIO FP MANUAL
9. Ventilation Cont.
C
Alternative separate kit (Exhaust outside & intake inside)
Figure 9.5 (Twin Pipe φ 3.25 in)
This configuration of the twin pipe kit allows to discharge the exhaust gasses outside.
The air supply is obtained with an air intake pipe. This allows to take air from the room
where the boiler is installed.
If either an additional 45° or 90° accessory elbow is used then the maximum permissible
lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.
Note: When utilizing this option, see page 14 for room ventilation details.
Installation:
• Drill hole C (on the wall template) through the outside wall that is less than 18”thick
• Cut the pipe as necessary so that no more than 6” protrudes from the house.
• Slide the exhaust pipe through the hole.
• Slide one rubber wall trim piece on the pipe from inside and one from outside.
• Attach each collar to the boiler with the gasket and screws provided.
• Insert each elbow into its corresponding collar.
• Connect each pipe to its corresponding elbow.
SAVIO FP MANUAL
21
9. Ventilation Cont.
D
Alternative separate kit (Exhaust outside & intake inside)
Figure 9.6 (Twin Pipe φ 3.25 in)
This configuration of the twin pipe kit allows to discharge the exhaust gasses outside.
The air supply is obtained with an air intake pipe. This allows to take air from the room
where the boiler is installed.
If either an additional 45° or 90° accessory elbow is used then the maximum permissible
lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively.
Note: When utilizing this option, see page 14 for room ventilation details.
Installation:
• Drill hole C (on the wall template) through the outside wall Drill hole C (on the wall
template) through the outside wall that is less than 18”thick.
• Cut the pipe as necessary so that no more than 6” protrudes from the house.
• Slide the exhaust pipe through the hole.
• Slide one rubber wall trim piece on the pipe from inside and one from outside.
• Attach each collar to the boiler with the gasket and screws provided.
• Insert each elbow into its corresponding collar.
• Connect each pipe to its corresponding elbow.
22 SAVIO FP MANUAL
9. Ventilation Cont.
E
Alternative separate kit (Exhaust & intake outside)
Figure 9.7 (Twin Pipe φ 3.25 in)
These kits allow for separation of the air supply pipe from the pipe that discharges the
exhaust gasses. Consequently it is possible to extend the flue system to a greater distance than that provided by the standard coaxial horizontal flue.
If either an additional 45° or 90° accessory elbow is used then the maximum permissible lenght of either pipe must be reduced by 3.0 ft or 5.4 ft respectively. The sum of the
lenghts of the two horizontal part must be less than 49. ft.
Installation:
• Drill holes B & C (on the wall template) through the outside wall Drill hole C (on the
wall template) through the outside wall that is less than 18”thick.
• Cut the pipes as necessary so that no more than 6” of intake pipe protrudes from the
house and the exhaust pipe is a minimum of 4 inches longer than the intake pipe.
• Slide the Intake and exhaust pipes through the respective holes.
• Slide one rubber wall trim piece on each pipe from inside and one from outside.
• Attach each collar to the boiler with the gasket and screws provided.
• Insert each elbow into its corresponding collar.
• Connect each pipe to its corresponding elbow (as shown in the diagram).
• Secure end cap on the intake and exhaust pipe outside the house.
SAVIO FP MANUAL
23
9. Ventilation Cont.
F
Standard Vertical-roof kit (Exhaust & intake outside)
Figure 9.8 (vertical pipe φ 3.1 / φ 4.9 in)
This kit allows vertical termination of the flue pipe through the roof. The kit is 1.2 min length.
Extension pieces (Co--axial) are also available which allows the flue system to be extended to
a total overall maximum permissible length.
Optional 45° and 90° elbows can be used to offset the flue route.
Each additional elbow reduces the overall acceptable length of the flue system as follows:
45° reduce length by 1.6 ft.
90° reduce length by 3.2 ft.
Installation:
• Drill hole through the outside roof.
• Cut the pipe as necessary.
• Slide the intake and exhaust pipes through the hole.
• Slide one rubber wall trim piece on the pipe from inside and one from outside.
• Connect exhaust (inner) pipe to concentric elbow.
• Connect intake (outer) pipe to concentric elbow.
• Secure elbow to boiler using gasket and four screws provided.
• Secure end cap on the intake pipe outside the house.
24 SAVIO FP MANUAL
10. Pipe Connections
The SAVIO boiler is supplied with a 3/4” stainless steel gas pipe (A in figure 10.1), 2 - 3/4” copper pipe (C,D in figure 10.1),2 – 1/2” (F,G in figure 10.1), located in a plastic bag in the boiler
package.
A)
B)
C)
D)
E)
F)
G)
Stainless steel gas pipe
Main circuit drain cock
C.h. supply copper pipe
C.h. return copper pipe
C.h. PRV discharge copper pipe
D h w hot water outlet
D h w cold water inlet
Figure 10.1
Installation:
• Remove the protective caps off boiler connections (Figure 10.1).
• Thoroughly clean the connections.
• Attach the supplied components to the boiler connections (see Figures 10.1). Be sure to
use the proper gaskets for the pipe connections.
• Before connecting the boiler to the heating system piping, review the suggested piping diagrams in Section 4 (page 11).
• If the c.h. system is above the boiler level, it is advisable to install c.h. cocks close to the
boiler for servicing operation.
• A hot water boiler installed above radiation level or as required by the Authority having jurisdiction, must be provided with a low water cutoff device elther as part of the boiler or at the
time of boiler installation.
SAVIO FP MANUAL
25
11. Gas Pipe Connections
Gas supply piping is to be sized and installed properly in order to provide a supply of gas sufficient to meet the maximum demand without undue loss of pressure between the meter and the
boiler. Consult with the National Fuel Gas Code ANSI Z223.1 for proper sizing of gas piping
for various lengths and diameters.
The boiler must be isolated from the gas supply piping system by closing its individual shutoff
valve during any pressure testing of the gas supply piping system at test pressures equal to or
less than 1/2 psi (3.5 kPa).
Direction of flow
A)
B)
C)
D)
E)
F)
A
B
C
F
Manual T-handle Shutoff Valve
Pressure Gauge Port
Flexible Gas Line to Burner
Male Union ¾” NPT
Pipe Cap
1” X 1” X ¾” TEE
Note: Height of valve above ground level to
conform to local codes, if any. Massachusetts statecode requires gas shut
off to be a tee handled gas cock.
E
D
Figure 11.1
Locate a drop pipe adjacent to, but not in front of the boiler. Locate a tee (F) in the drop pipe at
the same elevation as the gas inlet connection to the boiler. Extend the drop line with a nipple
towards the floor and cap to form a sediment trap (E). Install a shut off valve (A) before the tee
with sediment trap and a union after the tee before the combination gas valve (D).
When installing the boiler, make sure a pipe compound resistant to the action of liquefied petroleum is used. Check piping for leaks. Always check leaks with a water and soap solution.
The boiler and its gas connection must be leak tested before placing the boiler in operation.The
boiler and its individual shut-off valve must be disconnected from the gas supply piping system
during any pressure testing of that system at test pressures in excess of ½ psi(3.5 kPa).
WARNING
DO NOT USE A FLAME FOR CHECKING GAS LEAKS
26 SAVIO FP MANUAL
12. Electrical Connections/Wiring
12.1 Power Connection:
Removing Control Panel:
• Remove screws C.
A
A
Figure 12.1
Removing Front Panel:
• Remove the front panel by removing screws A
and sliding the front panel up and away from
the boiler
Removing Side Panel:
• Remove screws B
•
•
Figure 12.3
Move the lower part of the side panels (figure
12.3).
Pull the control panel. When completely pulled
out, the panel can rotate 45° downward.
D
D
D
C
C
B
B
•
B
B
Figure 12.2
Figure 12.4
Loosen screws D and remove the service
panel (Fig. 12.4).
For the electrical connection to the boiler use electric wires which conform to local regulations.The boiler,
when installed ,must be electricallybonded to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements,with the National Electrical Code,ANSI/
NFPA 70 and/or Canadian Electrical Code Part I CSA C22.1, Electrical Code.
In the USA, maintain a clearance of at least 4ft horizontally from the vent terminal to gas meters, electric
meters, regulators and relief equipment. In Canada, maintain a 6ft clearance between the vent terminal
and these devices.
•
12.2 Connection to the electricity supply:
Connect the electrical supply cable coming from the fused spur isolation switch to the power supply
terminal block of the boiler (as shown in figure 12.5) keeping the same connections for the live wire
and the neutral wire
120 VAC
15 AMP BREAKER
Service Man's Switch
Fire - O - Matic
To fused spur
isolation switch
3
2
Power supply
terminal block
1
External controls
terminal block
•
WARNING
N
L
Note: Do not connect live wires to
thermostat terminals 1-3.
Figure 12.5
Connect the earth wire(yellow/green). Boiler must be wired directly to earth ground on breaker panel.
SAVIO FP MANUAL
27
12. Electrical Connections/Wiring Cont.
12.3 Room Thermostat Connection:
• The room thermostat must be connected
to the terminal block situated next to the
control panel.
To fused spur
isolation switch
L
N
Power supply
terminal block
J
3
2
• When connecting any type of external
control, the jumper J in Fig. 12.6 must be
removed.
• The room thermostat must be connected
to the “Control Terminal Block” (Fig 12.7).
1
T
Room thermostat
(120V rating)
External controls
terminal block
120 VAC Control
Terminal Block
L
Figure 12.6
• Any external controls and connection lines
must be rated at 120 VAC but under no
circumstances should external live voltage be connected to the room thermostat
link on the boiler.
3
2
N
Power supply
terminal block
1
External controls
terminal block
Figure 12.7
• Connect the room thermostat between
terminals 1 and 3 as shown in Fig. 12.7.
12.4 Relay Panel Connection:
• The relay control must be connected to
the terminal block situated next to the
control panel.
To fused spur
isolation switch
L
• Connect the dry contact switch of the relay panel to the 120 VAC control terminal
block (Fig 12.9).
N
T
Power supply
terminal block
J
3
2
Generic Relay Control
(120V rating)
1
L
N
External controls
terminal block
3
120 VAC Control
Terminal Block
Figure 12.8
• When connecting any type of relay control, the jumper J in Fig. 12.8 must be removed.
28 SAVIO FP MANUAL
2
1
Power supply
terminal block
External controls
terminal block
Figure 12.9
• Connect the dry contact switch to terminals 1 and 3 shown in Fig. 12.9.
12. Electrical Connections/Wiring Cont.
12.5 Zone Valve Micro Switch Connection:
• The zone valve micro switch must be connected to the terminal block situated next
to the control panel.
To fused spur
isolation switch
L
Zone
Valve
Room
Thermostat
V
T
N
N
Power supply
terminal block
L
J
3
2
1
External controls
terminal block
3
1
120 VAC
Control Terminal
Block
120 VAC Control
Terminal Block
Figure 12.10
Figure 12.11
• When connecting the zone valve switch,
the jumper J in Fig. 12.10 must be removed.
• Connect the micro switch of the zone
valve to terminals 1 and 3 as shown in figure 12.11
• Connect the zone valve switch to the room
thermostat as shown in figure 12.11
12.6 Finishing
• Route the electrical supply cord and the external control cord as illustrated in Fig. 12.12.
To the external
control device
To the fused spur
isolation switch
Figure 12.12
• Lock the cords in place with the flexible cord clamps.
• Replace the control panel reversing the steps on page 27.
SAVIO FP MANUAL
29
13. Circulator Sizing
13.1 Circulator capacity as a function of ow rate:
Figure 13.1
The hydraulic speci cation in Fig 13.1 represent the pressure (available head for the
central heating system) as a function of the ow rate. The pressure loss due to the internal piping in the boiler has already been substracted.
When determining proper piping of the heating system, verify that the internal boiler circulator
will overcome the head loss of the system at the designed flow rate using the graph above.
If the internal circulator is adequate, direct system piping can be utilized. See section 4 page
11 for suggested direct supply/return piping.
If the internal circulator is inadequate, a secondary circulator must be utilized. See sections 14
for suggested primary/secondary piping.
13.2 Expansion vessel:
The height difference between the C.h. PRV (19 on page 10) and the highest point in the
system may be 23 ft at most. For greater differences, increase the pre-load pressure in the
C.h. expansion vessel (17 on page 10) and the system when cold, by 0.1 bar for additional
3.3 ft. For systems with volumes greater than 154l, an additional expansion vessel must be
provided.
30 SAVIO FP MANUAL
14. Piping
All external piping components are to be supplied by the installer. It is very important to use
a Primary Secondary piping scheme when an external circulator will be used. Also, when the
boiler is piped in a primary secondary manner, it is necessary to us the central heating flow
restrictor supplied with the boiler. The flow restrictor ensures that there will be enough back
pressure to make the central heating flow switch in a low head loss piping system like primary
secondary.
Installation of flow restrictor: The flow restrictor is installed inside the pipe tail that
attaches to the boiler. Place the flow restrictor into the
gasket for the central heating supply pipe tail. Place the
gasket on the pipe tail so the flow restrictor seats into
the pipe tail. Then install the pipe tail onto the boiler.
There are two methods for accomplishing a Primary Secondary piping system. The first is to
use two closely spaced tees for the boiler supply and return. An example is shown below in
Figure 14.1. The run legs should be sized so that there is no excessive head loss on the external circulator that is installed. In most circumstances 1 ¼” piping will be the best choice. When
the boiler is piped in this way, the external circulator will not have any hydraulic effect on the
Savio boiler. This is essential to ensure that the flow switch will operate properly.
Boiler
Supply
System
Supply
Boiler
Return
Must be less than 8"
¾”
System
Return
1 ¼”
The second method is a hydraulic separator. Hydraulic separators are available commercially;
however you can also construct your own. An example of a hydraulic separator is given in
Figure 14.2. It is important that the separator be at least 2” in size to ensure proper performance.
Boiler supply
Boiler Return
No more than 8"
¾”
1 ¼”
System
supply
2"
System
return
At least 16"
SAVIO FP MANUAL
31
14. Piping Cont.
14.1 Primary – Secondary Piping:
All external piping components are to be supplied by the installer.
It is very important to use an hydraulic separator before secondary circulators.
32 SAVIO FP MANUAL
14. Piping Cont.
14.2 Primary – Secondary Piping with Zone Valves:
All external piping components are to be supplied by the installer.
It is very important to use an hydraulic separator before secondary circulators.
SAVIO FP MANUAL
33
14. Piping Cont.
14.3 Manifold Piping with Zone Valves or Circulators (shown conn. to radiators):
All external piping components are to be supplied by the installer.
34 SAVIO FP MANUAL
15. Commissioning
15.1 Initial lling of the system:
• Remove the front panel of the case.
• Unscrew the cap on the automatic air
purger valve 3 (Fig 15.1) one full turn and
leave open permanently.
Figure 15.1
• Open the installer supplied automatic fill
valve between the cold water inlet and
Central Heating System (See 28 on piping diagrams in previous section).
• Open each radiator air vent starting at the
lower point and close it only when clear
water, free of bubbles, flows out.
• Purge the air from the pump by unscrewing the pump plug 2 (Fig. 15.2); release
the pump by turning the rotor in the direction indicated by the arrow on the information plate.
Figure 15.2
• Close the pump plug.
• Continue filling the system. The actual
reading should ideally be 1.3 bar (19 psi)
and not less than 0.3 bar (4.3 psi).
• Close all air release valves on the c.h.
system.
• Inspect the boiler and the system for water soundness and remedy any leaks discovered.
• Cold flush the system to remove any loose
particles and any system debris before
starting the boiler for the first time.
• Reassemble the front panel of the case.
• Return fill valve to automatic position.
15.2 Lighting the boiler:
Note: If external controls are fitted (e.g. room thermostat) ensure they “call for heat”.
WARNING: the boiler and its gas connection must be leak tested before the boiler is placed in operation.
•
•
Turn on the electricity supply to the boiler,
switching on the circuit breaker switch. The
appliance operation light A will flash every 4
seconds.
Turn the function selector C as in Fig. 15.3.
The appliance operation light A will flash every
2 seconds.
A
B
C
D
E
Figure 15.3
The boiler will now go through an ignition sequence and the burner will light.
If during the ignition attempt period the boiler fails to light, the full sequence control p.c.b.
will go to lockout and the lock-out signal lamp D will appear.
To reset the boiler turn the knob C (figure 15.3) on the 0 position and then press and release the boiler
reset button D (Fig. 15.3).
SAVIO FP MANUAL
35
15. Commissioning Cont.
15.3 Checking the gas pressure at the burner:
This boiler has been tested to the highest quality control standards.
The maximum and minimum gas pressures are already set during this quality control
process however the checking procedure must be followed to ensure maximum operating ef ciency from the boiler.
• Remove the front panel of the case.
• Loosen the internal screw 15 (Figure 15.4)
on the Outlet Pressure Test Point of the Gas
Valve and connect a pressure gauge using
a suitable hose.
Figure 15.4
• Set the c.h. temperature control knob to its
maximum position. If external controls are
fitted (e.g. room thermostat) ensure they
“call for heat”.
• Switch on the boiler.
• Check the maximum gas pressure and compare the value on the gauge with the value
indicated in the Section 2 on page 9 (gas
pressures at the burner).
36 SAVIO FP MANUAL
• Check the maximum gas flow at the gas
meter and compare the value indicated in
the section 2 on page 9 (gas flow rate).
• Switch off the boiler.
• Disconnect the gas modulator coil by removing the electrical connector E (Figure 15.4).
• Switch on the boiler.
• Check the minimum gas pressure and compare the value on the gauge with the value
indicated in the Section 2 on page 9 (gas
pressures at the burner).
• Switch off the boiler and re-connect the
electrical connector E to the modulator coil.
• Switch on the boiler.
• Check that the boiler lights up uniformly.
• Switch off the boiler, turn off the hot water
taps and disconnect the pressure gauge.
Important: after the checks all of the test
points must be sealed.
15. Commissioning Cont.
15.4 Adjustment of the gas pressure:
•
•
•
•
Remove the front panel of the case.
Open the gas valve inlet pressure test point
(16 in Fig. 15.5) at the valve input, connect
a suitable pressure gauge and check the gas
pressure of the supply network.
Remove the gauge and close the pressure
test point 16.
Open the gas valve outlet pressure test point
(15 in Fig. 15.5) and connect the gauge.
Figure 15.6
Ensure that the boiler is not range rated.
Rotate the maximum gas pressure adjustment
(F in Fig. 15.5) until you obtain the required
pressure (by rotating clockwise the pressure
increases).
• Turn the boiler off and disconnect one of the
two connectors (E in Fig. 15.5).
• Start the boiler and rotate the minimum gas
pressure adjustment (G in Fig. 15.5) until
you obtain the required pressure (by rotating
clockwise the pressure increases).
• Turn the boiler off and re-connect the wire to
the modulating operator.
• Start the boiler and check again the maximum
gas pressure setting.
• Turn the boiler off and disconnect the gauge.
Important: after the checks all of the test
points must be sealed.
•
•
•
•
Figure 15.5
Remove the protection cap I (Fig. 15.6) from
the mechanical pressure adjustment components levering with a flat screwdriver in the
slots H.
Start the boiler at its maximum power.
15.5 Checking the ignition device:
With the burner on high flame close the gas cock. After three ignition attempts (within about three minutes), the lock-out signal lamp must appear (D on Figure 15.3). To reset the boiler turn the knob B (figure
15.3) on the 0 position and then press and release the boiler reset button (C on Figure 15.3).
SAVIO FP MANUAL
37
15. Commissioning Cont.
15.6 Checking the burner ignition:
•
•
•
Turn the boiler OFF.
Open the gas valve outlet pressure test point
15 (figure 15.5) and connect the gauge.
Turn the boiler ON positioning the function selector C in the position shown in figure 15.7
and ensure that the room thermostat is set to
“heat demand”.
•
•
Repeat this process two to three times leaving 30 second intervals between each ignition. Check the ignition pressures and visually
check that the burner lights uniformly and in a
controlled manner.
To carry out the adjustment move the function
selector 3 to the OFF position (Fig. 15.9) and
use the device (ACC).
+
RISC
+
ACC
ON
1
•
Figure 15.7
Loosen screws D and remove the service
panel (figure 15.8).
D
D
•
•
•
•
•
•
•
•
•
•
•
•
Figure 15.8
Watch the gauge and check to see if the ignition pressure registerd corresponds to the
values given in the Technical Data. Turn off
the boiler and reignite it by turning the function
selector B to the 0 position and then back to
that indicated in figure 15.7.
3
4
OFF
•
D
2
•
•
•
Figure 15.9
Adjust the gas pressure at the injectors to the
value indicated in the tables of section 2. By
rotating the device clockwise the pressure increases.
After the adjustment operations bring the selector 3 of figure 15.9 back to the normal position (ON).
Reassemble the service panel.
Close the gas valve outlet pressure test point
15 (figure 15.5).
Reassemble the front pannel of the case.
Important: after the checks all of the test
points must be sealed.
15.7 Adjustment of the useful c.h. output:
Turn the boiler OFF.
Open the gas valve outlet pressure test point 15 (figure 15.5) and connect the gauge.
Turn the boiler ON positioning the function selector B in the position shown in figure 15.7 and ensure
that the room thermostat is set to “heat demand”.
Loosen screws D and remove the service panel (figure 15.8).
To carry out the adjustment use the adjustment device (RISC) with the help of a screwdriver.
By rotating the device clockwise the pressure increases.
Adjust the gas pressure at the burner to the value according to the useful c.h. output wanted (Tab.
15.1).
Reassemble the service panel.
Close the gas valve outlet pressure test point 15 (figure 15.5).
Reassemble the front pannel of the case.
38 SAVIO FP MANUAL
15. Commissioning Cont.
15.8 Labels placement:
3
2
4
1
5
Figure 15.10
Warning: The installation is not complete unless labels supplied are placed on the boiler as shown in Figure 15.10.
All the labels supplied with the boiler are numbered for reference.
According to Figure 15.10 place all the labels on the boiler. Use label numbered as 1 (already installed
in the front panel) to begin the placement in the correct way.
SAVIO FP MANUAL
39
15. Commissioning Cont.
15.9 Checking the ue system and combustion:
• The flue system should be visually checked for soundness. Check all clamps, gaskets and
fixings are secure and tight.
• Ensure that the flue terminal is sited correctly in accordance with the flue fitting instructions.
To check the exhaust gas:
• Remove the plugs indicated (Fig. 15.11).
• Insert the analyzer probe in the exhaust
gas sampling point or in the air intake
sampling point.
Air-Flue exhaust
sampling points
• Reference tables are given in the Sections 2 on page 9 of this manual for proper
CO2 levels.
Figure 15.11
15.10 Instructing the user:
• Hand over the User manual, this Installation,Operation and Service manual to the end user
and explain how to use the unit in Central Heating mode.
• Take the User step by step through the lighting instructions.
• Show the User how to switch off the appliance quickly and indicate the position of the electric service switch and the boiler on/off switch.
• Explain the proper use and adjustment of all system controls; this will ensure the greatest
possible safety and fuel economy.
• Explain the function and use of the function switch.
• Explain how to turn off the appliance for both short and long periods and advise on the precautions necessary to prevent damage should the appliance be inoperative when freezing
conditions may occur.
• Fill in the details required on the≠ Boiler Guarantee Certificate and hand to the User advising them to return the correct section for boiler Guarantee registration. Finally, advise the
User that, for continued safe and efficient operation, the appliance must be serviced by a
competent person at least once a year.
Useful output
Natural
Propane
KW
12
14
16
18
20
22
24
26
BTU/h
40950
47750
54600
61400
68240
75064
81900
88700
Pa
inwc.
m³/h
ft³/h
Pa
inwc.
Kg/h
lb/h
240
0.96
1.63
5.34
410
1.64
1.20
2.64
320
1.28
1.87
6.13
540
2.16
1.37
3.02
410
1.64
2.10
6.89
680
2.73
1.55
3.41
500
2.00
2.34
7.67
840
3.37
1.71
3.76
600
2.40
2.56
8.40
1010
4.05
1.88
4.14
710
2.85
2.78
9.12
1190
4.77
2.04
4.49
830
3.33
3.00
9.84
1390
5.58
2.20
4.85
950
3.81
3.22
10.56
1590
6.38
2.36
5.20
Table 15.1
40 SAVIO FP MANUAL
16. Gas Conversion
WARNINGS: Procedures to adapt the boiler to the type of gas available must be carried out by a competent and responsible person. Components used to
adapt it to the type of gas available must be genuine parts only.
Procedures:
• Check that the gas cock (30 on Section
4) fitted on the gas supply pipe is turned
off and the appliance is switched off at the
circuit breaker.
• Remove the front and side panels of the
case (see the section 17.2 Annual Maintenance – Dismantelling the External
Panels).
• Take off the lid of the sealed chamber.
• Remove the front panel of the combustion
chamber.
A
7
D
D
D
Figure 16.2
• Set correctly the dip-switch “2” to the correct position (Fig. 16.3) in accordance
with the following table.
Position of the
Gas supply
switch 2
Natural gas
On
L.P.G.
Off
Natural gas
L.P.G.
ON
1
2
3
ON
4
3
1
4
2
OFF
OFF
A
Figure 16.1
• Loosen the screws A and remove the
burner 7 (Figure 16.1)
• Carry out the conversion for the type of
gas, replacing the burner injectors correctly)
• Re-assemble the burner, the front panel
of the combustion chamber and the lid of
the sealed chamber.
• Extract the control panel as explained in
the section 12.1 of this manual.
• Loosen the screws D and remove the service panel (figure 16.2).
•
•
•
•
•
•
SAVIO FP MANUAL
Figure 16.3
Close the service panel.
Turn on the boiler.
Calibrate the gas valve according to the
instructions given in section 15.4 of this
manual.
Set the correct gas pressure for central
heating output required.
Stick on the inside of the left hand side
panel adjacent to the data badge the selfadhesive label (included with the conversion kit) indicating the type of gas, and the
gas pressures to which the appliance has
been set.
Reassemble the front and side panels of
the case.
41
17. Annual Maintenance
17.1 Warnings:
The procedures detailed in this chapter must be carried out only by a professionally qualified
person. Thus you are advised to contact an Authorised Service Agent.
For efficient and continuous operation of the boiler you are advised to have, at least once a
year, maintenance and cleaning done by an Approved Service Person.
Isolate the appliance from the electricity supply by turning off the fused spur isolation switch
adjacent to the appliance and turn off the gas cock, before carrying out any procedures, whatsoever, for cleaning, maintenance, opening or dismantling boiler panels.
17.2 Dismanteling the external panels:
Front Panel:
• Loosen the three screws A (Fig. 17.1)
• Lift and remove the panel.
Side Panels:
• Loosen the screws B (Figure 17.2). Bring the bottom of the panels away from the boiler and
lift them, freeing them from the top hooks.
A
C
C
A
B
B
Figure 17.1
B
B
Figure 17.2
17.3 Emptying the Central Heating System:
• Close the pressure reducing automatic fill
valve (28 on Section 4)
• Open the central heating drain cock (F in
Fig. 17.3).
• Empty the c.h. system.
• Close the central heating drain cock (F in
Fig. 17.3).
• Open the pressure reducing automatic fill
valve (28 on Section 4)
Figure 17.3
17.4 Emptying the Domestic Hot Water circuit:
• Close the inlet valve
• Open the system domestic hot water valves.
42 SAVIO FP MANUAL
17. Annual Maintenance Cont.
17.5 Cleaning the primary heat exchanger:
• Take off the front panel of the case, then the sealed chamber lid and the front panel of the
combustion chamber.
If you notice dirt on the fins of the primary heat exchanger (9 on page 10), cover the sloping
surfaces of the burner (7 on page 10) entirely in a protective layer (sheets of newspaper or
similar). Brush out the primary heat exchanger (9 on page 10) with a bristle paintbrush.
17.6 Checking the pressurization in the expansion vessel:
Empty the central heating system as described in section 17.3 of this chapter and check that the
pressure in the expansion vessel is not less than 1 bar (14.5 psi). See also section 13.2 page 30
of this manual. If the pressure should be lower, take steps to correct the pressure level.
17.7 Cleaning the domestic hot water exchanger
The descaling of the domestic hot water exchanger will be evaluated by the Authorised Assistance Centre Technician, who will carry out any cleaning, using specific products.
17.8 Cleaning the burner:
Follow the instructions for removing the external panels from 17.2. Remove the nine screws
labelled .Now you will have complete access to the combustion chamber.
The sloping and multi-gas type burner (7 on page 10) does not need special maintenance, but
it is sufficient to dust it with a bristle paintbrush..
17.9 Checking the ue:
Have the integrity of the flue outlet pipe (24 on page 10) air intake pipe (25 on page 10),
checked periodically, the venturi device (23 on page 10) cleaned and the efficiency of the flue
safety circuit checked at least once a year. For all the above maintenance operations it is advisable to call an approved Service Engineer.
To check the pressure at the venturi device, use the test points (12 on page 10).
• Remove the caps of the pressure test
points and connect a differential pressure
gauge.
• Switch on the boiler.
• Compare the value on the gauge with the
minimum values of venturi pressure indicated in the Section 2 on page 9.
Venturi test
points
Figure 17.4
17.10 Visual inspection of appliance:
Visually inspect all water joints, seals and connections for any evidence of leakage and retighten, grease or replace them as necessary.
17.11 Gas pressures and soundness:
Check appliance for gas soundness. Recheck operational pressures and adjust as necessary
as described in Section 15.4 page 37 of this manual.
SAVIO FP MANUAL
43
18. Vent Part Spares
For any spare parts, please contact BOYERTOWN 1-610-369-1450.
Description
Order Number
Twin pipe kit
10999.0393.0
44 SAVIO FP MANUAL
18. Vent Part Spares Cont.
For any spare parts, please contact BOYERTOWN 1-610-369-1450.
SAVIO FP MANUAL
Description
Order Number
Coaxial flue kit
10999.0387.0
45
18. Vent Part Spares Cont.
For any spare parts, please contact BOYERTOWN 1-610-369-1450.
Part
Description
Order Number
A
Roof flue kit
10999.0392.0
46 SAVIO FP MANUAL
19. Installer Notes
System Checkout:
Boiler Model No. ___________________
Serial No.______________________
Original Purchaser:
___________________________
Installer:
________________________
___________________________
________________________
___________________________
________________________
_______________________________________________________________________
Performance Tests:
GROSS STACK TEMPERATURE
__________________
ROOM TEMPERATURE (AMBIENT)
NET STACK TEMPERATURE
________________
_____________________
CO2
__________________
O2
___________________
SMOKE READING
___________________
COMBUSTION EFFICIENCY
_________________
COMMENTS ___________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
SAVIO FP MANUAL
47
N
19/09
2008
17962.1511.0 3808 (52A4)USA
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